Optimization of Emissions Reduction

Equipment (SCR)
Jeff Williams
SmartProcess
Business Development Manager
Presenters
Jeff Williams
John Hayden
Agenda
Overview
SCR Optimization
SCR project Case study
NOx / SO2 cap compliance
NOx / CO / CO
2
minimization
Opacity Reductions
Reduced Tube leaks
Less EFORS from sootblower
problems
Availability Environmental Management
Dispatch Response
Ramp Rate Improvements
Start-up guidance
Operational Flexibility
Fleet / Economic Evaluation
Real-Time Performance
Heat Rate Improvements
LOI reductions
Generation Management
Data
Interface
Multi-Regional
Fuzzy-Neural Network
Model Matrix
Adaptation
Optimization
1993 1996 1998 1999 2003
Low NOx Dispatch
system for LADWP
First Dynamic state space
models with neural network
component NeuCOP from
NeuralWare Later Aspen
Power Industry first
multivariable advanced
fuzzy logic feedforward
model based steam
temperature control
Power Industry first
software based intelligent
sootblowing combining
expert system and neural
networks
2001
Industry first Multivariable
Model matrix with adaptation
and Optimization engines
2004 2005
Acquired
By
Emerson
Named
Power
Industry
Center of
Excellence
for
Emerson
SmartProcess
powers ISA/POWID
facility of the year
History - Of SmartProcess Performance
and Optimization Experience Post 1990
Embedded Model Based
Control in Ovation expert
control system via APC.
Steam Temperature LDC
Industry First
Object based
Plant
performance tool
Industry First
Fleet wide
optimization
using portal
technology
2000
Industry First
Cyclone Boiler
Optimizer
2006
Released first
browser based
interface
SmartEngine
Developed and
Beta Tested First
Immunological
Self-Learning
system Patent
Pending
SmartProcess Firsts For Power
1
st
Dynamic Combustion Optimizer
1
st
Advanced Steam Temperature application
1
st
Intelligent Sootblower Optimizer
1
st
OPC based Performance Monitor (GPA)
1
st
Cyclone Optimizer
1
st
Fleet Optimizer
1
st
Open Web Enabled Economic Optimizer,
Combustion Optimizer, and Intelligent Sootblower
Solutions for Improved
Plant Performance
Unit Response
Optimization
Sootblower
Optimization
Fleet Optimization
SCR Optimization
Steam Temp.
Optimization
Performance
Monitoring
Economic
Optimization
Combustion
Optimization
LoopMetrics
Complete system
SCR Optimizer
Results
Improves efficiency
Maintains optimum temp
Extends 1
st
stage catalyst life
Take your SCR technology a
step further.
The SCR Optimizer
evaluates data to control
the ideal inlet temperature
and ammonia usage that
will reduce NOx
emissions and slip.
SCR Optimization Factors
SCRs operate most efficiently
at 600-670F
There are a number of layers
Excess ammonia spray
saturates the catalyst bed and
escapes the reactor (slip)
NOx inlet variability causes
uneven reactions
SCR Optimization
Control temperature via Bypass and O2 bias
Minimize NOx variability
Model reactor, predict flow requirement for zero slip
SmartProcess

Improves Emissions and Temperature

Control at CPSGs Brandon Shores Power Station
CHALLENGE
Optimize temperature control
Reduce emissions of NOx
Improve ammonia utilization and reduce slip
SOLUTION
SmartProcess SCR Optimization
RESULTS
120 hour improvement in 90% removal rate hours
250 tons of additional NOx reduction
Minimize the impact of varying conditions of coal
quality, cleanliness of boiler, mill selection, and
daily operation levels
Application
Unit #1 a 680-
megawatt coal-fired
generating unit with
a B&W boiler and
GE turbine
Case Study
SCR Temperature Optimization Project
375 Acre Site
Two 680 MW (Gross) Coal Fired Units
5000 to 6000 tons of coal burned per typical
day per unit. Delivery by barge.
400-500 tons fly ash per day produced per
unit. Fly ash reuse by ProAsh.
Selective Catalytic Reduction (SCR) for NOx
control.
167 Employees including Coal and Ash
Handling shared with Wagner Plant.
Air Quality Control System Project (Sorbent
Injection and Baghouse for Hg and SO3
control, Wet Scrubber for SO2 control) under
way to meet Healthy Air Act Requirements Jan
1, 2010.
Unit 1 commissioned in 1984 GE Turbine &
B&W Boiler.
Unit 2 commissioned in 1991 GE Turbine &
B&W Boiler.
