This document summarizes the use of an on-line coal analyzer to control blending of Powder River Basin (PRB) coal and Eastern Bituminous coal at the B. L. England power station. The station was required to limit sulfur in fuel to 1.7% annually and 1.9% monthly. A cross-belt analyzer was installed to continuously monitor sulfur in a 30% PRB, 70% bituminous coal blend being fed to the station's Unit 1 boiler. The analyzer controls vibrating feeders that layer the coals on conveyor belts to achieve the target blend. This allows real-time compliance monitoring rather than relying on separate lab analysis of each coal.
This document summarizes the use of an on-line coal analyzer to control blending of Powder River Basin (PRB) coal and Eastern Bituminous coal at the B. L. England power station. The station was required to limit sulfur in fuel to 1.7% annually and 1.9% monthly. A cross-belt analyzer was installed to continuously monitor sulfur in a 30% PRB, 70% bituminous coal blend being fed to the station's Unit 1 boiler. The analyzer controls vibrating feeders that layer the coals on conveyor belts to achieve the target blend. This allows real-time compliance monitoring rather than relying on separate lab analysis of each coal.
This document summarizes the use of an on-line coal analyzer to control blending of Powder River Basin (PRB) coal and Eastern Bituminous coal at the B. L. England power station. The station was required to limit sulfur in fuel to 1.7% annually and 1.9% monthly. A cross-belt analyzer was installed to continuously monitor sulfur in a 30% PRB, 70% bituminous coal blend being fed to the station's Unit 1 boiler. The analyzer controls vibrating feeders that layer the coals on conveyor belts to achieve the target blend. This allows real-time compliance monitoring rather than relying on separate lab analysis of each coal.
ABSTRACT: Compliance with a fuel sulfur regulatory limit was achieved at B. L. England Station through on- site blending of Powder River Basin (PRB) and Eastern Bituminous coals. A PGNA elemental cross-belt on-line analyzer was installed to control the blending of these two coals and to demonstrate the continuous compliance with the regulatory limit on the fuel firing in B. L. England Station Unit 1.
This paper describes the testing, calibration and certification efforts required to optimize the cross-belt analyzer performance and demonstrate compliance with day-to-day coal sulfur content limits. The approach used for reporting the compliance to the New Jersey Department of Environmental Protection is also discussed. The paper includes a comparison of the on-line analyzer test data with coal sampling lab data for sulfur, ash, heat content and moisture. Understanding each of these properties of the blended fuel is significant to the successful operation of this cyclone-fired unit.
Background
B. L. England Station Unit 1 (BLE-1), located in Beesleys Point, New Jersey, is required by statue to control the sulfur level in the coal-fired in this cyclone boiler. The specific compliance level is established in the fuel permit issued by the New Jersey Department of Environmental Protection (NJDEP). During the most recent renewal of the BLE-1 fuel permit, it was agreed that the compliance level would be 1.7% sulfur in fuel on an annual basis and 1.9% sulfur in fuel on a monthly basis. To comply with this standard, Atlantic City Electric Company (a wholly owned subsidiary of Conectiv) committed to firing a blend of Powder River Basin (PRB) and Eastern Bituminous coals. The Eastern Bituminous coal used in the blend for BLE-1 is the same coal fired in B. L. England Station Unit 2, which is equipped a wet flue gas desulphurization system to control SO 2 emissions from the unit.
The characteristics of the Eastern Bituminous and on-site blended coals are summarized in Table 1.
