Advanced Process Control to burn Alternate Fuels efficiently

Transcription

1 Advanced Process Control to burn Alternate Fuels efficiently Dr. F. Steege, V. Agrawal

2 Contents Overview of the Company Why Advanced Process Control (APC)? PiT Navigator Functionality Case Study Targets and Results of ÇIMSA Eskiehir plant Summary 2

3 STEAG Headquarters: Essen, Germany Germany's fifth largest electricity producer, market leader in cement automation and control solutions. Core Competencies: Power and Cement Industries Steag brings MW know-how in Gas fired, Coal fired, Oil fired, Sub critical and Supercritical Power plants, Renewable Energy services all through the globe Subsidiaries and representative offices all over the world - European countries and in Brazil, USA, India, Bangladesh and South Africa. Employees: 6,000 (3,900 in Germany / 2,100 abroad) Sales / EBITDA: 4 billion / 520 million. Capital expenditure: approx. 1 billion Installed 11,000 MW capacity: (8,700 MW in Germany / 2,300 MW abroad)

4 Organization Energy Technologies, Operation and Maintenance, Project Development, Plant Services, Renewable Energies, System Technologies and Training and Advisory Services. Cement and lime plants, Power plants, Waste incineration plants 4

5 STEAG Powitec Solutions for Cement Coal Mill Raw Meal Mill Preheater Kiln Cooler Cement Mill DeNOX PiT Video : Video camera for flame surveillance PiT Indicator : Intelligent Thermography for indicating temperature and flame variations over the time PiT Predictor : Soft Sensor to predict process values like FCaO, NOx PiT Navigator : Advanced Auto-Optimiser and adapive control for permanent process optimisation for Kiln, Cooler, Mills and SNCR 5

6 Why APC? Challenges : Most processes in clinker production have a long delay time. Important quality parameters are measured discontinuous. Fuels and, to a higher degree, alternative fuels have changing properties (calorific value, moisture, ). Kiln, Cooler and Mills are black boxes with very few measurements. Need to balance different targets during operation. Different operators handle the production process differently. Benefits : Increase in productivity and energy efficiency. Stabilization of operation. Automation and optimization of process. Maintaining clinker quality. 6

7 Table of Content Overview of the Company Why Advanced Process Control (APC)? PiT Navigator Functionality Case Study - Targets and Results of ÇIMSA Eskiehir plant Summary 7

8 PiT Navigator - Functionality Automatic and adaptive control based on NMPC. Controls main actuators of kiln and cooler: kiln speed and amount of rawmeal speed of ID fan coal amount at main burner and calciner alternative fuels at main burner, precalciner and hotdisc cooler fan flows cooler grate speed tertiary air flaps Connected to plant DCS Uses intensity and thermography images of cameras at kiln and cooler Uses neural prognosis models of important process values (for example Freelime values) to react fast to process changes 8

9 PiT Navigator - Use of Thermography Video Image Thermography Image Camera based on robust German design. AEDF Adaptive Electronic dust filter Lot of safety and customization options Extraction of Important Regions from Thermography 9

10

11 PiT Navigator - User Interface PiT Navigator Cement User Interface - Targets easy indication of each target status by color bar targets can be changed by customer during operation plant measurements that are not available are dislayed in grey password protected write mode 11

12 PiT Navigator FreeLime Prediction Prediction of important values by artificial Neural Networks for example Freelime (FCaO) analysis Prediction of FCaO values the moment the sample is taken fast reaction and not wait minutes till analysis results are finished Laboratory Analysis (dated back to time of sample taking) PiT Navigator Prognosis [%] 12

13 Table of Content Overview of the Company Why Advanced Process Control (APC)? PiT Navigator Functionality Case Study - Targets and Results of ÇIMSA Eskiehir plant Summary 13

14 Case Study - Plant Description ÇIMSA Cimento A.S. - Eskiehir in Turkey Unit #2 88 t/h clinker production One line of preheater cyclones with 5 stages Pre-calciner and hotdisc Primary fuels: steamcoal, petcoke and lignite Secondary fuels: tires, RDF Grate cooler (2 grates, 6 fans) 14

15 Case Study - Targets for PiT Navigator Automatic control of all relevant actuators at kiln and cooler Stable operation Reduction of specific energy consumption Increase of clinker production Increase of alternative fuel ratio at kiln 15

16 Case Study Detailed Results Eskisehir Kiln 2 Comparison of 2 days without PiT Navigator and 2 days with PiT Navigator Increase of alternative fuel ratio by 7 % absolute (21% relative increase) More stable alternative fuel ratio Automatic compensation of fails/changes at alternative fuel with primary fuel Alternative Fuel Ratio [%] PiT Navigator Off PiT Navigator On 16

17 Case Study Detailed Results Eskisehir Kiln 2 Comparison of 2 days without PiT Navigator and 2 days with PiT Navigator Much more stable secondary air temperature Reduction of standard deviation of secondary air temperature from 58 C to 27 C (-53%) Secondary Air Temperature [ C] PiT Navigator Off PiT Navigator On 17

18 Case Study Detailed Results Eskisehir Kiln 2 Comparison of 2 days without PiT Navigator and 2 days with PiT Navigator Increase of clinker production by 8 t/h mean More stable clinker production Clinker Production [t/h] PiT Navigator Off PiT Navigator On 18

19 Case Study Detailed Results Eskisehir Kiln 2 Comparison of 2 days without PiT Navigator and 2 days with PiT Navigator Specific energy = (coal amount main burner * coal heating value) / clinker production Redcuction of specific energy consumption by 0.5% More stable specific energy Specific Energy Consumption [kcal/ kg] PiT Navigator Off PiT Navigator On 19

20 Case Study Impact / Benefits Comparison of PiT Navigator and old system over a period of 2 months: Increase by 10.6% Status of last one year - Plant running: 323 days PiT Navigator at kiln active: 287 days (89%) PiT Navigator at cooler active: 290 days (90%) 20

21 Summary PiT navigator helps to efficiently combine environmental and economical targets. PiT Navigator for kiln and cooler is based on advanced control that Combines variety of control techniques to address different problem domains appropriately. Automatically adaptes learning during changing process. Incorporates flame analysis information using PIT Indicator. PiT Navigator offers following benefits for the cement plant Automation of the plant 24/7. Stabilization of process Increased usage of alternative fuels. Increase in throughput Reduction in specific energy consumption. 21

22 Thank you for your interest! For more information, please visit our stall 22