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Yokogawa FGD Optimization System Flue Gas Desulfurization
1
24th Feb, 2017
Alessandro Roncarati
Advanced Solutions Development Manager
Yokogawa Italia
| Document Number | March 23, 2016 | © Yokogawa Electric Corporation
CONFIDENTIAL 2
| GSC| April 20, 2016 | Copyright © Yokogawa Electric Corporation
Agenda
1. Yokogawa Introduction
2. FGD plant in Japan
3. FGD optimization overview
4. Benefits
5. Detail functions
6. Questions
3
Yokogawa Introduction
Corporate Information
4
Established as an electric meter research institute in Tokyo.
1915 1917
Produced Japan’s first electric meter.
1924
Released Japan’s first portable magnetic
oscillograph.
1950
Developed Japan’s first electronic recorder.
1975
Released the world’s first distributed control system
(DCS)
1984
Entered the high-frequency measuring instrument
business with digital oscilloscope.
1988 2015
Released analog LSI test system
100th Anniversary
100 years of history for control and measurement business
Products ＆ Solution portfolio
5
Corporate Management (ERP*) Integrated business operation systems
Production Management
(MES*) Systems for advanced control, simulation, production management, and scheduling
Plant Information management System
Asset Management
CAMS for HIS
Advanced Process Control & Operational Work Assistance
AXF
Magnetic Flowmeter
DYF
Digital Vortex Flowmeter
Field Instruments Field instruments, sensors, measuring instruments, analyzers and other equipment
EJA/ EJX
Differential Pressure Transmitter
US300
Ultrasonic Flowmeter
GC8000
Process Gas Chromatograph
YVP
Advanced Valve Positioner
YTA50/70 YTA100/300
Temperature Transmitter
Production Control Systems
Safety Instrumented System
Network Based Control System
* ERP = Enterprise Resource Planning
* MES = Manufacturing Execution System
Production & Operation Management System
Distributed
Control System (DCS)
TDLS
Tunable Diode Laser Analyzer
Worldwide Business Operations
Ｃ
Global network supporting business growth
As of the end of March 2015
World Headquarters
Yokogawa Electric
Corporation (Japan)
Yokogawa Corporation of
America (USA)
Yokogawa China (China)
Yokogawa Middle East & Africa
(Bahrain)
Yokogawa Europe
(Netherland)
13 subsidiaries and 1 affiliate in Japan 71 subsidiaries and 2 affiliates outside Japan
Yokogawa South America
(Brazil)
6
Yokogawa employee worldwide
7
As of March 31, 2015
Group companies in Japan 5,140
Yokogawa Electric Corporation
2,871
Group companies outside Japan
11,590 19,601 Worldwide
DCS Installation Map
8
NORTH AMERICA
Africa
Asia
Oceania
Middle East
South America
North America
Europe 970
712
422
20,775
426
660
2,610
EUROPE As of Jun. 2016
TOTAL
26,575 UNITS
AFRICA
MIDDLE EAST
OCEANIA AUSTRALIA (409) NEW ZEALAND (2)
NEW CALEDONIA (1) PAPUA NEW GUINEA (4)
FIJI (6)
ASIA SOUTH AMERICA
AUSTRIA (30) AZERBAIJAN (1) BELGIUM (222) BELARUS (17) BULGARIA (5) CROATIA (5) DENMARK (6) FINLAND (3)
FRANCE (251) GERMANY (283)
GREECE (21) HUNGARY (69) IRELAND (4) ITALY (153)
KAZAKHSTAN (17) LITHUANIA (1)
NETHERLANDS (193) NORWAY (10) POLAND (24)
PORTUGAL (8) ROMANIA (12) RUSSIA (799) SERBIA (12)
SLOVAKIA/CZECH (115) SLOVENIA (2) SPAIN (163) SWEDEN (2)
SWITZERLAND (18) TURKMENISTAN (12)
UK (106) UKRAINE (8) TURKEY (37)
SCOTTLAND (1)
ALGERIA (50) ANGOLA (16)
BOTSWANA (4) CONGO (14) EGYPT (64) GABON (10) GHANA (6) KENYA (3) LIBYA (5)
MOROCCO (24) MOZAMBIQUE (1)
NAMBIA (1) NIGERIA (50) SENEGAL (3)
SOUTH AFRICA (160) SUDAN (6)
SWAZILAND (2) TUNISIA (2) UGANDA (4) Tanzania (1)
BAHRAIN (37) DUBAI (1) IRAN (106) IRAQ (17)
JORDAN (5) KUWAIT (16) OMAN (61) QATAR (15)
SAUDI ARABIA (315) SYRIA (6) U.A.E (69)
YEMEN (11) Lebanon (1)
BANGLADESH (2) INDIA (1,579) MYANMAR (7) PAKISTAN (6) CHINA (2,921) KOREA (1,212) TAIWAN (525) JAPAN (12,794) MALAYSIA (311)
INDONESIA (380) PHILIPPINES (200) SINGAPORE (274) THAILAND (510) VIETNAM (47) BRUNEI (4)
