ArturoMonteroSPPA P3000 Useful

Instrumentation, Controls & Electrical
NOx Reduction by Combustion Optimization

SPPA-P3000 Combustion Optimization Solutions
September 28th 2016

Max Starke, Product Manager for Process Optimization
Arturo Montero, Sales Manager PG IE- Spain Siemens AG 2016. All Rights Reserved.
Spanish Generation Market Overview
Coal Fired Power Plants = 10.065 MW
1.- La Directiva de Emisiones Industriales

1A.- Directiva 2010/75/UE del Parlamento Europeo y del Consejo, de 24 de noviembre de 2010. (GIC ; > 50 MWt)
1B.- Directiva (UE) 2015/2193 sobre Limitacin de Emisiones de Instalaciones de Combustin Medianas (MIC; 1-50 MWt)
2.- Las Centrales Trmicas de Carbn en Espaa
Page 2 SPPA-P3000 Process Optimization Siemens AG 2016. All Rights Reserved. Power Generation Instrumentation, Controls & Electrical
SPPA-P3000_siemens day 28th-v4a.ppt
1A.- La Directiva de Emisiones Industriales 2010/75/UE

*) Alternativas y Calendario de Aplicacin
1B.- Directiva (UE) 2015/2193 Emisiones (MIC; 1-50 MWt) :

*) Alternativas y Calendario de Aplicacin
2.- Las Centrales Trmicas de Carbn en Espaa
TCNICAS CLSICAS para Reducir los NOx
SPPA-P3000 Combustion Optimization & SNCR/SCR
Tcnicas
Medidas Primarias Medidas Secundarias

Avoid NOx formation = good combustion Remove NOx after combustion
Mtodos mecnicos Mtodos de Control Mtodos chemicol

(Combustion with low temperature + low O2) (Optimum, low O2 + fuel distribution in boiler) (Chemical clearing of flue gas with Ammonia / Urea)
Name Method Potent. NOx Reduction: 15-35% Reduccin Cataltica

LEA Low excess air <10%
Staged Staged air 10-40% +O2 Reduction: 0.2-1.0% (Heterognea)
- BOOS Burners out of service

(Efficiency 0.1-0.5%)
- BBF Biased burner firing
- OFA Over-fire air
FGR Flue gas recirculation <20% Reduccin Reduccin
LNB Low-NOx burners 20-30%
Air-staged & air/fuel-staged
ADDITIONAL Benefits: Cataltica Selectiva NO
AFLNB LNB <40%
RIR Reburning/in-furnace
<20%
CAPEX (compared with SCR) Selectiva Cataltica
NOx reduction
OPEX (SCR) (SNCR)
Life Time
Unique direct measurement and optimization
inside combustion zone
Measurement positions Measurement, Calculation, Optimization
Laser based Measurement of Temperature- and
Concentrations- ( H2O, O2, CO, CO2, ...) values directly
in the combustion zone
SPPA-P3000: Calculation and evaluation of temperature-
2D-Measurent in Classical: and concentration distribution through
combustion zone Point measurement Computer-Aided Tomography (CAT)
far downstream
Optimization through hybrid combustion control, using
classical model based control structures and adaptive
neural network
Temperature distribution in the combustion zone
homogenous combustion optimization

increased efficiency
reduced emissions before afterwards
Approved Technology...
designed for the harsh boiler environment
Boiler Electronic equipment room

Boiler
Junction
(top view) Sensor Head box
(Transmitter)
Measurement cabinet
1
1
2
2
3
Sensor Head 3
40
(Receiver) Mux 40 Demux
Transmitter Receiver
Junction
box
No sensitive electronics near the boiler Central installation of sensitive components,

Automatic cleaning (rodders + air) e.g. in electronic equipment room
Online alignment (SensAlign) Measurements currently possible:
Long service life time 100,000 h (use of - Temperature, O2, CO, CO2, H2O
standard telecommunication components) - Further development potential
Standardised systems with 10-24 paths
Modular variation of paths
Absorption Spectroscopy
a renown and established measurement technique
Absorption spectroscopy measures the absorption of

radiation (e.g. photons) at specific wavelengths. The
absorption intensity varies as a function of frequency
causing absorption spectrums.
Absorption spectroscopy is employed as an analytical
chemistry tool to determine the presence of a
particular substance in a sample and to quantify the
amount of the substance present.
Infrared and ultraviolet-visible spectroscopy are
common in analytical applications.
Absorption spectroscopy is also employed in studies
of molecular and atomic physics, astronomical
spectroscopy and remote sensing.
Computer Aided Tomography (CAT)
Measurement, Reconstruction und Interpolation
Values of Temperature-,
Path-average values intersection points Distribution of
Concentration
Computer Aided Tomography commonly used

