Detailed model for robust feedback design of main steam temperatures in coal fired boilers

Main steam temperatures play a significant role in large coal fired power plant operation. Ideally, main steam temperatures should be accurately controlled to protect the thick wall components against long term overheating and thermal stress while meeting the design conditions at the steam turbine inlet. Although high steam temperatures are beneficial for thermal efficiency, it accelerates creep damage in high temperature components which is detrimental to the life of components. Alternatively, low steam temperatures increase the moisture content at the last stage blades of the turbine, causing the blades to deteriorate and fail. Control of the outlet steam temperature according to design conditions at variable loads is maintained via a balance between heat input (flue gas temperature and mass flow rate), evaporator outlet steam mass flow and spray water. The present control philosophy accuracy of main steam temperatures at an Eskom coal fired power plant was evaluated and compared to the latest technology and control strategies. Improving and optimizing steam temperature controls ensures design efficiency while maintaining long term plant health. The level of spatial discretization applied in simplifying the real boiler for modelling purposes was approached at a relatively high level. The intention was to model normal operating conditions and certain transients such as variable heat input and load changes to see its effect on steam temperatures and to be able to evaluate the performance of different temperature control techniques. The main outcome of this project was to design a robust control system for a dynamic model of the boiler using sets of low order linear models to account for uncertainty. The main concepts, models and theories used in the development of this dissertation include: 1) A detailed thermo-fluid model developed using Flownex to have high fidelity models of the process under varying operating conditions. This model was used to test and evaluate the robust controller design. 2) System Identification in Matlab to construct mathematical models of dynamic systems from measured inputoutput data and identify linear continuous time transfer functions under all operating conditions [1]. 3) Quantitative Feedback Theory (QFT) to design controllers for an attemperator control system at various onload operating conditions. This design was used understand the engineering requirements and seeks to design fixed gain controllers that will give desired performance under all operating conditions. 4) The design of a valve position controller to increase the heat uptake in a convective pass, thereby improving efficiency: Excessive attemperation in the superheater passes is generally associated with high flue gas temperatures which decrease thermal efficiency. Therefore, robust control of the attemperation system leads to an increase in heat uptake between the flue gas and steam in the boiler, resulting in a reduction in the flue gas temperature leaving the boiler, thus improving efficiency. The robust QFT controllers were set up using the valve position control technique and were used to confirm the improvement of control performance. The theories mentioned above were used to understand the control performance under varying plant conditions using a standard cascaded arrangement. It incorporated robust control design and engineering requirements such as bandwidth, plant life, spray water and thermodynamic efficiency. The control effort allocated to each superheaterattemperator subsystem in the convective pass was designed as a multi-loop problem

Dynamic behavior investigations and disturbance rejection predictive control of solvent-based post-combustion CO2 capture process

Increasing demand for flexible operation has posed significant challenges to the control system design of solvent-based post-combustion CO2 capture (PCC) process: 1) the capture system itself has very slow dynamics; 2) in the case of wide range of operation, dynamic behavior of the PCC process will change significantly at different operating points; and 3) the frequent variation of upstream flue gas flowrate will bring in strong disturbances to the capture system. For these reasons, this paper provides a comprehensive study on the dynamic characteristics of the PCC process. The system dynamics under different CO2 capture rates, re-boiler temperatures, and flue gas flow rates are analyzed and compared through step-response tests. Based on the in-depth understanding of the system behavior, a disturbance rejection predictive controller (DRPC) is proposed for the PCC process. The predictive controller can track the desired CO2 capture rate quickly and smoothly in a wide operating range while tightly maintaining the re-boiler temperature around the optimal value. Active disturbance rejection approach is used in the predictive control design to improve the control property in the presence of dynamic variations or disturbances. The measured disturbances, such as the flue gas flow rate, is considered as an additional input in the predictive model development, so that accurate model prediction and timely control adjustment can be made once the disturbance is detected. For unmeasured disturbances, including model mismatches, plant behavior variations, etc., a disturbance observer is designed to estimate the value of disturbances. The estimated signal is then used as a compensation to the predictive control signal to remove the influence of disturbances. Simulations on a monoethanolamine (MEA) based PCC system developed on gCCS demonstrates the excellent effect of the proposed controller

Flexible operation of coal fired power plant integrated with post combustion CO2 capture using model predictive control