SRILANKA (3)
ARGENTINE (12) BRAZIL (594) BOLIVIA (1) CHILE (4)
COSTA RICA (1) COLOMBIA (17)
CUBA (14) EL SALVADOR (1)
MEXICO (49) NICARAGUA (1)
PANAMA (2) PERU (1)
TRINIDAD TOBAGO (2) URUGUAY (2)
VENEZUELA (11)
CANADA (24) USA (944)
CENTUM is Well-accepted Widely in the Market
Yokogawa’s Sales Records
FGD
CCPP
Coal Firing Central Control Room
Solar
Wind Farm
Geothermal
More than 1,600 systems
for power plants
10
Recent Fossil Fuel Fired Power Plant Customers
Tuas Stage I, Singapore
600MW x 2, oil, CS & Simulator 720MW x 4, coal, CS3000 &
simulator
Eraring, Australia
Pha Lai 2, Vietnam
300MW x 2, coal, CS3000 &
simulator
Pucheng, China
330MW x 2, coal, CS3000 Maritza East II, Bulgaria 200t/h x 8, FGD, CS3000
NTPC Rihand, India 500MW x 2, coal, CS3000
Jeddah South, Saudi Arabia 4x730MW, oil Centum VP
Arcelor Mittal Tubarao, Brazil 75MW x3,
Off-gas (ferrous), CS3000, CS
Tobata PP, Japan 250MW, Gas, CS3000
375MW,Gas, CS3000
Loy Yang A,
Australia
550MW x 4, coal, CS3000 &
simulator
550MW x 2, coal, CS3000
Taichung, Taiwan
500MW x 4, coal, CS3000
Liddell, Australia
NTPC Lara, India, Supercritical
800MW x 2, coal, Centum VP
Vung Ang 1, Vietnam 600MW x 2, Coal, Centum VP
KEPCO Yeosu, Korea 350MW CFB, Centum VP
Tachibana-wan, Japan 1050MW x2, FGD, CS
Cairo West, Egypt 350MW x2, Oil/Gas, CS3000
Suralaya, Indonesia
400MW x 4, coal, CS3000
NTPC Indra Gandhi, India, 500MW x 3, coal, CS3000
Raipur, India, Supercritical
685MW x 2, coal, Centum VP
NTPC Kudgi, India Supercritical 800MW x 3, coal, Centum VP
Retrofit
Retrofit
Retrofit Retrofit Retrofit Retrofit
Turceni, Romania 330MW x 4, FGD, CS3000
TES4 Phase2, Mongolia 420t/h x 8, coal, CS3000 simulator
Retrofit
Nigrie, India, Supercritical 660MW x 2, coal, Centum VP
Nghi Song 1, Vietnam 300MW x 2, Coal, Centum VP
Retrofit
Mong Duong2, Vietnam 600MW x 2, Coal, Centum VP
Supercritical
Gas Turbine Power Plant Customers
Kahrama IWPP,
Algeria 369MW, IWPP
Nubaria CCPP, Egypt 750MW, CCPP
Sidi Krir CCPP, Egypt 750MW, CCPP
Banha CCPP, Egypt 750MW, CCPP
Giza North CCPP,
Egypt 2 x 750MW, CCPP
Enel St. Barbara, Italy
400MW, CCPP
BBE, Spain
800MW, CCPP
NIPP Calabar, Sapele, Ihovbor,
Nigeria 560MW, 450MW, 450MW
SEC Shoaiba II, Saudi Arabia 1200MW, CCPP
PTT Utility Co., Thailand 151MW, CCPP
Thai National Power, Thailand 110MW, CCPP
Bukit Panggal, Brunei 110MW, CCPP
Channel Island, Australia 216MW,CCPP
Condamine, Australia 135MW, CCPP
Bcaresti Vest, Romania 180MW, CCPP
Kemalpasa, Turkey 130MW, CCPP
Vemagiri, India 3 x 370MW, CCPP
Punta del Tigre, Uruguay 500MW, CCPP
TermoPernambuco, Brazil 460MW, CCPP
Fenix Power Chilca,
Peru
530MW, CCPP
Termozulia, Venezuela
460MW, CCPP
Trinidad and Tobago Elec. 720MW, CCPP
Taean IGCC, Korea 300MW, gasification Dongducheon, Korea
1900MW, CCPP
Tokyo Gas, Japan 100MW, CCPP
JFE Chiba, Japan 149MW, CCPP
Tront Airport, Canada 117MW, Cogen
Black Hills Energy, US
100MW, CCPP
Front Range, US
480MW, CCPP
SEC PP13&14, Saudi Arabia 2 x 1980MW, CCPP
Global customers in power sector
13
Integrated Control and Monitoring System for Power Plant
PRM
Vnet/IP: 1Gbps
Plant Information
Management
Integrated plant
resource management
Plant Simulator
Ethernet
Operator station
Turbine run up system
Instructor system
Main computer system
Input/Output system
- Power generating unit
/steam collection
Total Plant Operation
Field Instruments
EJA/X transmitter
-Integrated field
device
management
- HART
- Foundation
Fieldbus
- Wireless
- High performance, durability & reliability
- Field-proven silicon resonant sensor
- HART, Foundation Fieldbus, Wireless
- Against H2S gas
BOP
Controller
Boiler
Controller
Boiler/ Turbine Protection System Turbine
Controller
Safety System
- SIL3 certified Safety System
- Integrated system to DCS
Prosafe-RS
Remote
I/O
- 5ms servo control
- 5-10ms turbine protection
- True integration on DCS
Turbine Control
DCS
- Large application in a
single architecture.