Plant Information & History
Boiler Design
Hot-side Precipitator located before the Air Heaters
Types of Coal and Unit Operation
Coal
Low Sulfur Eastern Bituminous Coal and/or Synfuel
(mined in Kentucky / West Virginia)
Russian
Other Foreign Coals As Requested by
Operation
Day: high load regulation - 680
Night: lower loads 550 and below
Ozone Season May to September
Rules:
SCR Design is 90% NOx Reduction (Diff. Between SCR
Outlet and Inlet NOx)
Minimum Desired SCR Inlet Temp. = 585F (can achieve 90%
NOx reduction at or above this temp.)
Minimum Inlet Temp. = 555F (if temp. drops below, ammonia
flow ceases)
Maximum Economizer Outlet Temp. = 680F (limitation is
ductwork expansion joint material)
Ammonia Slip < 5 ppm (measured at SCR Outlet)
Temperature controlled by combination of economizer
bypass dampers and economizer outlet dampers
NOx Reduction Capabilities
Overfire Air: SCR:
Expected NOx Reduction: 90%
(Delta between inlet & outlet NOx)
Used to reduced
inlet NOx down
to 0.4 lb/mmBtu
SCR Systems
Located on the hot-side of the boiler after the hot-side precipitators.
Installed in 2001 to reduce NOx
The SCR Design
The SCR design mandates a minimum inlet flue gas temperature of 555 degf to keep the SCR's
in-service. An economizer bypass system, which was part of the initial design, allows flue gas to
bypass the economizer section of the boiler and then re-mix with the economizer outlet flue gas
to increase overall flue gas temperature to the SCR. Some temperature is also lost as the gas
passes through the precipitator (see details on next slide).
The Problem
Bad Stuff!!! Heat Loss
60 deg drop
After installation of SCRs and for several years following, Brandon Shores struggled with standard DCS
controls to maintain this minimum SCR inlet temperature during ozone season mainly due to the heat
loss experienced across the precipitators and limitations of the standard DCS control strategies. When
the SCR inlet temperature goes below 555 degf, the SCR ammonia system in the SCR automatically
trips off and all NOx emissions are sent directly to stack which results in a high cost to the utility.
Before This Project
Solution:
Control the SCR Inlet Temperature using the Economizer Bypass Damper and Economizer Inlet
Damper
Use Economizer Remix Temperature as Feed-forward
Results:
The base controls would go into a Hunting mode unexpectedly. The bypass damper would
continually move from 0-100% (trend on next slide)
The SCR inlet temperature lagged behind the economizer remix temperature significantly.
Controlling the SCR inlet temperature was difficult.
A change in the remix temperature could take up to 90 minutes to fully realized in the SCR inlet
temperature
Low SCR inlet temps (due to low loads) tripped the ammonia system. This resulted in a large
cost Impact due to higher NOx.
SCR inlet temperature below 585F results is less than optimum SCR performance
(SCR Catalyst is most effective between 585F & 600F)
Overall there were design problems with the original base DCS controls
Damper Swings
Combustion Optimization Ruled Out
Why?
Burner Register Controls are Manual.
No DCS feedback regarding burner register positions.
The flyash quality is constantly monitored by flyash processing
facility and must me maintained at all times (process cannot
handle large fluctuations in LOI).
Prior attempt to manipulate combustion via a Neural Network
was unsuccessful.
In 2006, Constellation contracted Emerson Process Management Power and Water Solutions to
provide an optimization system to first study the boiler design and provide an optimization system to
optimize the SCR inlet flue gas temperature using a combination of advanced DCS control structures
and a fuzzy neural model based optimization system.
Emerson SmartProcess
Goals of Project
Improve Base Ovation DCS Controls at Higher Loads for More Consistent Economizer Remix
Temperature and SCR Inlet Temperature
Add Optimization to Increase SCR Inlet Temperatures at Lower Loads and Reduce Shutoff of
Ammonia Due to Low SCR Inlet Temperatures
SCR Temperature Optimization
Part #1
New DCS Base Temperature Controls Design
New Ovation DCS Base Remix Temperature Controls Design
Ovation DCS is Now Controlling Economizer Remix Temperature by Using the Economizer
Bypass Damper and Economizer Outlet Damper (rather than attempting to control SCR inlet
temp).
