Enhancing energy efficiency in thermal power plants is a critical endeavour that supports both operational sustainability and the reduction of energy consumption and emissions. By following well-established “thumb rules,” it is possible to implement strategies that optimize boiler performance and overall plant efficiency.
The guidelines mentioned below, when effectively applied, can lead to significant energy savings while maintaining operational excellence and fostering a sustainable energy future.
1. Feedwater Temperature Operation
For every 6°C increase in feedwater temperature, fuel consumption for the same quantity of steam generation is reduced by approximately 1%. This highlights the importance of optimizing pre-heating systems and improving heat recovery to enhance feedwater temperatures.
2. Flue Gas Temperature Control
Reducing flue gas temperature by 22°C can lead to a 1% increase in boiler efficiency. Regular monitoring and adjustments to flue gas systems can help achieve this reduction, contributing to improved thermal efficiency.
3. Redundant Air Reduction
A 15% reduction in excess air can improve boiler efficiency by about 1%. While maintaining an excess air level of 20% is acceptable, it’s essential to monitor oxygen levels closely. Strive for a targeted excess air level of around 3%, ensuring that CO emissions do not exceed 50 ppm.
4. Impregnated Steam Temperature
For saturated steam, the temperature (T) can be calculated using the formula:
[ T = 2 \ sqrt {P\times 100} + 1]
Where P is the pressure. Understanding this relationship aids in optimizing steam conditions for better efficiency.
5. Sequestration of Steam Lines
Proper insulation of steam lines and components can reduce heat loss significantly. Effective insulation can result in an overall efficiency improvement of up to 2% compared to poorly insulated systems.
6. Soot Blowing Authority
Implementing an effective soot blowing schedule can enhance boiler efficiency by 1-2%. Regular cleaning of heat exchange surfaces is essential to maintain optimal thermal performance.
7. Turbine Exhaust Temperature
For every 10°C reduction in turbine exhaust temperature, steam turbine efficiency can increase by approximately 1%. Focus on cooling systems and heat recovery solutions to capitalize on this opportunity.
8. Conservation of Turbine Blades
Regular maintenance and thorough cleaning of turbine blades can yield efficiency improvements of up to 2%. This ensures optimal aerodynamics and performance of the turbine.
9. Advanced Control Strategies
Adopting advanced control strategies and automation can enhance overall plant efficiency by 1-3%. Incorporating technologies such as predictive maintenance and real-time monitoring can lead to substantial operational improvements.
10. Equipment Upgrades
Investing in high-efficiency equipment and technologies can result in efficiency improvements ranging from 5-10%. Evaluate current technologies and consider upgrades to stay competitive and efficient.
11. Use of Energy Complements
Incorporating fuel additives can boost boiler efficiency by up to 2%. These additives can improve combustion characteristics and overall fuel performance.
12. Understanding Boiler Loading
While there is no straightforward relationship between boiler loading and efficiency, it is essential to note that boiler efficiency at loading levels below 50% is typically around 85% of its maximum efficiency (optimal between 85% and 95%). Understanding this dynamic can help in operational decision-making.
Conclusion:
These guidelines provide a robust framework for thermal power plant engineers to enhance efficiency and reduce energy consumption. By systematically implementing these strategies, it can be ensured that the operations are not only effective but also environmentally sustainable. Continuous monitoring, regular maintenance, and a commitment to innovation will drive success in achieving energy efficiency targets.
Let’s embrace these principles and work towards a more energy-efficient future for the power plants.
Author:
Mr. Ashwini Mishra
Vice President
Gallantt Ispat Limited
very Important considerations for improving boiler performance and overall plant efficiency. Everyone should read and share this article. You will undoubtedly receive results if you follow the above thumb rule.
I really appreciated how you explained each & every critical point about energy optimisation. It gave me a new perspective .
Thanking you for sharing!!!