HELE - High Efficiency Low Emission

Yokogawa FGD Optimization System Flue Gas Desulfurization

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27th Sep, 2016

Yokogawa Electric Corporation

Agenda

Introduction to Yokogawa

Flue Gas Desulphurization plant in Japan

Yokogawa optimization software system

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3

Introduction to Yokogawa

Corporate Information

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Established as an electric meter research institute in Tokyo.

1915 1917

Produced Japan’s first electric meter.

1924

Released Japan’s first portable magnetic

oscillograph.

1950

Developed Japan’s first electronic recorder.

1975

Released the world’s first distributed control system

(DCS).

1984

Entered the high-frequency measuring instrument

business with digital oscilloscope.

1988 2015

Released analog LSI test system

100th Anniversary

100 years of history for control and measurement business

Products ＆ Solution portfolio

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Corporate Management (ERP*) Integrated business operation systems

Production Management

(MES*) Systems for advanced control, simulation, production management, and scheduling

Plant Information management System

Asset Management

CAMS for HIS

Advanced Process Control & Operational Work Assistance

AXF

Magnetic Flowmeter

DYF

Digital Vortex Flowmeter

Field Instruments Field instruments, sensors, measuring instruments, analyzers and other equipment

EJA/ EJX

Differential Pressure Transmitter

US300

Ultrasonic Flowmeter

GC8000

Process Gas Chromatograph

YVP

Advanced Valve Positioner

YTA50/70 YTA100/300

Temperature Transmitter

Production Control Systems

Safety Instrumented System

Network Based Control System

* ERP = Enterprise Resource Planning

* MES = Manufacturing Execution System

Production & Operation Management System

Distributed

Control System (DCS)

TDLS

Tunable Diode Laser Analyzer

DCS Installation Map

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NORTH AMERICA

Africa

Asia

Oceania

Middle East

South America

North America

Europe 970

712

422

20,775

426

660

2,610

EUROPE As of Jun. 2016

TOTAL

26,575 UNITS

AFRICA

MIDDLE EAST

OCEANIA AUSTRALIA (409) NEW ZEALAND (2)

NEW CALEDONIA (1) PAPUA NEW GUINEA (4)

FIJI (6)

ASIA SOUTH AMERICA

AUSTRIA (30) AZERBAIJAN (1) BELGIUM (222) BELARUS (17) BULGARIA (5) CROATIA (5) DENMARK (6) FINLAND (3)

FRANCE (251) GERMANY (283)

GREECE (21) HUNGARY (69) IRELAND (4) ITALY (153)

KAZAKHSTAN (17) LITHUANIA (1)

NETHERLANDS (193) NORWAY (10) POLAND (24)

PORTUGAL (8) ROMANIA (12) RUSSIA (799) SERBIA (12)

SLOVAKIA/CZECH (115) SLOVENIA (2) SPAIN (163) SWEDEN (2)

SWITZERLAND (18) TURKMENISTAN (12)

UK (106) UKRAINE (8) TURKEY (37)

SCOTTLAND (1)

ALGERIA (50) ANGOLA (16)

BOTSWANA (4) CONGO (14) EGYPT (64) GABON (10) GHANA (6) KENYA (3) LIBYA (5)

MOROCCO (24) MOZAMBIQUE (1)

NAMBIA (1) NIGERIA (50) SENEGAL (3)

SOUTH AFRICA (160) SUDAN (6)

SWAZILAND (2) TUNISIA (2) UGANDA (4) Tanzania (1)

BAHRAIN (37) DUBAI (1) IRAN (106) IRAQ (17)

JORDAN (5) KUWAIT (16) OMAN (61) QATAR (15)

SAUDI ARABIA (315) SYRIA (6) U.A.E (69)

YEMEN (11) Lebanon (1)

BANGLADESH (2) INDIA (1,579) MYANMAR (7) PAKISTAN (6) CHINA (2,921) KOREA (1,212) TAIWAN (525) JAPAN (12,794) MALAYSIA (311)

INDONESIA (380) PHILIPPINES (200) SINGAPORE (274) THAILAND (510) VIETNAM (47) BRUNEI (4)

SRILANKA (3)

ARGENTINE (12) BRAZIL (594) BOLIVIA (1) CHILE (4)

COSTA RICA (1) COLOMBIA (17)

CUBA (14) EL SALVADOR (1)

MEXICO (49) NICARAGUA (1)

PANAMA (2) PERU (1)

TRINIDAD TOBAGO (2) URUGUAY (2)