-“Pair & spare” non-stop
controller.
CENTUM VP
Integration of 3rd
party equipment
- Vibration monitoring system
- Electrical equipment
IEC61850, Profibus
- Grid SCADA/RTU
GW
Operator Training Services
Advanced
Process Control
- Long-term data
storage, data & alarm
logging, performance
calculation
15
FGD Plant in Japan Flue Gas Desulfurization
Thermal Power Plant: Coal fired
P. 16
Boiler Scope
Coal Handling Ash Handling
FGD
Bottom Ash Water/ Waste water
treatment
Demin
Fuel Oil
BOP
Turbine Scope Electrical
Where is FGD in the power plant?
FGD plant installation history in Japan
0
50
100
150
200
250
300
0
500
1000
1500
2000
2500
3000
Total capacity (10⁶m³ N/h)
No. of plant Instllation of FGD Plant
The number of installation
Total processing capacity
The number of installation 102 183 323 543 768 994 1134 1192 1227 1266 1329 1362 1366 1405 1583 1741 1758 1789 1810 1843 1914 2014 2099 2173 2142 2249 2228 2257 2336 2094 1993 1908 2077
Total processing capacity 5.4 9.3 18 28.8 42.7 79.5 104 111 115 117 122 127 127 129 133 155 155 169 176 179 194 205 210 214 215 216 222 233 248 224 218 221 209
17
Installed for Oil fired Installed for Coal fired
1970 1985 2000 2015
No. of FGD plant
Yokogawa DCS references for FGD in Japan
Electric Utility Power Station UnitGeneration
Capacity
FGD Plant
Supplier
Operation
Date
Kansai Electric Maizuru 1 900MW CCEC Jul-04
Kyushu Electric Reihoku 1 700MW IHI Jun-03
2 700MW IHI Jul-95
Chubu Electric Hekinan 1 700MW MHI Oct-91
2 700MW KHI Jun-92
3 700MW MHI/CCEC Apr-93
4 1,000MW KHI/BHK Mar-01
5 1,000MW KHI/BHK Mar-02
Hokuriku Electric Nanao Ohta 1 500MW CCEC Mar-95
2 700MW CCEC Jul-98
Tsuruga 1 500MW IHI Jan-91
2 700MW IHI Oct-00
Shikoku Electric Tachibana-wan 1 700MW MHI Jul-00
Chugoku Electric Misumi 1 1,000MW MHI Jul-98
Hokkaido Electric Tomato Atsuma 2 600MW MHI Jan-85
4 700MW MHI Oct-02
Electric Power Development Tachibana-wan 1 1,050MW MHI Jul-00
2 1,050MW BHK Jan-01
Matsuura 1 1,000MW Hitachi Jan-91
2 1,000MW IHI Jul-97
Matsushima 1 500MW Sumitomo Machine Jan-81
2 500MW Hitachi Jun-81
Takehara 3 700MW IHI Mar-83
Yokogawa’s DCS share for FGD in Japan: 60%
18
Tachibanawan, Japan: 2 x 1,050MW, coal-fired
Integrated system of environmental control facilities,
for one of the largest coal-fired power plants in Japan
Tachibanawan Thermal Power Station
Owned by J Power
2 x 1,050 MW
Owned by Shikoku Electric
Power 700MW
Maizuru, Japan: 900 MW coal-fired
Location: Kyoto Prefecture, Japan Owner: Kansai Electric Power Co. FGD: Chiyoda Control system for environmental control facilities: CENTUM Control scope:FGD, EP(electric precipitator), ash handling, and waste water treatment Scope: *System design/engineering *Configuration *Project management *commissioning service *Field equipment, *Maintenance contract
http://www.kumagaigumi.co.jp/hyosyo/hy_040513_2.html
21
Yokogawa FGD Optimization System Overview Flue Gas Desulfurization
Flue gas desulphurization types
22
Seawater
Scrubbing
Wet
* With humidification, ** With product recycling
Process Absorbent Byproduct Efficiency
Lime/Limestone
scrubbing
Spray
absorption
Fluid bed CFB/
GSA process
Dry injection
LIFAC
Ca(OH)2 / gypsum max. 98%
CaCO3 (saleable)
Ca(OH)2 useable for max. 95%
landfill
CaCo3 useable for max. 95%
landfill
CaCO3 useable for max. 40%
landfill max. 60%*
max. 80%**
Semi-
dry
Dry
Seawater
ScrubbingSeawater dissolved max. 97%
in seawater
Target
Limestone Scrubbing – Flow Diagram
Inlet SO2
Outlet SO2
To control outlet SO2
within regulation limit
Recirculation
pump x 4-6 pcs
Flue gas flow
23
