The Economic drivers for excellence in Operations and Maintenance are improved heat rate for reduced CO2, reduced production costs and reduced slagging and fouling when firing lower grade & higher sulfur fuels. Application of the fundamentals in measuring and controlling the fuel and air inputs into the furnace can and has resulted in significant improvements in plant operations. Simultaneous achievement of load response, control, reliability, stability and environmental performance at the Stanton Energy Center (SEC) demands optimization of the furnace inputs. The purpose of this paper is to serve as a case study of the extreme importance of air and fuel flow measurement and control on a 450MW B&W wall fired unit, using Unit 2 for the case study. Just for reference, the unit description is as follows:

/pdf/the-extreme-importance-of-total-air-fuel-flow-measurement-on-52uicktw65.pdf

The extreme importance of total air & fuel flow measurement on a 450mw b&w wall fired unit firing high sulfur fuels

Often overlooked are the factors that boiler combustion and performance play in the overall heat rate performance of pulverized coal plants. For example; a large utility boiler can be tested and found to be meeting the original design boiler efficiency by completing an ASME boiler heat loss method performance test. Yet the unit heat rate may be off design by over 300 Btu’s per kWh due to the non optimization of airflows, air in leakage, high desuperheating spray water flows to the reheater and superheater, auxiliary power consumption and/or non optimum steam temperatures (2, 3, 4, 5, 7, 23). In fact, there are at least twenty two operations and maintenance controllable heat rate factors that are controllable by excellence in O&M at the boiler (2). The top ten of these boiler operations and maintenance controllable variables (based on our experience) are:

/pdf/applying-the-fundamentals-for-best-heat-rate-performance-of-24p40i2m1j.pdf

Applying the Fundamentals for Best Heat Rate Performance of Pulverized Coal Fueled Boilers

The O & M staff of AES Westover Station in Johnson City, New York wisely took a holistic approach to optimizing combustion within Unit 8's boiler in order to reduce its NOx emissions while maintaining acceptable levels of carbon-in-ash content. The results of major modifications, centered on the addition of a fan boosted overfire air system, were a 60% reduction in NOx levels, improved unit reliability, and a project payback period measured in months rather than years. As this project proved, the whole is more than the sum of its parts. 7 figs., 2 tabs.

Apply the fundamentals to improve emissions performance

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Apply the fundamentals to improve emissions performance