1 VN Bhamidipati is a Sr. Engineer at Conectiv BL England Station, 900 North Shore Road, Beesleys Point, NJ 08223. Tel: 609-390-5167. Email: venkata.bhamidipati@conectiv.com. 2 Charlie Rose is VP of Technical Services of SGS Minerals Services, 16415 Addison Rd. Suite 309, Addison, TX 75001.Tel: 972-818-2600. Email:Charlie.rose@sgs.com. 3 J. Russell, MPR Associates, Inc. 320 King Street, Alexandria, VA 22314. 2 BHAMIDIPATI INTERNATIONAL ON-LINE COAL ANALYZER TECHNICAL CONFERENCE Table 1. Comparison of Fuel Characteristics Fuel Characteristics Units Eastern Bituminous 30% PRB Coal Blend Proximate Analysis a. Moisture % 5.15 10.29 b. Ash % 9.80 7.46 c. Volatile Matter % 35.79 35.29 d. Fixed Carbon % 49.59 46.95 Ultimate Analysis a. Hydrogen % 5.21 5.70 b. Carbon % 71.54 67.70 c. Nitrogen % 1.31 1.23 d. Sulfur % 2.39 1.57 e. Oxygen % 9.44 16.35 f. Ash % 9.80 7.46
Heating Value Btu/lb. 12855 12053 Free Swelling Index 7.8 7.2 Hardgrove Grind Index 57 51 Ash Fusion Temperature Reducing Atmosphere a. Initial Deform o F 2115 2124 b. Softening o F 2190 2178 c. Hemi o F 2340 2236 d. Fluid o F 2400 2337 Slag Viscosity Factor (T 250 value) o F > 2500 2494
Chlorine % 0.06 0.05 Fouling Index 0.17 0.22 Slagging Index 0.83 0.60 Base/Acid Ratio 0.34 0.39
The blended fuel permitted for use in BLE-1 was limited to 30 percent PRB. Based on an extensive testing program conducted in 2001-2002, this blend was demonstrated to provide the necessary regulatory improvement in sulfur emissions without adversely impacting unit operations. One important factor in establishing a suitable fuel blend was maintaining the design slag viscosity factor to ensure proper tapping of the cyclones and furnace. Fuel blends with a higher percentage of PRB coal would have required extensive modification to the boiler and electrostatic precipitators that were not part of the fuel permit renewal process.
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On-site Coal Blending System
The coal handling system at B. L. England Station was originally constructed to support the operation of BLE-1 in 1961. This system was expanded in 1964 to support the operation of a second unit, BLE-2. Figure 1 shows an overview of the existing coal handling system.
The coal handling system extends from the coal stockpile adjacent to the rail yard to the bunkers for BLE-1 and BLE-2. The material handling system (shown to the left of the main conveyor in Figure 1), located adjacent to the crusher house, is for handling tire derived fuel, a supplemental fuel that is not currently fired at B. L. England Station. It should be noted that the coal stockpile is surrounded by environmentally protected wetlands, visible at the top of the Figure 1.
Wetlands Coal Stockpile Rail Line Rail Car Unloader Crusher House Material Handling System Main Conveyor
Figure 1. Arrangement of B. L. England Station Coal Handling System
Both of the B. L. England Station units are supplied through the common, non-redundant coal handling system. Therefore, the addition of on-site coal blending required modification of the existing systems that accommodate the unloading, stack-out, and storage of two different coals.
Blending of the coal on-site is achieved by layering loads the appropriate percentages of contract coal and PRB coal from separate piles onto the conveyor belt system. Based on the 30-day test firing, adequate mixing of the blend occurs at the crushers and transition points in the conveyor system.
The existing fuel handling equipment was used to limit the cost of implementing on-site blending and allow continued use of the existing conveyor arrangement to supply both BLE-1 and BLE-2. Figure 2 shows the layout of the coal handling system and the location of the transition points responsible for mixing the two coals prior to loading into the bunker. The coal stockpile is 4 BHAMIDIPATI INTERNATIONAL ON-LINE COAL ANALYZER TECHNICAL CONFERENCE
segregated into two separate piles. The existing vibratory feeders are used to control the delivery from the PRB coal stockpile onto the reclaim conveyor belt that has been previously loaded from the bituminous coal stockpile. The coal supply for BLE-2 is provided without operating the feeders under the PRB stockpile.
Figure 2. Layout of B. L. England Station Coal Handling System Control of Coal Blending Process
Control of the blend supplied to BLE-1 depends on accurately loading the single conveyor belt from each of the coal stockpiles. The conveyor system was equipped with two belt scales to measure the blend supplied. The existing four-idler belt scale (Scale #1) located on Conveyor #17 (See Figure 2) is used to measure the total coal flow to the bunkers. This scale provides a measurement accuracy of 1%. A second belt scale (Scale #2) was installed as part of the on-site blending system modifications to measure the quantity of bituminous coal on the conveyor belt. This two-idler belt scale is located on Conveyor #16, upstream of the PRB coal stockpile feeders. The two-idler belt scale has an accuracy of 2 to 3%. The amount of PRB coal supplied for the blend is controlled based on the difference of the measure weight of bituminous coal (Scale #2) and the total weight of the blend (Scale #1). It was determined that in this service that the lower accuracy of Scale #2 would not 5 BHAMIDIPATI INTERNATIONAL ON-LINE COAL ANALYZER TECHNICAL CONFERENCE
significantly impact the overall accuracy of the measurement of the blend. The reclaim feeders on Conveyor #16 are controlled based on the signals provided by the two belt scale to establish the fuel blend bunkered for BLE-1.