VENEZUELA (11)

CANADA (24) USA (944)

CENTUM is Well-accepted Widely in the Market

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FGD Plant Flue Gas Desulfurization

FGD plant installation history

0

50

100

150

200

250

300

0

500

1000

1500

2000

2500

3000

Total capacity (10⁶m³ N/h)

No. of plant Installation of FGD Plant

The number of installation

Total processing capacity

The number of installation 102 183 323 543 768 994 1134 1192 1227 1266 1329 1362 1366 1405 1583 1741 1758 1789 1810 1843 1914 2014 2099 2173 2142 2249 2228 2257 2336 2094 1993 1908 2077

Total processing capacity 5.4 9.3 18 28.8 42.7 79.5 104 111 115 117 122 127 127 129 133 155 155 169 176 179 194 205 210 214 215 216 222 233 248 224 218 221 209

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Installed for Oil fired Installed for Coal fired

1970 2010

No. of FGD plant

Yokogawa DCS references for FGD in Japan

Electric Utility Power Station UnitGeneration

Capacity

FGD Plant

Supplier

Operation

Date

Kansai Electric Maizuru 1 900MW CCEC Jul-04

Kyushu Electric Reihoku 1 700MW IHI Jun-03

2 700MW IHI Jul-95

Chubu Electric Hekinan 1 700MW MHI Oct-91

2 700MW KHI Jun-92

3 700MW MHI/CCEC Apr-93

4 1,000MW KHI/BHK Mar-01

5 1,000MW KHI/BHK Mar-02

Hokuriku Electric Nanao Ohta 1 500MW CCEC Mar-95

2 700MW CCEC Jul-98

Tsuruga 1 500MW IHI Jan-91

2 700MW IHI Oct-00

Shikoku Electric Tachibana-wan 1 700MW MHI Jul-00

Chugoku Electric Misumi 1 1,000MW MHI Jul-98

Hokkaido Electric Tomato Atsuma 2 600MW MHI Jan-85

4 700MW MHI Oct-02

Electric Power Development Tachibana-wan 1 1,050MW MHI Jul-00

2 1,050MW BHK Jan-01

Matsuura 1 1,000MW Hitachi Jan-91

2 1,000MW IHI Jul-97

Matsushima 1 500MW Sumitomo Machine Jan-81

2 500MW Hitachi Jun-81

Takehara 3 700MW IHI Mar-83

Yokogawa’s DCS share for FGD in Japan: 60%

Above is some reference projects only. The share is for utility companies.

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Yokogawa FGD Optimization System Flue Gas Desulfurization

Yokogawa Advanced Solutions

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Production Asset EnergySafety and

SecurityKnowledge

Sequence of event

Recorder

Terminal Management

(Truck,Train Ship)

Analyser Maintenance

Advanced Process

Control

Batch and Grade

Tracking Device Maintenance

Laboratory

Information

Management System

Production Accounting

Production Scheduling

Safety Functional

Monitoring

Safety Override

Advisor

Asset Performance

Dashboard

Alarm

Analysis

Alarm

Master Database

Blend Property

Control

Oil Movement

Plant Simulation

Production

Performance

Dashboard

Wireless (Infratructure

and applications)

Cyber Security

Process Control

Domain

Energy Real Time

Optimizer

Energy Performance

Monitoring

Combustion

Control and

Optimization

Procedure

Management

Task Management and

Shift Handover

Procedural

Automation

Operator

Training Simulator

Incident and MOC

Management

Advanced Operator

Graphic

Pipeline Management

Benefits of APC

Page.12

104

102

100

98

96

94

92

90

Specification or limit

BEFORE APC APC ONLINE SETPOINT MOVED

CLOSER TO LIMIT

PE

RC

EN

T O

F L

IMIT

Standard deviation

of controlled variable

Base Case Stabilise

Operator target

Benefits

Flue Gas Desulfurization

Boiler

Flue Gas Combustion Air

► For

Fossil Fired

Power

Furnace / Flue Gas Draft

Flue Gas Flow

- Furnace / Flue Gas Temp.

O2 Analysis

NOx Analysis

SO2 Analysis

Dust Monitoring

Induced Draft Fan

(Vibration)

- Induced Draft Fan

(Lub. Oil & Winding Temp)

- Gas Recirculation Fan

(Lub. Oil & Winding Temp)

Gas Recirculation Fan

(Vibration)

Air Press.

Air Flow

- Air Temp.

