Integration of Coal-fired Power Plants Fireside Optimization Tools with the IDAES Platform.

This Small Business Innovative Research project targets the development of a computer-based tool (model) for use by coal-fired power plants to predict heat transfer losses in the water wall and convective pass sections of the boiler. The proposed tool combines Microbeam’s mechanistic ash generation and deposition models (AGM) for use in the Institute for the Design of Advanced Energy Systems (IDAES) platform’s BoilerHeatExchanger model. The integrated tool will predict the impact of ash accumulations on heat transfer surfaces as a function of coal properties, plant operating conditions, and boiler design. The tools will provide the opportunity for coal-fired plant operators to optimize coal properties and/or boiler operating conditions to improve plant heat rate and reliability. The primary focus of Phase I is to establish the technology proof-of-concept of an IDAES-AGM BoilerHeatExchanger model to predict plant heat rate. As a first step Microbeam proposes to utilize Microbeam’s AGM mechanistic tools to provide thermal properties information that can be used in the IDAES BoilerHeatExchanger model. Microbeam will work with the IDAES group and a utility to incorporate the relevant design and operating information into the BoilerHeatExchanger model to allow for testing the use of thermal conductivity information to provide relevant heat rate information. Heat rate and associated operating conditions will be compared to the results obtained with the prototype IDAES – AGM mechanistic ash model platform. The main benefit of the proposed work is to develop operational tools that provide guidelines that increase flexibility, efficiency, and reliability through management of coal properties and plant operations. The efficiency and reliability of the existing fleet of power plants is affected by the thermal and mechanical stresses because of cyclic operating due to the variability in renewable energy. The stresses combined with fireside ash deposition decreases thermal efficiency and provides ash related materials that contribute to corrosive chemical attack resulting from a cycling mode of operation. Developing innovative methods to minimize the impact of ash-related materials during load cycling on plant structural integrity and power plant heat rate is essential to maintaining the existing fleet of plants. The public benefit of the proposed work is the development of a new technology to provide new methods to improve the efficiency and reliability of the existing fleet of coal-fired power plants. The improved efficiency and reliability of the coal fleet will ensure the ability to have a stable grid and keep the cost of electricity low.