The growing demand for CO2 capture from coal-fired power plant (CFPP) has increased the need to improve the dynamic operability of the integrated power generation-CO2 capture plant. Nevertheless, high-level operation of the entire system is difficult to achieve due to the strong interactions between the CFPP and post combustion CO2 capture (PCC) unit. In addition, the control tasks of power generation and CO2 removal are in conflict, since the operation of both processes requires consuming large amount of steam. For these reasons, this paper develops a model for the integrated CFPP-PCC process and analyzes the dynamic relationships for the key variables within the integrated system. Based on the investigation, a centralized model predictive controller is developed to unify the power generation and PCC processes together, involving the key variables of the two systems and the interactions between them. Three operating modes are then studied for the predictive control system with different focuses on the overall system operation; power generation demand tracking and satisfying the CO2 capture requirement. The predictive controller can achieve a flexible operation of the integrated CFPP- PCC system and fully exert its functions in power generation and CO2 reduction

Improvement of environmental aspects of thermal power plant operation by advanced control concepts

The necessity of the reduction of greenhouse gas emissions, as formulated in the Kyoto Protocol, imposes the need for improving environmental aspects of existing thermal power plants operation. Improvements can be reached either by efficiency increment or by implementation of emission reduction measures. Investments in refurbishment of existing plant components or in plant upgrading by flue gas desulphurization, by primary and secondary measures of nitrogen oxides reduction, or by biomass co-firing, are usually accompanied by modernisation of thermal power plant instrumentation and control system including sensors, equipment diagnostics and advanced controls. Impact of advanced control solutions implementation depends on technical characteristics and status of existing instrumentation and control systems as well as on design characteristics and actual conditions of installed plant components. Evaluation of adequacy of implementation of advanced control concepts is especially important in Western Balkan region where thermal power plants portfolio is rather diversified in terms of size, type and commissioning year and where generally poor maintenance and lack of investments in power generation sector resulted in high greenhouse gases emissions and low efficiency of plants in operation. This paper is intended to present possibilities of implementation of advanced control concepts, and particularly those based on artificial intelligence, in selected thermal power plants in order to increase plant efficiency and to lower pollutants emissions and to comply with environmental quality standards prescribed in large combustion plant directive. [Acknowledgements. This paper has been created within WBalkICT - Supporting Common RTD actions in WBCs for developing Low Cost and Low Risk ICT based solutions for TPPs Energy Efficiency increasing, SEE-ERA.NET plus project in cooperation among partners from IPA SA - Romania, University of Zagreb - Croatia and Vinca Institute from Serbia and. The project has initiated a strong scientific cooperation, with innovative approaches, high scientific level, in order to correlate in an optimal form, using ICT last generation solutions, the procedures and techniques from fossil fuels burning processes thermodynamics, mathematical modelling, modern methods of flue gases analysis, combustion control, Artificial Intelligence Systems with focus on Expert Systems category.

Reinforced coordinated control of coal-fired power plant retrofitted with solvent based CO2 capture using model predictive controls

Solvent-based post-combustion CO2 capture (PCC) provides a promising technology for the CO2 removal of coal-fired power plant (CFPP). However, there are strong interactions between the CFPP and the PCC system, which makes it challenging to attain a good control for the integrated plant. The PCC system requires extraction of large amounts of steam from the intermediate/low pressure steam turbine to provide heat for solvent regeneration, which will reduce power generation. Wide-range load variation of power plant will cause strong fluctuation of the flue gas flow and brings in a significant impact on the PCC system. To overcome these issues, this paper presents a reinforced coordinated control scheme for the integrated CFPP-PCC system based on the investigation of the overall plant dynamic behavior. Two model predictive controllers are developed for the CFPP and PCC plants respectively, in which the steam flow rate to re-boiler and the flue-gas flow rate are considered as feed-forward signals to link the two systems together. Three operating modes are considered for designing the coordinated control system, which are: (1) normal operating mode; (2) rapid power load change mode; and (3) strict carbon capture mode. The proposed coordinated controller can enhance the overall performance of the CFPP-PCC plant and achieve a flexible trade-off between power generation and CO2 reduction. Simulation results on a small-scale subcritical CFPP-PCC plant developed on gCCS demonstrates the effectiveness of the proposed controller

Neural network approach for predicting drum pressure and level in coal-fired subcritical power plant

