Optimization Solutions in Thermal Power Plants

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1 Shailesh Vidyarthi, 9th Energy Efficiency Summit 2010, Chennai Optimization Solutions in Thermal Power Plants September 4, 2010 Slide 1

2 The need of the hour is to optimize the resources and rapidly adopt energy efficiency techniques and improvement mechanisms. - CII, 9 th Energy Efficiency Summit 2010 September 4, 2010 Slide 2

3 Contents Today s energy challenges ABB in Energy Efficiency Optimax Plant Optimization Solution Introduction Product Portfolio Optimax Products Typical Layout Summary September 4, 2010 Slide 3

4 Contents Today s energy challenges ABB in Energy Efficiency Optimax Plant Optimization Solution Introduction Product Portfolio Optimax Products Typical Layout Summary September 4, 2010 Slide 4

5 Today s energy challenges Rising demand Europe and North America 5.4% 26% China 94% 177% IEA forecast Growth in primary energy demand Growth in electricity demand M. East and Africa 89% 140% India 116% 261% September 4, 2010 Slide 5

6 Today s energy challenges Present Scenario in India Demand for energy has risen steadily in the past decade. Electricity consumption is rising even faster, and is set to increase about 76 percent between 2007 and 2030 under current policies and trends (IEA estimate). India has set an ambitious target of generating 78,700 MW by Need of the hour is maximum utilization of installed capacity( Average PLF in thermal power stations for power utilities has gone up by around 12% for the period ) September 4, 2010 Slide 6

7 Today s energy challenges Present Scenario in India 64.7% 78.7% 84.98% Central PLF *Ministry of Power, India September 4, 2010 Slide 7

8 Today s energy challenges Present Scenario in India Aim for overall improvement in efficiency of power plants in India. September 4, 2010 Slide 8 *Ministry of Power, India

9 Today s energy challenges Cut link between growth, energy use and emissions Meeting these challenges requires the world to: Reduce the correlation between economic growth and energy use Reduce the correlation between energy use and emissions Energy efficiency Renewable sources of energy September 4, 2010 Slide 9

10 Contents Today s energy challenges ABB in Energy Efficiency Optimax Plant Optimization Solution Introduction Product Portfolio Optimax Products Typical Layout Summary September 4, 2010 Slide 10

11 ABB in energy Efficiency Only 20% of primary energy generates economic value. The rest is lost to conversion processes, transportation and operational inefficiencies Primary energy Transport Generation T&D Industrial processes Industrial production Available energy 80% of energy is lost September 4, 2010 Slide 11

12 ABB in energy Efficiency Reducing losses along the energy chain ABB technology helping at every step Primary energy Transport Generation T&D Industrial processes Industrial production Available energy Improved well efficiency Higher pipeline flows More efficient fuel combustion Lower line losses, higher substation efficiency ABB technology can double energy productivity Improved productivity More efficient motors & drives Process Automation Marine & pipelines Power plant automation Grid operation Process automation Drives & motors September 4, 2010 Slide 12

13 Contents Today s energy challenges ABB in Energy Efficiency Optimax Plant Optimization Solution Introduction Product Portfolio Optimax Products Typical Layout Summary September 4, 2010 Slide 13

14 Introduction Solutions for improving economic performance and asset management Operations Systems Monitor and predict plant performance, improve efficiency and issue early warnings for equipment diagnosis and preventive maintenance. Environmental Systems Optimize your combustion process and reduce emissions with Advanced Process Control solutions. Asset Lifecycle Systems Schedule the most economical operation of different units (unit commitment) and improve maintenance planning based on lifetime consumption. Maintenance Systems Reduce costs of maintenance activities and improve maintenance work flow. September 4, 2010 Slide 14

15 Contents Today s energy challenges ABB in Energy Efficiency Optimax Plant Optimization Solution Introduction Product Portfolio Optimax Products Typical Layout Summary September 4, 2010 Slide 15

16 Product Portfolio September 4, 2010 Slide 16

17 Contents Today s energy challenges ABB in Energy Efficiency Optimax Plant Optimization Solution Introduction Product Portfolio Optimax Products Typical Layout Summary September 4, 2010 Slide 17