Control Structures Use Bypass Damper First Then Begin to Use the Economizer Outlet Damper
When Bypass is Fully Opened and Remix Temperature is Below Setpoint
SCR Inlet Temperature is More Consistent/Predictable as a Result of the Better-Controlled Remix
Temperature
Base Full Load Remix Temperature Setpoint is ~ 600F
Remix Temperature Must Not Exceed 680F Due To Precipitator Issues
Remix Temperature Setpoint Slides to ~600F as Load Decreases
600F is Minimum Setpoint
Graphic Changes for the new
Temperature Control Design
Temperature
Control Mode
Graphic Changes for the new
Temperature Control Design
Select: Remix or
SCR Inlet Mode
Current
Mode indication
Bypass & Outlet Dampers
Auto/Manual
Process & Setpoint
Values
Graphic Changes for the new
Temperature Control Design
Damper Mode Indications: REMIX = Ctrl Remix Temp; INLET = Ctrl SCR Inlet Temp
Graphic Changes for the new
Temperature Control Design
Remix Temperature Controls:
General Tips
The new DCS controls for the Econ Remix temperature are designed to be used: through
the entire load range, year round, and with the SCR in or out of service
If remix temperature thermocouple goes Bad Quality, an alarm will appear. The
recommendation is for operator to go to Manual on both dampers
Switching to old mode of controlling the SCR inlet temp is an option, but this mode
utilizes remix temperature as Feed-Forward
Switching between the old temperature controls and new temperature controls can be
done with the dampers in Auto.
Note: A small bump may occur since the two modes are controlling slightly different
processes.
Ops should monitor dampers while making the switch
The goal is to remove the old temperature controls at the end of the year
SCR Temperature Optimization
Part #2
Optimization of SCR Inlet Temperatures at Lower Loads (SCR OPT)
SCR Inlet Temperature Optimization at
Lower MW Loads
The Specific Low Loads: ~350 MW to ~450 MW
The Goal: Raise SCR Inlet Temperatures at Lower MW Loads to Keep Ammonia System in
Service and Raise % Removal of NOx
The Method: Calculate and inject optimal bias settings for 2 Ovation DCS control
parameters
1. Bias O2 Setpoint
Purpose: More Air in Boiler Gives Higher Temperatures. The
current range of bias is a 0 1.9% increase in O2
2. Biases ID Fans
Purpose: Bring two SCR inlet temperatures closer together to
raise
minimum temperature. The current range is 5% of
total bias
(One Fan +2.5% and the Other Fan -2.5%)
SCR Inlet Temperature Optimization at
Lower MW Loads
Ovation DCS Control Modifications
New Optimization Bias Added to O2 Loop
When SCR OPT Optimization System is On and SCR OPT O2 Bias is selected, SCR OPT O2 Bias will
be used instead of operator bias
Range of Bias is 0-1.9%: Additional air will result in higher SCR inlet temps at lower loads
SCR OPT O2 Bias will be removed once load > 450 MM
If the operator needs to bias O2 at loads > 450, then the O2 Bias should be removed from the SCR
OPT control and the bias should be done as before.
When MW load is decreasing at night, the operator should put SCR OPT in control of the O2 bias
SCR Inlet Temperature Optimization at
Lower MW Loads
Ovation DCS Control Modifications
Furnace O2 Control Loop
New Optimization Bias Added to ID Fan Loop
When the SCR OPT Optimization System is On and the SCR OPT ID Fan Bias is selected, the
SCR OPT ID Fan Bias will be used instead of any operator bias
The current range of bias is a total of 5% (one ID Fan can be +2.5% and the other can be -
2.5%). This bias will allow the SCR inlet temps to be controlled closer together.
The SCR OPT ID Fan Bias will be removed once load > 450 MM
If the operator needs to bias the ID Fans at loads > 450, then the ID Fan Bias should be
removed from SCR OPT control and the bias should be done as before
When load decreases at night, SCR OPT should be put in control of ID Fan Bias.
21/22 ID FAN Control Loop
SCR Inlet Temperature Optimization at
Lower MW Loads
Ovation DCS Control Modifications
Graphic Changes for the new
SCR Inlet Temperature Optimization
Optimizer Status
SCR OPT PROGRAM TROUBLE
SCR OPT Program is Not Running or Aggregates Program is
Not Running
ACTION: Call Emerson
BOILER NOT READY
Boiler Permissives Have Not Been Met for Boiler Optimization
ACTION: Check Permissive Window on This Graphic to See Which Permissive is Not Met
SCR OPT READY TO ENABLE
All Boiler Permissives Made
SCR OPT Programs Are Running
SCR OPT Optimization is OFF
OPTIMZER READY
All Boiler Permissives Made
SCR OPT Programs Are Running
SCR OPT Optimization is ON
O2 and ID Fans Are Not in SCR OPT Control
OPTIMIZER ON O2 ONLY
All Boiler Permissives Made
SCR OPT Programs Are Running
SCR OPT Optimization is ON
