Better Technology

For a Cleaner Environment

 POWER PLANTS¶ MAIN COMPONENTS & CONTROL
Jenö Kovács

‡ Power generation

± Power generation principles

± Direction of development
± Example: World¶s first supercritical CFB OTU boiler

‡ Main control tasks

± Power control
± Frequency control
± Unit control principles
 SCHEDULE

‡ Power generation

± Power generation principles

» Thermal and electrical power
» Energy sources and energy conversion processes (with/out combustion)
» Steam (gas) cycle plants
» Efficiency map
± Fuel flexibility:
» Fluidization principle
» BFB, CFB boilers
± Possibility to increase efficiency: OTU boilers
± Example: First supercritical CFB OTU boiler (Lagisza)
 POWER GENERATION

Energy sources Power Plants Energy demand

Renewable Without combustion

wind, solar, hydro, tidal, wind- , solar- , hydro- , Electrical power
wave, geothermal, geothermal- , tidal-, electricity
biomass/fuel wave power plants

Thermal power
Fossil With combustion steam
coal, oil, gas, peat coal, oil, gas, peat hot water
biomass/fuel
steam/gas cycle
Nuclear
Nuclear power plant
 POWER GENERATION
Primary energy carriers:
solar-, wind-, hydro-, tidal-, marine power
Geothermal energy

Pyhäkoski hydro power plant

Wind turbine Tidal turbine

Solar Two ± Mojave Desert, California 11 MW Photovoltaic Wave energy

 COMBUSTION BASED POWER GENERATION

Chemical Thermal Mechanical Electrical

energy energy energy energy
Boiler Turbine ~
oil, gas,
coal, peat,

z
biomass, Emissions
wood,
RDF, REF,
waste
 COMBUSTION BASED POWER GENERATION
Gas turbine (GT) power plant

K | 32  44%

Chemical Thermal Mechanical Electrical

energy energy energy energy
Boiler
hot flue
GT ~
gas
District heating or
Steam generation

air flue gas

 COMBUSTION BASED POWER GENERATION
Steam turbine (ST) power plant

Chemical Thermal Mechanical Electrical

energy energy energy energy
Boiler
steam
ST ~
Process District
steam heating
water
 POWER GENERATION
Meri-Pori condensing power plant: 565 MWe

VTT Energia (1999): Energia Suomessa. Tekniikka, talous ja ympäristövaikutukset. Edita Oy, Helsinki.
 POWER GENERATION
Rauhalahti C(ombined)H(eat)P(ower) plant: 87 MWe + 205 MWth

Source: Timo Järvinen & Eija Alakangas, VTT Energy, ALTENER AFB-NET V - Part 2 l Cofiring, l Rauhalahti CHP plant l
 POWER GENERATION
Efficiency = energy out / energy in

QS >95%
60  90% >95%
QF

Energy in Energy in Mechanical Electrical

fuel, QF steam, QS energy, QM energy, QE
Boiler ST ~
QM
32  45%
QS
QM  Q T Thermal
60  85% energy, QT
QS

Overall efficiency = (QE+QT)/QF = (60-90%) * (35-85%) * 95% = 20-72%

 POWER GENERATION
Nowadays requirements

‡ Less pollution
± Same amount of fuel (kg/sec) more energy out (MW) = Higher efficiency
± Solution (besides green/renewable energy):
± Increase the efficiency of combustion
± Increase the efficiency of steam cycle
± Combined heat and power generation (CHP)

‡ Fuel flexibility
± Burn many different fuels in the same boiler
± Coal, peat, RDF, wood, «
± Solution:
± Fluidized bed combustion
 POWER GENERATION
Fluidized bed combustion

Solution to fuel flexibility and combustion efficiency (>80%)

Flue gas

Flue Flue
gas gas

Fue Fue
l
Fue
l

Ai Ai Ai

Fixed Bubbling fluidized bed Circulating fluidized bed

 Foster Wheeler Fluidized Bed Technology
Increasing fuel-flexibility

143 BUBBLING FLUIDIZED BED (BFB) BOILERS

FLUID BED TECHNOLOGY First unit ‡ Ideal technology for biofuels
1976
‡ Total 7100 MWth BFB sold
‡ 141 in operation
Flue gas ‡ 2 under construction

304 CIRCULATING FLUID BED (CFB) BOILERS

1979 ‡ Total 18 602 MWe CFB sold
‡ 260 in operation for variety fuels:
Fuel coal, lignite, petroleum coke, biomass,
RDF, etc.
‡ 44 under construction
‡ Biggest unit in operation 300 MWe