18 Optimax Plant Performance Monitoring Performance monitoring of power plants or water desalination plants Calculates deviation between the expected and the measured data Offers online thermodynamic models and what-if simulations Reduces plant fuel costs Improves predictive maintenance Early detection of degradation possible Provides the maximum flexibility in reconfiguring or dynamically modifying system parameters even during system operation September 4, 2010 Slide 18

19 Optimax Plant Performance Monitoring September 4, 2010 Slide 19

20 Optimax Plant Performance Monitoring Project References Intermountain Power Service Corporation, Delta, Utah USA, Unit #1 & 2: 950 MW each, Coal Fired Power Plant PPL, Montana,Colstrip Power Plant, USA, Unit 1 & 2 333MW, Unit 3 & MW CCPP Kirchlengern Unit 2 of Roxboro plant(675 MW) September 4, 2010 Slide 20

21 Optimax Plant Performance Monitoring Benefits 140k$ saved annually at Unit 2 of Roxboro plant(675 MW), North Carolina, USA. In addition, 100k$ annual saving achieved with performance tests reduction. Information Management Using OPTIMAX, the detection of leakages at Astoria PP (Unit 30,360 MW), USA. result in cost saving equivalent of 150k$ per year. 50k$ can be saved annually by reducing the man power. September 4, 2010 Slide 21

22 PowerCycle Model-based tool able to accurately simulate thermodynamic behavior of the plant under varying ambient conditions and different steady-state operating modes Calculation options Simulation Data Validation Optimization September 4, 2010 Slide 22

23 PowerCycle-Simulation Advantages: Easy usage of existing component characteristics Obtain not only Expected power and efficiency, but all detailed process values (p, T, flows, ) Even non-measured failures (e.g. leakage) are detected September 4, 2010 Slide 23

24 PowerCycle-Simulation Steady-State simulation of thermodynamic behavior of the plant and its equipment Online Simulations What-If Simulations Deviations from the optimal efficiency can be recognized. September 4, 2010 Slide 24

25 PowerCycle-Data Validation Measured values are integrated into the model Alarm is generated if computed value deviates from the process value by more than a specified interval. It is used for predictive maintenance and avoid unnecessary trips due to faulty alarms September 4, 2010 Slide 25

26 PowerCycle-Optimization A parameter can be varied and its effect (resulting). Effect can be cost. This can be used for optimized set points during operation to provide decision support to the operator. September 4, 2010 Slide 26

27 PowerCycle Project References 2 CCPP * 400 MW Middle-East desalination plant Coal-fired PP in Germany Fujairah Water and Power Plant (FWPP). September 4, 2010 Slide 27

28 PowerCycle Benefits What-if simulations and optimization result in 1% fuel savings for a plant consisting of 2 CCPP * 400 MW. By determining the optimal load distribution over the 2 GT s, nearly 100k$ saved per year. In a Middle-East desalination plant, 1.8% water production costs saved by calculating optimal set points for the Multi-Stage Flash (MSF) process. Determining a better sub-cooling at a coal-fired PP in Germany, resulted in 110k$ saving per year. September 4, 2010 Slide 28

29 Combustion Optimizer Based on Model Predictive Control techniques (MPC) for closed loop combustion optimization of boilers fired with pulverized coal. Models the multivariable nonlinear relationships of the combustion process. The relationships between signals/parameters are identified by analyzing their historical data. September 4, 2010 Slide 29

30 Combustion Optimizer Improves boiler efficiency, reduces emissions, lowers operating costs NO x reduction. Heat rate improvement Steam Temperature O2 control ( Excess) Burner Tilt September 4, 2010 Slide 30

31 Combustion Optimizer September 4, 2010 Slide 31

32 Combustion Optimizer Project References 6x500 MW Jaenschwalde Plant,Vattenfalls,Germany PPL, Montana,Colstrip Power Plant, USA Unit 1 & 2 333MW Unit 3 & MW September 4, 2010 Slide 32

33 Combustion Optimizer Benefits Environmental System Reduce NOx by 8-40 % Heat rate improvements of: % at base load % at swing load Reduction of unburned carbon in ash by 1-5 % Reduction of CO2 generation Maintenance of CO at desired levels Improve availability September 4, 2010 Slide 33

