Energy Efficiency

and
Intelligent Power Plants
Rameshbabu R S
10th May, 2006
The Center For Bits And Atoms
MIT

Honeywell International Inc

Broad and Diverse Business, Technologies and Products

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Emission

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Context for Industrial Energy Efficiency

Demand

Plant Performance Management

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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

TLC
MPC

ELA-T

ACC

ELA-B

Backpressure turbine(s)
(w/extractions)

ACC
Steam Let-down
Station(s)

Condensing turbine(s)
(w/extractions)

ACC
Several boilers operating
to common steam header

ACC Advanced Combustion Control

ELA-B Economic Load Allocation for Boiler
ELA-T Economic Load Allocation for Turbine

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TLC Tie Line Control

MPC Master Pressure Control
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Sample Optimization Benefits

Scenario for Industrial Power:
HPI/Chemical plant relying on steam delivery from in-house
boiler unit

Item
Steam production capacity [t/h]
Steam production costs [/t]
Plant Daily Production [/day]
Lost production on off-spec steam [/h]
Trips due to off-spec steam [h/yr]
Annual Revenue [/yr]
Steam production costs [/yr]
Profit (w/out fixed+input costs) [/yr]
Optimization Benefit [/yr]

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Original
Optimized Notes
200
200
6.75
6.65 1.5 % improvement
1 000 000
1 000 000
20 833
20 833
72
36 50 % trips eliminated
363 500 000 364 250 000
11 824 598 11 647 229
351 675 402 352 602 771
927 369

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Sample Optimization Benefits

Scenario for District Heating:
CHP selling heat, power, and power ancillary services
Item
Original Optimized
Winter average heat delivery [t/h]
300
300
Summer average heat delivery [t/h]
85
85
Winter average power delivery [MW]
80.0
81.6
Summer average power delivery [MW]
40.0
40.4
Annual Operations [h]
8 760
8 760
Availability factor [%]
0.92
0.92
Ancillary services regulatory range [MW]
8
12
Ancillary services contracted [months]
6
6
Heat price [/GJ]
12
12
Power price [/MWh]
32
32
Ancillary service price [/MW/h]
23
23
Total annual revenue [/yr]
71 368 734 72 028 654
Optimization Benefit [/yr]
659 920

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Notes

2% improvement
1 % improvement
1 month off
enhanced flexibility

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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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Aerospace

Automation Control

Specialty Materials

Transportation Systems

We are building a world thats

Safer and more secure
More comfortable and energy efficient
More innovative and productive

We are Honeywell.

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www.honeywell.com

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