ATMOSPHERIC FLUIDIZED BED GASIFIER

1981 ‡ Ideal technology for biomass and RDF
‡ 9 gasifiers sold
Air

Developed in the 60¶ s

 FOSTER WHEELER CFB
Process Description
Steam
Feed water to drum

Steam drum

Solids separator Steam outlet

Downcomer Economizer

Combustion chamber Feed water inlet

Air heater
Fuel
Dust collector
Limestone

Fly ash
Induced draft fan
Bottom ash Secondary air fan

To ash silos Primary air fan

 INCREASING NET EFFICIENCY
Supercritical steam pressure

Highest achievable plant efficiency with supercritical steam parameters. One of the most effective
measures for achieving high power plant efficiency is selecting a high design steam pressure.
Efficiency increases by roughly 3% on making the transition from 167 bar (e.g. drum boiler) to 250 bar,
without significant increases in investment costs

Source [3]: Siemens AG Power Generation (2001): Benson Boilers for maximum cost-effectiveness in power plants
 INCREASING NET EFFICIENCY
Supercritical steam pressure

Source: J. Franke, R. Kral, and E. Wittchow (1999):

Steam generators for the next generation of power plants aspects of design and operating performance. VGB Power Tech 12/99.
 INCREASING NET EFFICIENCY
Natural Circulation vs. O(nce)T(hrough)U(nit) Design

(subcritical) (sub/supercritical)

Source: Siemens AG Power Generation (2001): Benson Boilers for maximum cost-effectiveness in power plants
 PKE LAGISZA POWER PLANT
The World¶s 1st Supercritical CFB-OTU Boiler

Lagisza 460 MWe (condensing power plant), bituminous coal

‡ The 460 MWe Lagisza CFB plant will replace 5 smaller power plants within PKE

PKE -Lagizsa
 PKE LAGISZA POWER PLANT
The World¶s 1st Supercritical CFB-OTU Boiler

Lagisza 460 MWe (condensing power plant), bituminous coal

‡ The 460 MWe Lagisza CFB plant will replace 5 smaller power plants within PKE

‡ Improved plant efficiency 34,7% to 45,0%

‡ Improved emissions
SO2 92% ~ 22 300 t/year reduction
Furnace:
NOx 71% ~ 4 700 t/year reduction
Depth: 11 m (36 ft)
CO2 28% ~ 970 000 t/year reduction
Width: 28 m (92 ft)
Height: 48 m (157 ft)
 UNIT & LOCAL CONTROL
&
GRID FREQUENCY CONTROL
 UNIT & LOCAL CONTROL

OVERALL CONTROL AIMS

Quantitative target: the required power (MW e/th)
Qualitative target: frequency & voltage
steam pressure & temperature

UNIT CONTROL
optimal/econimical operation of power plant
following changes/schedule in power requirement
maintaining emissions

LOCAL CONTROL
receives setpoint from unit control
maintains temperature, pressure, flow, ...
 UNIT CONTROL
Example of a condesing power plant (MWe)

Power / frequency
measurement

p
 UNIT CONTROL

‡ Generated Power (MWe)

PMWe KG ˜ PMWturbine KG ˜ KT ˜ PMWsteam

ª kJ º ª º
PMWsteam «kW  ª kg º ˜ 'h« kJ »
m
¬ sec »¼ « sec »
¬ ¼ ¬ kg ¼

enthalpy : h ~ p ressure , Temperature

PSTEAM PT PMWe
Turbine ~
 UNIT CONTROL
Fixed pressure operation

‡ Boiler follow mode PT RH

PRESSURE
SET POINT
S +/-
± Power generation controlled by turbine
PID
admission valves 2
G
± Pressure controlled by boiler demand
± Storage capacity of boiler is utilized in
load changes. (if drum type boiler)
± Rapid response to changes in load +/- S
PID MW SET
demand 1 POINT
± Difficult pressure control
BOILER
DEMAND
± Frequency support is possible.
 UNIT CONTROL
Fixed pressure operation

‡ Boiler follow mode with feedforward PT FT RH

P SET
POINT
S +/-
± Power generation controlled by turbine
PID PD
admission valves 2 1
G
± Pressure controlled by boiler demand
± Storage capacity of boiler is utilized in
load changes. S MW SET
POINT
± Rapid response to changes in load

PD
+/+

2
demand
+/-
± Difficult pressure control
BOILER
DEMAND PID
± Frequency support is possible. 1