There is increasing need for tighter controls of coal-fired plants due to more stringent regulations and addition of more renewable sources in the electricity grid. Achieving this will require better process knowledge which can be facilitated through the use of plant models. Drum-boilers, a key component of coal-fired subcritical power plants, have complicated characteristics and require highly complex routines for the dynamic characteristics to be accurately modelled. Development of such routines is laborious and due to computational requirements they are often unfit for control purposes. On the other hand, simpler lumped and semi empirical models may not represent the process well. As a result, data-driven approach based on neural networks is chosen in this study. Models derived with this approach incorporate all the complex underlying physics and performs very well so long as it is used within the range of conditions on which it was developed. The model can be used for studying plant dynamics and design of controllers. Dynamic model of the drum-boiler was developed in this study using NARX neural networks. The model predictions showed good agreement with actual outputs of the drum-boiler (drum pressure and water level)

Review of dynamic modelling, system identification and control scheme in solvent-based post-combustion carbon capture process

Solvent-based post-combustion carbon capture (PCC) process is widely viewed as the most viable option for reducing CO 2 emission. This technology has been deployed globally and many researches have been conducted in this area. In this paper, current status of dynamic modelling, system identification and control scheme of solvent-based PCC process is reviewed. Different research directions of these areas are discussed to conclude the existing challenges. Based on this, this paper is also trying to provide potential solutions as possible pathways for flexible and economical operation

Control and analysis of crucial parameters for an automatic boiler unit in a chemical industry

A boiler plays a significant role in a processing industry, particularly in chemical industry. It requires proper adoption of control techniques for supplying accurate temperature, pressure, steam, and water flow to produce chemicals. An uncontrolled boiler can shut down the whole process. Therefore it requires a continuous monitoring system for avoiding such shutdown. In the past few decades, relay logic, embedded or process card systems were used for controlling the boiler system. In the conventional system, the controlling scheme was also complex for troubleshooting because process cards are used only once. In order to overcome this type of problem Supervisory Control and Data Acquisition (SCADA) and Programmable Logic Controller (PLC) system helps to collect data and information about the flow of boiler from various sensors. In this paper, SCADA and PLC assist in controlling crucial parameters using Proportional Integral Derivative (PID) control. PID controller used in this paper is programmed according to the boiler operation's need, and the data can be stored and analyzed using the SCADA system. The results in this paper help the industrial personnel for boiler automation, allowing the plant operator to observe the crucial parameters for increasing boiler efficiency and reducing the financial losses.&nbsp

Study of power plant, carbon capture and transport network through dynamic modelling and simulation

The unfavourable role of CO₂ in stimulating climate change has generated concerns as CO₂ levels in the atmosphere continue to increase. As a result, it has been recommended that coal-fired power plants which are major CO₂ emitters should be operated with a carbon capture and storage (CCS) system to reduce CO₂ emission levels from the plant. Studies on CCS chain have been limited except a few high profile projects. Majority of previous studies focused on individual components of the CCS chain which are insufficient to understand how the components of the CCS chain interact dynamically during operation. In this thesis, model-based study of the CCS chain including coal-fired subcritical power plant, post-combustion CO₂ capture (PCC) and pipeline transport components is presented. The component models of the CCS chain are dynamic and were derived from first principles. A separate model involving only the drum-boiler of a typical coal-fired subcritical power plant was also developed using neural networks.The power plant model was validated at steady state conditions for different load levels (70-100%). Analysis with the power plant model show that load change by ramping cause less disturbance than step changes. Rate-based PCC model obtained from Lawal et al. (2010) was used in this thesis. The PCC model was subsequently simplified to reduce the CPU time requirement. The CPU time was reduced by about 60% after simplification and the predictions compared to the detailed model had less than 5% relative difference. The results show that the numerous non-linear algebraic equations and external property calls in the detailed model are the reason for the high CPU time requirement of the detailed PCC model. The pipeline model is distributed and includes elevation profile and heat transfer with the environment. The pipeline model was used to assess the planned Yorkshire and Humber CO₂ pipeline network.Analysis with the CCS chain model indicates that actual changes in CO₂ flowrate entering the pipeline transport system in response to small load changes (about 10%) is very small (<5%). It is therefore concluded that small changes in load will have minimal impact on the transport component of the CCS chain when the capture plant is PCC