e.g. in medicine technique (CT)
Installation of laser measurement equipment
Requires only Minimum Effort and 1-2 Days of Outage
8-10 mm slot for boiler

access
Mounting stem
Mounting
bolts
Pneumatic
cylinder Mechanic slag
rodder
Measurement head
Laser measurement system equipped with
Automatic Cleaning and Laser Centering
Port rodder retracted Port rodder extended
Boiler wall
Slagging
SPPA-P3000 Combustion Optimization
Sending Correction Signals into Exiting I&C Structures
Existing I&C system Boiler
Correction
Signals
before optimization after optimization
2D-Measurement Combustion
temp. & gas (inhomogeneous combustion) (combustion homogenization)
Optimisation
concentrations
Controllers
+
Temp.
+
Controller OFA 2
OFA 2.2
O2 +
+
Controller OFA 1
OFA 2.1
CO Controller
Burner 1
+
+
Secondary
air & fuel
Combustion optimization strategies
Minimizing excess air increases efficiency + reduces NOx
Optimization
Combustion and process

1 NOx
Optimum Zone
Comfort Zone
parameters
2 Efficiency
3 O2
4 CO
Optimum Excess air
Measuring and homogenizing the combustion process avoids local emission & temperature peaks. This
gives room for the optimization of the excess air level - beneficial for both the NOx emissions and the
efficiency!
Is the boiler operated in the comfort zone or in the optimum zone?
SPPA-P3000 Combustion Optimization - Examples
NOx reduction increasingly important - worldwide
KCPL La Cygne, EDF West Burton & Cottam, Reference

710 MW Hard Coal 500 MW Hard Coal Plants
NOx-Reduction 20% NOx-Reduction > 22-34%
GenOn Keystone, Huaneng Rizhao,

850 MW Hard Coal 680 MW Hard Coal
Infracor Marl,
Efficiency Improvement Efficiency Improvement
125 MW Hard Coal &
Petrochemicals + 0.5%
Efficiency Improvement O2 - 0.9%
& NOx Reductions NOx - 14.4%
RWE Neurath & Niederauem,
300-1000 MW Lignite
Efficiency Improvement Mark-E Elverlingsen,
Coal - 1.8t/h
310 MW Hard Coal & MBM Co-Firing
CO2 - 4.4t/h
Improved Co-Firing & NOx Reductions
EDF Cottam Unit 3 - Case Study
Set-Up & Improvements of Combustion Optimization
Process Data Evaluation Process Optimization Potential Configuration: Front fired boiler
Cttam Unit 3
NOx
500 200
400 160
Laser measure-
300 Plant Assessment: 120
NOx reduction Potential: > 30% ment plain
Efficiency Improvement: ~ 0.25%
200 80
Nose
Limit ~110ft Over fire
100 40
99ft air control
OFA
CO
0 0 Secondary
2,5 3 3,5 4 4,5 5 5,5 6
O2 MW [%] O2 SL air control
NOX h average mg\Nm3 Reg NOX mg/Nm3 CO Eco A ppm Reg CO ppm
SL
Laser Path Layout SL

For: SA
SL Mill
Single combustion Bias
chamber,
Front & back FD Fan
wall access, Bias
Front firing,
S1 S2 S3 S4 S5 S6 S7 S8
3-sided OFA A1 A2 A3 A4 A5 A6
~10x24m OFA
EDF Cottam Unit 3 Case Study Results:
Reduced NOx with Efficiency Improvements
Cottam Unit 3 - Optimsation Test Results at 530 MWel
560 mg/Nm -112 mg/Nm

551 mg/Nm
NOx reduction
( -20%)
-139 mg/Nm
maximum
443 mg/Nm 416 mg/Nm NOx reduction
( -25%)
Combustion optimization control loops & set-point corrections