± Feedforward (PD-type) from load

demand or steam flow to boiler FEEDFORWARD
demand is used to improve (OPTIONAL)

pressure control during load

changes.
 UNIT CONTROL
Fixed pressure operation

‡ Turbine follow mode PT RH

PRESSURE
SET POINT

± Power generation controlled by boiler S +/-

PID
demand 2
± Pressure controlled by turbine admission G
valves
± Storage capacity of boiler is not utilized
for rapid load changes.
± Sluggish response to changes in load +/- S
PID MW SET
demand 1 POINT
± Accurate (easy) pressure control
BOILER
DEMAND
± Frequency support is not possible.
± Feedforward from load demand to boiler
demand is recommended to improve
load change rate. (see next slide)
 UNIT CONTROL
Fixed pressure operation

‡ Turbine follow mode with feedforward PT RH

PRESSURE
SET POINT

± Power generation controlled by boiler S +/-

PID
demand 2
± Pressure controlled by turbine admission G
valves
± Storage capacity of boiler is not utilized
for rapid load changes. +/- S
± Sluggish response to changes in load PID MW SET
1 PD POINT
demand 1
± Accurate (easy) pressure control
BOILER
DEMAND
+/+
± Frequency support is not possible.
± Feedforward (PD-type) from load demand
to boiler demand is used to improve
load change rate. FEEDFORWARD
 UNIT CONTROL
Variable pressure operation

‡ Natural sliding pressure mode 100

± Operation with fully open turbine

Steam pressure (% pmax)

80
admission valves

‡ Modified sliding pressure mode 60

± Operation with slightly throttled 40

turbine admission valves.
± Throttling reserve of turbine
valves can be used for Natural sliding pressure
20
immediate changes of limited Modified sliding pressure
size in power generation.
0
20 40 60 80 100
Load (% MCR)
 COORDINATED UNIT CONTROL EXAMPLE
(MODAKOND by ABB)

Source: http://library.abb.com/GLOBAL/SCOT/scot221.nsf/VerityDisplay/B471E93C2DBFAB2BC1256E2300382268/$File/PT_ModConSol_MODAN_Rev5.pdf
 FREQUENCY CONTROL
Grid area of UCTE
(Union for the Co-ordination of Transmission of Electricity)
 FREQUENCY CONTROL in UCTE

‡ Always an equilibrium between electricity production and consumption should exist

± Grid frequency is a measure of the equilibrium

‡ Primary control
± Reaction time max. 30 seconds (UCTE)
± Fast power reserves are used (turbine and condensate throttling reserves)
± P ±type control Æ deviation corrected but steady-state error exists

‡ Secondary control
± To remove steady state error after the primary frequency
Generator
control droop
action(S)
± Secondary control restores primary control reserves
PGn ˜ 'f
SG
‡ Tertiary control fn ˜ 'PG
± Base load of a unit given mainly based on rough electricity  PGn
Ÿ 'PG consumption ˜ 'f k ˜ 'f
predictions. fn ˜ SG
FREQUENCY CONTROL
Time scale
 FREQUENCY CONTROL
Example

1. Initially no power exchange between networks

No frequency deviation

'P1 0 'P2 0

'f 0

Network 1 Network 2
 FREQUENCY CONTROL
Example

1. Initially no power exchange between networks

No frequency deviation

2. Shudden loss of power in the area 2

'P1 0 'P2 0

'f z 0
'f

Network 1 Network 2
 FREQUENCY CONTROL
Example

3. First primary control activated: replace the lost power

'f z 0
P P
P 'P1

P P

Network 1 Network 2
 FREQUENCY CONTROL
Example

3. First primary control activated: replace the lost power

4. Then the failure area is located and secondary control is applied

'f z 0
'f
P PS
P 'P1

P P

Network 1 Network 2
 UNIT CONTROL
Variable pressure operation

REQUIRED POWER CHANGE AVAILABLE RESERVES

6
RH
Power change (% PN )

MSTR
5
CFB
4
OTU G

3
CTR
2 CTR
CTR

0 MSTR = MAIN STEAM THROTTLING RESERVE

0 10 20 30 40 CTR = CONDENSATE THROTTLING RESERVE
Time (s)
 LAGISZA PROCESS SIMULATION
Grid frequency support (primary and secondary)

Generator power

378

368

358
MW

348

338

328

318
0 100 200 300 400 500 600 700 800 900
Time (s)

Setpoint Simulated
CONCLUSION

Questions?
Comment?

Thank you!