Although the scales can be used to control the blend of PRB and bituminous coal supplied to BLE-1, using this method to comply with the fuel in sulfur requirement would depend on performing separate analyses of each fuel in the blend. Due to the variability of coal, in particular the bituminous coal purchased by BLE-1, frequent laboratory analyses of representative coal samples would be required to comply with the fuel permit with on-site blending. Further, the inventory would need to be separated between trains. It is also important to the operation of the cyclone-fired BLE-1 boiler to understand other fuel properties, such as the heating content and coal ash viscosity temperature (T 250 ) of the blend, to ensure reliable operation of BLE-1.
As a result of these factors, it was determined that an on-line coal analyzer would be installed as part of the on-site blending upgrades to control the coal stockpile feeders. A cross-belt type, nuclear coal analyzer was installed on Belt #17 to continuously monitor sulfur in the blended coal. The on-line coal analyzer is used for controlling and reporting the sulfur content of each bunker loading operation for BLE-1. It also provides effective monitoring of the other fuel properties significant to boiler operation and prevents unacceptable variations in stack emissions. The agreement between the NJDEP and Conectiv for BLE-1 requires control of sulfur in the fuel be reported based on the on-line coal analyzer with quarterly sampling and analysis of the coal used to verify the coal analyzer accuracy.
Coal Analyzer Calibration
Conectiv installed a Thermo-gamma-metrics nuclear analyzer to monitor sulfur in fuel. The nuclear analyzer provides ash elemental analyses and measurement of the coal moisture to allow calculation of the heating content of the coal. The specific guarantees were provided by the vendor for::
Sulfur: 0.08% accuracy for a sulfur range of 0.2 to 1% as-received sulfur 0.07% accuracy for a sulfur range of 1% to 3% as received sulfur Ash: 0.825% accuracy over a range of 5.0% to 10% ash 1.485% accuracy over a range of 10% to 18%.
No guarantee was provided for the measurements of heating content, moisture or ash oxides.
Calibration of the nuclear analyzer included:
Initial testing using reference and standards at Thermo-gamma-metrics fabrication shops Reference standard testing at B. L. England Station Initial calibration and certifying testing as per ASTM 6543 Calibration and testing at quarterly intervals, using reference standard and sampling
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Analyzer Performance
Table 3 shows the results of the initial field calibration and performance tests for coal sulfur done in January 2004. 4 A summary of all results from the calibration and performance test is given in Appendix A. Note that for the recalibrated analyzer the estimate of the sulfur imprecision (one standard deviation of measurement error) is 0.045% sulfur. Figure 6 charts the 45 sets of sulfur data used for calibration and six additional sets collected in April 2004, after the calibration. The post calibration data indicates that the sulfur calibration is stable.
Table 3: Results Of Field Calibration And Performance Test For Sulfur Number of data sets 45 Reference Measurement Error Variances Variance Std Dev Product (30 minute sub-lots) 0.15305 0.391 Meas Error Of Reference 1 (Odd) 0.00325 0.057 Meas Error Of Reference 2 (Even) 0.00412 0.064 Meas Error Of Avg Reference Values 0.00184 0.043 Range 1.63 Min, Max 1.41 3.04 Regression With Measurement Error Std Dev Rel Std Correlation 0.988 Slope (Reg. Factory Cal on Avg Ref) 1.0283 Ste Of Slope 0.00153 Z(1) Of Slope 18.492 Z(0) Of Slope 671.407 Intercept (Reg. Factory Cal on Avg Ref) 0.1234 Ste Of Intercept 0.0030 Z(0) Of Intercept 41.624 Meas Error Of Newly Cal Analyzer 0.00203 0.045 2.4% Lambda (ratio of meas error variances) 1.099 P (lambda + slope squared) 2.156 Std Deviation Of Residuals 0.063 Grubbs Calculations Variance Std Dev Guarantee LCL UCL Grubbs ECA (N ) Estimate for Sulfur 0.00203 0.045 0.070 0.023 0.071
In April 2004 after the ECA had been updated with the field calibration, the three reference blocks furnished by Thermo Electron, the manufacturer of the analyzer, were each interrogated ten times, each time interrogating for sixty minutes. This established an initial control chart for instrument performance. The charts were updated in July and October, each time repeating the 60 minute interrogation twice. See Figures 7-9. The control charts indicate that the instrument performance remains stable.