(1) Balancing air/fuel-ratio at burner level Air Damper 32 x Secondary Finally
(2) Vertical air structuring with BOFA Flow 2 x BOFA Fan
(3) Total O2 level optimization at ECO 1 x O2 Set-point achieved
(4) Stabilizing wind box pressure Air Damper 32 x Secondary >30%
(5) Balancing of FD-fan air supply biasing 1 x FD-Fan
EDF Cottam Unit 3 - Case Study
Combustion Optimization for NOx Reduction
EDF Cottam 3 500 200
Laser Arrangement
Configuration: Frontat Boiler
fired Walls
boiler
NOx
400 160
Cottam Unit 3
300 120
200 80
Limit
100 40
0
CO 0
2,5 3 3,5 4
O2 MW [%]
4,5 5 5,5
O2
6
Laser measure-ment
NOX h average mg\Nm3 Reg NOX mg/Nm3 CO Eco A ppm Reg CO ppm
plain
1 x 500
4 500 MW,
MW, Steinkohle
hard coal ++ bio
Biomasse, BJ ~1968
mass, erection 1965-70
Nose
Cottam
NO CUTLAS
x emission LT before:
levels Modernisierungspotential
400 550 mg/Nm ~110ft
Over fire
Performance
NOx Emissionenbased
400optimization
550 mg/Nm , 99ft air control
OFA
NOx reduction: >30%
Secondary
Demand for boiler stress red. & flexibility increase SL air control
Underlying CUTLASS I&C System SL
Laser Path Layout SL

For: SA
SL
Single combustion
chamber,
Front & back
wall access, Mill
Front firing, control
3-sided OFA
S1 S2 S3 S4 S5 S6 S7 S8
A1 A2 A3 A4 A5 A6
~10x24m OFA
C&I Optimisation enhances the efficiency, flexibility, availability and
decrease emissions of thermal power plants
Achieved Cottam Achieved West Achieved Neurath

NOx reduction Burton Load gradient
achieved: >30% NOx reduction tripled
O2 reduction: 0.5% achieved: >22% Minimum load
(~0.25 efficiency) O2 reduction: >0.7% reduced by 40%
(~0.35 efficiency) Efficiency increased
EDF Cottam Unit 3 Case Study Results:
Control Modules for Set-Point Corrections
Process
Combustion I&C setpoints Laser Measurements (LM)
Optimization Optimisation
Control Modules BOFA
O2 level 1 x O2 BOFA BOFA

optimization at ECO B A
Vertical
air stucturing 2 x BOFA
by BOFA Fan Flow
Balancing of local
air/fuel-ratio
based on LM 32 x
Secondary
Air Damper
Stabilizing Position
wind box pressure
Windbox
Balancing of FD FD
FD-fan air supply B A
based on LM 1 x FD-Fan Bias
A B C D
Example Economic Benefit Calculation
Expected (NOx: -15%, O2: -0.5%)
Combustion Optimization Improvements
Lower emissions
Benefit of SPPA-P3000 Process Optimization solutions Lower NOx emissions
GNF La Robla 2 Com bustion Optimization EXPECT be fore afte r
NOx concentration (before SCR) 800 680 mg/m3
Lower CO2 emissions
NOx
-15%
General Plant Data
O2 - content flue gas 02 5 4,5 %
Formul
Description
a
Value Unit Flue gas temperature t RG 140 140 C - 0.5%
PG Further efficiency increases l 38 38 %
Unit Average Power 350 MW
Operation time tB 5000 h/a
Lower Carbon in Ash
Carbon in ash Asche 1 1 %
Efficiency of plant (gross) h l 38 %
Disposed ash m Asche 0 0 t/a
Specific price of electricity e 32,2105 55 EUR/MWh
Fuel - Hard coal - Benefit Calculation
Calorific value H u 25 MJ/kg
Ash content of coal gA 10 % Basis of calculation:
Disposal costs for ash k Asche 0 EUR/t
k Br
Efficiency Increase (O2 / fuel, fan power red.)
Specific price of fuel 85 EUR/t
Price of ammonia k NH3 400 EUR/t CO2 Reduction
Price of NOx certificate e NOx 0 EUR/t Ammonia reduction
Specific price of CO2 e CO2 8 EUR/t
Calculation dependent on estimations of market prices, cost,
Results and Benefit
Increased availability t 0 h/a operating hours etc.
Change of efficiency ges / 0,28 % More benefits that can be calculated with GNF internal
Benefit N 390.000 EUR/a information: Increased Life Time, Thermal Stress reduction,
CO2-Reduction mCO2 3.600 t/a
etc.
Fuel Savings (0.28 efficiency), Power & CO2 Reduction = 223.000 Euro per Year
Ammonia Savings = 168.000 Euro per Year
* Market boundary conditions adjusted according to GNF data from May 2015.
SPPA-P3000 Combustion Optimization
System Features / Differentiation
1. Fast implementation time