O2 Bias in SCR OPT Control, ID Fan Bias Not in SCR OPT Control
OPTIMIZER ON IDS ONLY
All Boiler Permissives Made
SCR OPT Programs Are Running
SCR OPT Optimization is ON
O2 Bias Not In SCR OPT Control, ID Fan Bias In SCR OPT Control
OPTIMIZER RUNNING
All Boiler Permissives Made
SCR OPT Programs Are Running
SCR OPT Optimization is ON
O2 Bias In SCR OPT Control, ID Fan Bias In SCR OPT Control
Graphic Changes for the new
SCR Inlet Temperature Optimization
Optimizer Status
Graphic Changes for the new
SCR Inlet Temperature Optimization
Optimizer System Buttons
Overall SCR OPT Optimization System:
On/Off
SCR OPT Optimizer - Bias ID Fans
Status
On Optimize On & controlling ID bias
Off Optimizer Off & not controlling ID bias
Hold SCR OPT Optimizer Off, but does
have
control of ID Bias (if SCR OPT
optimizer is
turned on, it will have control of ID
Bias)
SCR OPT Optimizer - Bias O2
Status
On Optimize On & controlling O2 bias
Off Optimizer Off & not controlling O2 bias
Hold SCR OPT Optimizer Off, but does have
control
of O2 Bias (if SCR OPT optimizer is
turned on,
it will have control of O2 Bias)
Graphic Changes for the new
SCR Inlet Temperature Optimization
Optimizer System Buttons
Graphic Changes for the new
SCR Inlet Temperature Optimization
Optimizer System Permissives
SCR OPT PROGRAM READY
SCR OPT program is operational
AGR PROGRAM READY
AGR program is operational
SCR PATH 21 AND 22 OPEN
Both flow paths must be open to turn scr optimization system on
SCR 21/22 INLET TEMPS AND 21/22 REMIX TEMPS GOOD QUALITY
Must have good quality on all 4 temperatures for optimization to be on
Bad quality on any of the 4 will automatically turn SCR OPT scr optimization off and
optimization biases will go to ~0
LDC DEMAND OK
LDC demand must be >310 mw to turn optimization system off
If demand goes below 310 mw, optimization system will automatically turn off and any
optiimization biases will go to ~0
4 OR MORE COMPS IN SERVICE
SCR OPT SCR optimization system can only be turned on if 4 or more compartments are
in service
21/22 ID CONTROLLER IN AUTO
21/22 ID fan controllers must be in AUTO for CRO to enable the ID fan bias for SCR OPT
FURNACE O2 CONTROLLER IN AUTO
Furnace O2 controller must be in AUTO for CRO to enable the o2 bias for SCR OPT
BOILER READY
Logical AND of permissives 3-8 above. Indicates the boiler is ready for
optimization
Graphic Changes for the new
SCR Inlet Temperature Optimization
Optimizer System Permissives
Graphic Changes for the new
SCR Inlet Temperature Optimization
LDC
Messages are the same as in slide 28
Graphic Changes for the new
SCR Inlet Temperature Optimization
Fan Controls
IVY Should Be On and In Control of Biases of ID Fans and O2
High Loads: SCR OPT should not move ID Fans or O2, Optimization Biases should be 0
If operator needs control of either at high loads, SCR OPT should be Off for that parameter. Bias the
normal way.
Once excursion ends, control of that parameter should be returned to SCR OPT (optimization).
Ramping Unit Down
As unit ramps Down, SCR OPT (optimization) will try to control SCR inlet temp to ~580 585F
(alarm occurs at 560F, ammonia trips at 555 F)
SCR OPT (optimization) will also try to bring SCR 21 inlet temp and SCR 22 inlet temp closer
together
Biases will be applied to O2 and ID Fans from SCR OPT (optimization)
Make sure SCR OPT is On and Controlling ID Fan Bias and O2 Bias prior to ramp down for maximum
effect
Ramping Unit Up
As unit ramps up, SCR OPT (optimization) Biases to O2 and ID Fans should slowly bleed out to a
value near 0 as load increases.
Unless operator removes optimization control of these Biases, SCR OPT (Optimization) will still
have control of Biases
SCR Optimization
General Tips
AES Alliant Energy Ameren Energy Generating American
Electric Power Constellation Power Source Generation
Dairyland Power Cooperative Duke Power Dynegy Power
Generation Eastman Kodak (Tennessee Eastman) Edison
Mission Energy Electric Energy Inc. Elektrownia im. T.
Kosciuszki S.A. Elektrownia Kozienice, S.A. Entergy
Louisiana Florida Power & Light Grand River Dam Authority
Keyspan Energy Korea Electric Power Corporation
(KEPCO) MidAmerican Energy Mirant Corporation Nevada
Power Panda Energy International PSEG Power Public
Service of New Hampshire Saudi Electric Company
Seminole Electric Cooperative Sempra Energy Resources
Southern California Edison University of Michigan We
Energies Xcel Energy Zespol Elektrownia Ostroleka, S.A.
Years of experience in process control design,
implementation, and field installation
With more than 400 SmartProcess
installations on many different
control systems, Emerson is the
market leader in advanced control.