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Unburned Carbon In the fly ash

UBC versus CO2 Emission

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Steam Generator

Air

Secondary air

Primary air

Burner

Air preheater

Heat Input: Coal Losses: Flue gas heat loss Gaseous LOI (CO) Unburned Carbon Radiation Ash Heat Loss
Precipitator Flue gas

Coal bin Pulverized fuel

Coal
Mill Air fan

Intermediate storage tank

UBC
Fly ash

Air

Power Station Basis Data (example): Mean continuous load (Basis: steam production) 100 Full-load (100% MCR) operating hours per year Coal mass flow (100% load) Excess air ratio (100% load) %

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6 000 [hrs] 300 1.25 [shtn/h]

Gross heat input (calculated for 100 % load)

Gross electric power output (100% load) Net power efficiency

7 109 [BTU/hr 106]

750 36 [MWel] [%]

Combustion Heat Loss

Unburned carbon in ash CO 1.11% Other losses Sensible ash heat loss Boiler radiation heat loss

5.5% Flue gas heat loss

Goals of good combustion practice: Reduction of excess air Reduction of fly ash carbon content Reduction of CO 5 [%-points] 1 [%-points] 80 [ppmdv]

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Sources of Improvement

Carbon in ash Flue gas heat loss improvement

(0.43 % absolute)

Other
improvements (0.13 % absolute)

CO

Fuel savings: 10,000 shtn/yr at 30 US$ per shtn: we focus on your process 300 000 US$ per year Savings in CO2 emissions: 26 493 shtn/a CO2 emission credit
Assumed market price within intern. CO2 emission trading system: 5 $ per ton 132 000 $ per year reduced CO2 emission

Total boiler losses 6 % (absolute)

total fuel heat savings = 0.57 %

0.43% reduction in flue gas heat loss 0.10% reduction in solid LOI (carbon in ash) 0.04% reduction in gaseous LOI (CO)

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Steam Generator

Air

Secondary air

Primary air

Burner

Air preheater

Heat Input: Coal mass flow & CV Losses: Flue gas temperature & O2 CO Unburned Carbon in Fly Ash Coal analysis (Ash Content) Ash Temperature
Precipitator Flue gas

Coal bin Pulverized fuel

Coal
Mill Air fan

Intermediate storage tank

UBC
Fly ash

Air

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MECONTROL UBC Sensor

Screw

Measuring Chamber

Drive Shaft

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MECONTROL UBC Measurement Principle

Dielectric constant of fly ash is a function of the carbon content. Measuring the shift of frequency in a resonator ( f) the carbon content can be calculated.

UBC = A + B f A and B are the calibration coefficients

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Measurement Data of MECONTROL UBC

Kanal 2 Kanal 3

Wedel
1000 900 800 700 600 500 400 300 200 100 0 28.07.2001 00:00

1000 900 800

Temperatur Kanal 2 Temperatur Kanal 3

Rest-C [0,01%]

700 600 500 400 300 200 100 0 18.07.2001 00:00 20.07.2001 00:00 22.07.2001 00:00 24.07.2001 00:00 26.07.2001 00:00

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Trial run at BEWAG "Reuter West" power plant

125 Secondary Air x 1000 (inverted) [m/h] STP 130 135 140 145 150 10 9 8 7 6 5 UBC [%]

155
160 165 170 06:00
1 % O2
Secondary Air (MECONTROL Air) UBC ETG 17 (MECONTROL UBC) UBC ETG 18 (MECONTROL UBC)

4
3 2 1 18:00

07:00

08:00

09:00

10:00

11:00

12:00 Time

13:00

14:00

15:00

16:00

17:00

Remark: Listed values of secondary air amount are only for one burner plane.

Result of SA Reduction Trial Run

Boiler Optimization Program

Trial run at BEWAG "Reuter West" power plant
18 16 CO x10 [mg/m] STP 14 12 10 8
UBC Fly ash (MECONTROL UBC) UBC Fly ash (Lab analysis) O2 Boiler / DeNOx outlet CO Stack

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4.5 4 3.5 3 2.5 2 O2 [%]

UBC [%];

6
4 2 0
7:00 7:30 8:00 8:30 9:00

1.5
1 0,5 0
9:30 10:00 10:30 11:00 11:30 12:00 12:30 13:00 13:30 14:00 14:30 15:00 15:30 16:00 16:30 17:00

Time

Result of SA Reduction Trial Run

Boiler Optimization Program

General calculation example with parameter variation Basis: 5 % UBC in fly ash; 4.3 % O2 in flue gas
0.45% O2 UBC at 7.2 % gA

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0.40% 0.35% 0.30% 0.25%

Increase in efficiency*

Excess air reduction most efficient !

0.20%
0.15%

UBC at 3.6 % gA

0.10%
0.05% 0.00% 0% 1% 2% 3% 4% 5% 6%

*) Without power savings of fans

O2-content of flue gas; UBC in fly ash UBC in fly ash

Parameters for Efficiency Improvement

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Boiler / Mill Optimization by UBC Monitoring

Trial run at Wedel power plant 8 Secondary airBasis: n = 1.259 7 O2 [vol.-%]
Excess air: nabs= 7.6 %-pts h = 0.5 %-pts

400 Secondary air x 1000 [m/hr] STP 380 360 340 320 300 280 260 240 UBC
Basis: gash = 3.6 %

Resulting efficiency increase: 0.42 %-pts !

UBC: Cabs = -2 %-pts h = -0.08 %-pts

UBC [wt.-%];

O2 right duct O2 left duct

220 200

Time

Excess Air Reduction

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Boiler / Mill Optimization by UBC Monitoring

Datteln
20 18 16 14 12 10 8 6 4 2 0 09.08. 00:00
Kanal 0 geglttet Mittelwert Kanal 0

Rest-C [%]

11.08. 00:00

13.08. 00:00

15.08. 00:00

17.08. 00:00

19.08. 00:00

21.08. 00:00

23.08. 00:00

25.08. 00:00

27.08. 00:00

29.08. 00:00

Coal type change

Power Station Farge, Power Utility E-on

5

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620

4,5

600

SA1+CA
4

SA2

TA NOx [mg/m]
580

[Vol.-%]

3,5

560

2 3

540

2,5

520

O2 boiler out 2 10:00 11:12 12:24 13:36

NOx before Kat. 500 14:48 16:00 17:12

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Boiler Optimization Program

750 MW units Germany
Ash benefication ? 22%

Amonia savings 15%

CO2 sales 27%

Fuel Savings 36%

savings potential

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Boiler Optimization Program

750 MW units USA
Fuel Savings 22% CO2 sales 17% Ash benefication ? 6%

NOx credits 55%

savings potential

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Boiler Optimization Program

Savings pa 750 MW unit
$500,000 $450,000 $400,000 $350,000 $300,000 $250,000 $200,000 $150,000 $100,000 $50,000 $0,000

US Germany

Nox credits/Amonia

Fuel Savings

CO2 sales

Ash benefication ?

savings potential

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Boiler Optimization Program

Determine the O2/UBC, O2/CO and O2/NOx impact due to different air admission (Secondary air, Tertiary air, Overfire air, etc.) Change overall O2-level on the back pass with favorable excess air supply
Run boiler with optimized O2-settings

Action Items for UBC Control