34 Soot-Blowing Advisor It is based on a Neural net model Heatloss vs. Sootblowing kwh 8.64E+10 kj 1 Heat Loss [MJ/d] kj/kwh Heat for Sootblowing [MJ/d] Total Heat Loss [MJ/d] Heat Loss [MJ/d] 400 Heat for Sootblow ing [MJ/d] 350 Total Heat Loss [MJ/d] 300 It can initiate Soot-blowing sequences Heat Loss [MJ/d] It monitors cleanliness and performance of the various boiler sections # Sootblowing/day Calculated Heat Transfer Factors Sootblowing signals September 4, 2010 Slide 34

35 Soot-Blowing Advisor Tells the operator when and where to soot blow and for how much time. Minimizes the overall cost for soot blowing. Stops reduction of heat transfer efficiency and hence reduces loss of fuel. Avoids high rates of tube wastage in the vicinity of soot blowers due to excessive wall blowing Base line heat Rate BTU/kwhr Reheater Superheater Economizer Furnace Surface Effectiveness Furnace Dirtiness % September 4, 2010 Slide 35

36 Soot-Blowing Advisor Project References 265 MW Rawhide Energy Station Unit #1, Colorado,USA. September 4, 2010 Slide 36

37 Soot-Blowing Advisor Benefits At the 265 MW Rawhide Energy Station Unit #1 60k$ saved with extended cleaning schedule Operation cost reductions of 180k$ achieved by minimizing the reheat spray flow September 4, 2010 Slide 37

38 BoilerMax It is used for Boiler Start-up Optimization for large utility to meet base load to have shorter startup time. Similarly shorter shutdown time. Based on nonlinear dynamic model. It reduces startup costs for having plants of higher capacities having frequent startups. Traditional vs. BoilerMax Fuel flow HP-Bypass position LS-Temperature Savings with BoilerMax dt thickwalled component unused potential design limits September 4, 2010 Slide 38

39 BoilerMax Project References Walsum Unit 10, 750 MW, Duisburg, Germany KW Staudinger, 622 mw, Germany KW Ingolstadt, 420 mw, Germany KW Zolling, 450 mw, Germany KW Heyden, 900 mw 5units, Germany Ingolstadt unit 420 MW, Germany, 4 oil-fired unit September 4, 2010 Slide 39

40 BoilerMax Benefits For a coal-fired unit of 700 MW, BoilerMax may reduce startup costs by 10 to 15%, resulting in savings of 130k$ per year September 4, 2010 Slide 40

41 Contents Today s energy challenges ABB in Energy Efficiency Optimax Plant Optimization Solution Introduction Product Portfolio Optimax Products Typical Layout Summary September 4, 2010 Slide 41

42 Typical Layout Office Engineering Maintenance Accounting OPTIMAX Client OPTIMAX Client OPTIMAX Client OPTIMAX Client Internet Firewall Fuel Demand Process Quality Balances Reporting Monitoring Diagnostics Simulation Optimization System Server Billing & Settlement Information Mgmt Calculation Server Maintenance Mgmt DCS Interfaces Metering System Unit 1 ABB DCS 1 Unit 2 ABB DCS 2 Unit Other DCS ABB ABB Group Group PSP-PRU September / ma 4, Slide Slide 42

43 Contents Today s energy challenges ABB in Energy Efficiency Optimax Plant Optimization Solution Introduction Product Portfolio Optimax Products Typical Layout Summary September 4, 2010 Slide 43

44 Summary Optimization Energy Efficiency, Fuel Conservation, Low Emissions Power Plant Performance Reporting and Improvement under the Provision of the Indian Energy Conservation Act; Evonik,VGB are working under Indo German Program. There were talk on regulations for the efficiency of Power Generation in European Union* Different Power plants in India under the above banner have a Energy Management Policy which talks about efficiency and cost-effectiveness*. Power and Productivity for a Better world September 4, 2010 Slide 44

45 Summary Thank you for your patience. Any questions please. For any clarifications please write to September 4, 2010 Slide 45

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