Benefits of FGD Optimization System
Operation cost savings for limestone
Benefits
700MW, Base load 300 days/ year, 7 cent Euro/kW (cost)
Operation cost savings for FGD house load Average 14% reduction of FGD house load
600k -800k Euro/ unit/ year cost saving
Optimization for various types of coal
648 kg limestone saved per day
The process is more stable in transient situation like the change or mixing of coal
24
1. Control SO2 lower than regulation limit
• Primary objective of FGD plant
2. Optimize limestone slurry flow control
• By advanced and predictive control
3. Adjusted to various types of coal (Mixed)
• Even if coal changed, mixed, automatically optimized
4. Adjusted to plant aging
• Adjusted to spray nozzle plugging, pump performance deterioration
FGD Optimization Key Features
25
FGD Optimization Key Features
5. Predict CaCO3 value
• Prevent over-injection of limestone
• Once over-injected, plant must be stopped for clean-up
6. Adjusted to mix firing with heavy oil
• Initial start-up with heavy oil firing
7. Adjusted to load change
• Optimization range: 15% to 100%
8. Each pump operation time is averaged
• All pump operation time is averaged
• Pump running time is optimized by calculation
26
27
Detail functions
Optimization Control Scheme
MPC: Model based Prediction
by Exasmoc
Process value prediction By Exarqe
ERC: Enhanced Regulatory Control
FGD normal control system
- SO2 value prediction
- CaCO3 value
prediction
- pH bias prediction
- Optimized Slurry
flow calculation
- Optimized pH
calculation
- Slurry flow set point calculation
- pH set point calculation
- FF control for abnormal cases
- Slurry flow control
- pH control
Advanced control: Optimization
28
You can save your operation cost
of FGD plant by optimization system
Message
Please contact Yokogawa for details
Hiroyuki Ogata, Yokogawa Europe B.V.
E-mail to: [email protected]
Distributed Temperature Sensor
Temperature Profile
Monitoring with Fibre Optic
Yokogawa Europe B.V.
Feb. 24, 2017
Appendix.
DTSX Features and
application for power plant
Continuous monitoring for large/long equipment
32
Standard multi-mode optical fibre
T1 T2 T3 T4 ……….
DTSX Instrument
T6,000
Modbus/TCP or Serial
Ethernet
Optical Fibre Sensor Cable
Features
*Measuring temperature profile using fibre optic up to
50 km distance with resolution up to 0.010C
*Settable spatial resolution from 0.1 up to 2 m.
*Scalable, compact, light weight, & industrial ready design
T5,999
T5,998 T5,997
T5,996
T5,995
Backscattered light provides temperature at every 1m.
Thermal power plant’s application
33
Coal
Vessel
Coal Banker
Belt Conveyer
Boiler Turbine
Generator
Transformer
Coal Bunker
Spontaneous fire or abnormal heat
by coal oxidation
Belt Conveyor/Bunker.
Spontaneous fire or abnormal heat
by coal oxidation
Generator/Turbine
Fire or abnormal heat by
Circulating equipment problem
Transformer.
Fire or abnormal heat
by leaked oil and heavy
loading
Chimney
Temp. abnormality by
imperfect combustion
Drainage Water
Effect on the environment
by heated water
Chimney
Drainage
Coal Bunker
Summary
35
DTSX (Distributed Temp. Sensor)
Applications *Fire prevention/detection in conveyor systems and cable
tray/rack
*Real time temperature monitoring for power
transmission line
Advantages
*Increase plant safety
*Power transmission monitoring and optimization
Features *Measuring temperature profile using fibre optic
up to 50 km distance with resolution up to 0.010C
*Settable spatial resolution from 0.1 up to 2 m.
*Scalable, compact, light weight, and
industrial ready design