Energy Efficiency and
Intelligent Power PlantsRameshbabu R S
10th May, 2006The Center For Bits And Atoms
MIT
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Broad and Diverse Business, Technologies and Products Broad and Diverse Business, Technologies and Products
Aerospace
Specialty Materials
Automation and Control
SolutionsTransportation
and Power Systems
Honeywell International Inc
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Context for Industrial Energy Efficiency
Emission
DemandGeneration
Plant Performance Management
Dis
trib
uted
Dem
and
Man
agem
ent
Equipm
ent Perform
ance Optim
ization
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Key Components of Intelligent Power plant
• Process monitoring and optimization
• Plant and Unit performances analysis
• Economical analysis of plant for optimization
• Schedule optimization
• Advanced control technologies
• Equipment health management
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Process Monitoring, Optimization & Mgmt
• Real-time Process data collection
• Real-time process statistics
• Real-time process monitoring
• Schematics visualization & analysis
• Reports Generation
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Performance Calculation & Analysis
• Plant Performance• Unit Performance• Mass and Energy
Balance• Boiler• Turbine• Feedwater Heater• Condenser• Cooling Tower
• Air Preheater• Feedwater Pump• Condensing Pump• Circulating Pump• Induced Draft Fans• Force Draft Fans• Primary Air Fans• Combustion Turbine
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Economical analysis and optimal operation guidance
• Calculate and compare between the actually controllable parameters and expected parameters to obtaining the energy losses
• Analyze the reasons of deviation by expert system, and providing the operation direction
• Primary Controllable Losses
- Main Steam Pressure
- Main Steam Temperature
- Reheat Steam Temperature
- Carbon Content of Fly Ash
- More…• Primary uncontrollable Losses
- RH Pressure Loss- Fuel Thermal Value- HP Turbine Efficiency- More…
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Optimal Operational Schedule
• Receive the instruction from EMS (Energy Management System), then distribute the load to each unit, meanwhile reduce the gross coal consumption and ensure safe, steady and economical running.
• Integrate the equal Incremental Rate and Neural Network arithmetic to predict the load variation.
• Consider all restricted conditions and running steadily, to ensure running safely and economically.
• Flexible running modes, and satisfy various conditions.
• E.g. Sootblowing- How to measure & monitor the cleanliness or fouling?
- How to quantify the degree of contamination?
- How to measure the change in heat transfer efficiency of the surface?
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Advanced Control Technology
• E.g. Advanced Combustion Control- To optimize the excess air in the
combustion process to decrease CO emission
- Calculate the best relationship between oxygen, air flow, coal supply, main steam flow and so on
• Online Performance Test- Boiler Performance Test
- Turbine Performance Test
- Condenser Performance Test
- Air Preheater Leakage Test
- Vacuum Leakage Test
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Typical Sol: Industrial Power Plant
ACC
ACC
ACC
EL
A-B
TLC
ELA-TMPC
Several boilers operating to common steam header
Backpressure turbine(s) (w/extractions)
Condensing turbine(s)(w/extractions)Steam Let-down
Station(s)
ACC – Advanced Combustion ControlELA-B – Economic Load Allocation for BoilerELA-T – Economic Load Allocation for Turbine
TLC – Tie Line ControlMPC – Master Pressure Control
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Sample Optimization Benefits
• HPI/Chemical plant relying on steam delivery from in-house
boiler unit
Scenario for Industrial Power:
Item Original Optimized NotesSteam production capacity [t/h] 200 200Steam production costs [€/t] 6.75 6.65 1.5 % improvementPlant Daily Production [€/day] 1 000 000 1 000 000Lost production on off-spec steam [€/h] 20 833 20 833Trips due to off-spec steam [h/yr] 72 36 50 % trips eliminatedAnnual Revenue [€/yr] 363 500 000 364 250 000Steam production costs [€/yr] 11 824 598 11 647 229Profit (w/out fixed+input costs) [€/yr] 351 675 402 352 602 771Optimization Benefit [€/yr] 927 369
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Sample Optimization Benefits
• CHP selling heat, power, and power ancillary services
Scenario for District Heating:
Item Original Optimized NotesWinter average heat delivery [t/h] 300 300Summer average heat delivery [t/h] 85 85Winter average power delivery [MW] 80.0 81.6 2% improvementSummer average power delivery [MW] 40.0 40.4 1 % improvementAnnual Operations [h] 8 760 8 760Availability factor [%] 0.92 0.92 1 month offAncillary services regulatory range [MW] 8 12 enhanced flexibilityAncillary services contracted [months] 6 6Heat price [€/GJ] 12 12Power price [€/MWh] 32 32Ancillary service price [€/MW/h] 23 23Total annual revenue [€/yr] 71 368 734 72 028 654Optimization Benefit [€/yr] 659 920
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Summary
• Specific Benefits of the Industrial Energy Efficiency Sol- Improved stability of steam headers, responsiveness to steam
demand
- Increased power generation flexibility
- Minimized operations cost
- Overall efficiency increase
- Fuel cost savings
- CO2 Emission Reduction
• A comprehensive Intelligent Power Plan is aimed to improve the overall Energy Efficiency in following aspects- Improved Generation Efficiency
- Improved Energy Consumption Efficiency
- Reduced Emission
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We are building a world that’s…Safer and more secure
More comfortable and energy efficient
More innovative and productive
We are Honeywell.
Aerospace Automation Control Transportation SystemsSpecialty Materials
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www.honeywell.com