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Heat rate improvement and emission reduction via combustion optimization. 16 th International energy and environmental technology systems conference May 12 -14, 2010 İstanbul, TÜRKiYE. Harun Bilirgen, Ph.D. Lehigh University Energy Research Center Bethlehem, PA 18015, USA.

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heat rate improvement and emission reduction via combustion optimization

Heat rate improvement and emission reduction via combustion optimization

16th International energy and environmental technology systems conference

May 12 -14, 2010

İstanbul, TÜRKiYE

Harun Bilirgen, Ph.D.

Lehigh University

Energy Research Center

Bethlehem, PA 18015, USA

combustion optimization

Combustion Optimization

Involves modifications to boiler operating parameters to achieve desired optimization goal, subject to imposed constraints

Cost-effective alternative to hardware modifications for emissions reduction and performance improvement

Maximize effectiveness of existing hardware or hardware modifications

goals

Goals

Emission reduction such as NOx and Hg

Heat rate (Btu/kWh – efficiency) improvement

Reduce furnace slagging/fouling

unit description

Unit description

125 MW-net

Front wall-fired

Sub-critical

Single reheat

12 low-NOx burners

5 pulverizers

Over-fire Air (OFA)

combustion tuning

Combustion Tuning

CO distribution over the flue gas duct before unit tuning (average CO = 105 ppm,

average O2 = 3.1 Percent)

combustion tuning1

Combustion Tuning

CO distribution over the flue gas duct after unit tuning (average CO = 21 ppm, average O2 = 2.9 Percent)

parametric testing

Parametric Testing

OFA register position vs. NOx emissions at various economizer O2 levels

parametric testing1

Parametric Testing

Furnace excess oxygen vs. NOx emissions at various OFA register positions

parametric testing2

Parametric Testing

Furnace excess oxygen vs. heat rate at various OFA register positions

ann architecture

ANN Architecture

Data obtained from

parametric tests

NOx, Heat rate, CO, FEGT

Output

Hidden

Input

model verification

Model verification

Measured and predicted NOx vs. test number

model results for nox and hr

Model results for NOx and HR

NOx emission and heat rate vs. economizer oxygen level

optimization results

Optimization Results

NOx emissions vs. heat rate map with optimal settings

results and recommendations

Results and recommendations

Boiler/combustion optimization is a tool to increase boiler efficiency and reduce emission

In general, 30 percent NOx reduction and less than 1.0 percent heat rate improvement

Estimated annual saving $500,000/yr

Additional benefits; increase unit availability

turkish power plants

Turkish power plants

  • Benefit from the combustion optimization projects
    • instrumentation
    • boiler tuning
    • performance testing
  • Coal drying
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