O2 Analysis

Forced Draft Fan

(Vibration)

- Forced Draft Fan

(Lub. Oil & Winding Temp)

Flue gas desulphurization types

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Seawater

Scrubbing

Wet

* With humidification, ** With product recycling

Process Absorbent Byproduct Efficiency

Lime/Limestone

scrubbing

Spray

absorption

Fluid bed CFB/

GSA process

Dry injection

LIFAC

Ca(OH)2 / gypsum max. 98%

CaCO3 (saleable)

Ca(OH)2 useable for max. 95%

landfill

CaCo3 useable for max. 95%

landfill

CaCO3 useable for max. 40%

landfill max. 60%*

max. 80%**

Semi-

dry

Dry

Seawater

ScrubbingSeawater dissolved max. 97%

in seawater

Target

Limestone Scrubbing – Flow Diagram

Inlet SO2

Outlet SO2

To control outlet SO2

within regulation limit

Recirculation

pump x 4-6

Flue gas flow

Result

pH

Inlet SO2

No. of Pumps

MW load

Slurry flow

Outlet SO2

Optimization OFF: 8 hours Optimization ON: 8 hours

Actual data of 700MW coal fired unit in Japan

8 hours 8 hours

No. of Pump reduced from 5 to 3

Outlet SO2 is below target

Coal type changed to high sulfur coal

負荷(MW)

OutletSO2(ppm)

Slurry flow(m3/h）

PUMP

Flue gas flow（km3N/h）

Boiler Load (MW)

2days

InletSO2（ppm)

APC ON

Actual data of Boiler load 0 to 700MW

700MW coal fired unit in Japan

700MW 630MW 420MW

Outlet SO2 set point: 19

ppm

Outlet SO2 regulation: 25 ppm

Optimization Control Scheme

MPC: Model based Prediction

by Exasmoc

Process value prediction By Exarqe

ERC: Enhanced Regulatory Control

FGD normal control by DCS

- SO2 value prediction

- CaCO3 value

prediction

- pH bias prediction

- Optimized Slurry

flow calculation

- Optimized pH

calculation

- No. of Pump control

- Slurry flow set point calculation

- pH set point calculation

- FF control for abnormal cases

- Slurry flow control

- pH control

Advanced control: Optimization

Optimization can be added to existing system

Optimization and DCS control scheme

Lime stone slurry flow

Conventional Control by DCS

pH Control

Optimization Function

Outlet SO2 PV

pH value

Slurry flow

Outlet SO2 set point

Recirculation pump selection

MWD

Inlet SO2 PV

Flue gas flow pH set point

Pump inc/dec

Slurry flow bias

Slurry flow bias

SO2/ CaCO3 Prediction

pH- Total SOx F(x)

Total SOx Bias

Total SOx

Optimize lime stone slurry flow

Model

Predictive Control

Recirculation Pump Control

- FGD Perform - pH control

Slurry flow

Recirculation Pump Operation

2 Pumps

3 Pumps

4 Pumps

5 Pumps

pH Value

MW Load

Total SO2 value

pH - Pump curve

pH value of outlet SO2 Limit

Pump operation and pH set point

Normal operation pH high limit value

Normal operation pH low limit value

Recirculation pump start/ stop

pH value control

1. Control SO2 lower than regulation limit

• Primary objective of FGD plant

2. Optimize number of operating recirculation pumps

• Conventional: No. of pumps are not controlled well

• To reduce house load

3. Optimize lime stone slurry flow control

• By advanced and predictive control

4. Adjusted to various types of coal (Mixed)

• Even if coal changed, mixed, automatically optimized

FGD Optimization Key Features

FGD Optimization Key Features

5. Adjusted to plant aging

• Adjusted to spray nozzle plugging, pump performance deterioration

6. Predict CaCO3 value

• Prevent over-injection of limestone

• Once over-injected, plant must be stopped for clean-up

7.Adjusted to load change

• Optimization range: 15% to 100%

8. Automatic pump start/ stop

• Operators do not need to start/ stop manually

System Configuration

APC server can connect to variety of OPC compliant DCS platforms and control

systems. APC Client can be run on DCS consoles as rich or thin client.

.

Benefits of FGD Optimization System

Operation cost savings for FGD pump load

• 600k -800k Euro/ unit/ year cost saving

700MW, Base load, 300 days/ year, 7 cent Euro/kW (cost)

Operation cost savings for limestone

Optimization for various types of coal

Actual data of power plant in Japan References of 2x 700MW coal fired (in operation) To be used for 2x 1000MW coal fired plants (next year)

Benefits

Thank you for your attention.

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