4 The main reason for the factory calibration being about 10% relative on the high lies with the actual belt speed being different from the speed assumed when the factory calibration was done. 7 BHAMIDIPATI INTERNATIONAL ON-LINE COAL ANALYZER TECHNICAL CONFERENCE
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Figure 8: Reference Block 102 Interrogation April -- October 2004 5.15 5.20 5.25 5.30 5.35 5.40 5.45 5.50 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Test Number %
S u l f u r %Sulfur UCL CL UCL
Figure 9: Reference Block 103 Interrogation April -- October 2004 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Test Number %
S u l f u r %Sulfur UCL CL UCL
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Conclusions
The cross-belt nuclear coal analyzer installed at BLE-1 provides a reliable method for controlling the blend of PRB and Eastern Bituminous coals fired to comply with the Sulfur in Fuel permit. Measurement of the sulfur content on a continuous basis allows the specific blend ratio of the two fuels to be optimized on a daily basis. Accurate reporting of the Sulfur in Fuel to satisfy the requirements of the permit is also provided by the use of the nuclear coal analyzer as part of the on- site coal blending system. The operating information provided concerning the ash, heating content and heating constituents will be used in controlling future unit operations.
The accuracy of the cross-belt nuclear coal analyzer was demonstrated through the use of the extensive sampling required to satisfy ASTM 6543 calibration requirements. The test boats and more limited sampling will be used quarterly to demonstrate the continued calibration of the cross-belt nuclear coal analyzer. This approach, negotiated with the New Jersey Department of Environmental Protection (NJDEP), provides the quality assurance for the regulatory reporting performed based on the nuclear analyzer.
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APPENDIX A: Initial Calibration/Performance Test Summary Statistics Note: All contents are percent of coal by weight Moisture Sulfur Ash SiO 2 Al 2 O 3 Fe 2 O 3 CaO K 2 O TiO 2 BTU AST Product standard deviation 3.840 0.391 1.268 0.610 0.242 0.339 0.146 0.035 0.010 850 15 Product range (using duplicate average reference values) 9.98 1.63 2.37 4.75 1.06 1.62 0.49 0.173 2501 0.056 105 One std dev of meas error of duplicate average ref values 0.181 0.043 0.259 0.191 0.066 0.064 0.033 0.021 0.008 62 18 Correlation of CQM values with duplicate avg ref values 0.983 0.988 0.902 0.914 0.535 0.973 0.444 0.115 0.232 0.972 0.386 Current CQM gain 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 Current CQM intercept 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 Current trace ash And bound moisture 0.000 N/A 0.000 N/A N/A N/A N/A N/A N/A Calculated optimal gain 19.9352 0.9725 0.8980 0.7785 0.9940 0.8250 0.9090 3.5883 1.8426 Calculated optimal intercept -221.09 -0.1200 1.0357 0.1291 -1.5839 0.2671 -1.0131 -1.3005 -0.0480 Optimal trace ash and bound moisture 0.000 N/A 4.605 N/A N/A N/A N/A N/A N/A Grubbs est of std dev of CQM meas error -- current calibration 3.648 0.048 0.740 0.293 0.366 0.093 0.315 0.077 0.017 Grubbs est of std dev of CQM meas error -- recalibrated 0.688 0.045 0.537 0.184 0.363 0.049 0.286 0.261 0.031 192 21 Lower confidence limit of Grubbs estimate 0.540 0.023 0.420 0.100 0.280 0.032 0.220 0.200 0.023 Upper confidence limit of Grubbs estimate 0.920 0.071 0.720 0.280 0.490 0.072 0.380 0.350 0.042 Vendor Grubbs guarantee None 0.070 0.750 None None None None None None Product range for which guarantee is applicable N/A 2.00 3.00 N/A N/A N/A N/A N/A N/A Passes Grubbs test N/A Yes Yes N/A N/A N/A N/A N/A N/A
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