- Installation: 1-2 days during outage, 2 weeks commissioning
- Optimization: 2-3 months during operation
2. No mechanical modification required,
100 % adaptable to later process modifications
3. Reduced CAPEX
- if installed in existing T3000
- synergies for two Installations
4. Improved OPEX with Guaranteed Minimum Improvements
- 10%-34% NOx reduction
- 0.25%-0,25% O2 reduction (~0.15 to 0,5 % efficiency increase )
5. Improves Boiler Lifetime and Flexible Operation
6. Laser Measurement enhances SNCR / other solutions
SPPA-P3000 Combustion T Measurement (Optimization)
Phase 1.- Mechanical works
VIDEO
Phase 2.- Electrical Works
Phase 3.- Commissioning
C&I optimisation to enhance the efficiency, flexibility, availability and decreases
emissions of thermal power plants
Runback Plus
Laser Based Combustion Optimisation
Life Time Plus No changes to mechanical
Hybrid-Combustion Optimisation equipment
High availability
Low Loss Start
Fast Start
Combustion Optimiser Fast Ramp
Soot Blower Optimiser Frequency Control
High efficiency High flexibility
Temperature Optimiser Dispatch Control
Low Throttling Minimum Load Reduction
Best Point Maximum Load Plus
Low emissions
NOx Minimiser
CO2 Minimiser
LoI Minimiser
RWE Neurath Unit D:
Contractual targets reached and greatly exceeded
starting contract proven further possible

situation (trial run) potential
Load gradient 5 MW/min 12 MW/min 15 MW/min 20 MW/min x 3.0

270 MW 250 MW
Minimum load (gross) 440 MW 290 MW (w/o bypass
operation)
(with risks, e.g. minimum
fire interlock)
40%
Primary frequency 18 MW by 18 MW by
45 MW 50 MW
control (PFC) throttling of inlet valves condensate throttling x 2.5
Secondary frequency
n.a. 66 (75) MW 100 MW 110-115 MW
control (SFC) New
Simultaneous PFC and 18 MW 18 MW
n.a. still under investigation
SFC 66 (75) MW 75 MW New
D: 9 days
"Hot" commissioning - 10 days -
E: 32 hours
D: 8 months
Optimsation phase - - -
E:1-2 months
Source:
Page 28 SPPA-P3000 Process Optimization Siemens AG 2016. All Rights Reserved. Power Generation
PowerGen Instrumentation,
Europe Presentation 2013 Controls & Electrical
SPPA-P3000 Process Optimization
Gracias por Published by and Copyright 2016:
Siemens AG
Power Generation
Instrumentation & Controls
su atencin
Siemensallee 84
D-76187 Karlsruhe
Phone: + 49 7 21 / 5 95 - 69 43
Fax: + 49 7 21 / 5 95 - 67 21
E-Mail: contact-pgl1@siemens.com
www.siemens.com/ic
Por favor no duden en Subject to change without prior notice.
The information in this document contains
contactarnos general descriptions of the technical options

available which do not always have to be
present in individual cases.
The required features should therefore be
specified in each individual case at the time
of closing the contact.
con sus dudas SPPA-P3000 Process optimization

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Instrumentation, Controls & Electrical

NOx Reduction by Combustion Optimization

September 28th 2016

1.- La Directiva de Emisiones Industriales

2.- Las Centrales Trmicas de Carbn en Espaa

1A.- La Directiva de Emisiones Industriales 2010/75/UE

1B.- Directiva (UE) 2015/2193 Emisiones (MIC; 1-50 MWt) :

2.- Las Centrales Trmicas de Carbn en Espaa

Medidas Primarias Medidas Secundarias

Mtodos mecnicos Mtodos de Control Mtodos chemicol

Name Method Potent. NOx Reduction: 15-35% Reduccin Cataltica

- BOOS Burners out of service

homogenous combustion optimization

Boiler Electronic equipment room

No sensitive electronics near the boiler Central installation of sensitive components,

Absorption spectroscopy measures the absorption of

Computer Aided Tomography commonly used

8-10 mm slot for boiler

Port rodder retracted Port rodder extended

Combustion and process

KCPL La Cygne, EDF West Burton & Cottam, Reference

GenOn Keystone, Huaneng Rizhao,

Laser Path Layout SL

560 mg/Nm -112 mg/Nm

Combustion optimization control loops & set-point corrections

Laser Path Layout SL

Achieved Cottam Achieved West Achieved Neurath

O2 level 1 x O2 BOFA BOFA

1. Fast implementation time

starting contract proven further possible

Load gradient 5 MW/min 12 MW/min 15 MW/min 20 MW/min x 3.0

Gracias por Published by and Copyright 2016:

Por favor no duden en Subject to change without prior notice.

The information in this document contains

contactarnos general descriptions of the technical options

con sus dudas SPPA-P3000 Process optimization

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