Online Coal Analyzers in the

The world leader in serving science US Utility Industry

Richard Woodward
Thermo Fisher Scientific
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EPRI Webcast
7 October 2008
 Presentation Outline

ƒ PGNAA principle of operation

ƒ Background
ƒ Common utility applications
ƒ PGNAA Analyzers
• Two different models
• Choosing between them
ƒ Getting the most value from the analyzer
• Software packages

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 Prompt Gamma Neutron Activation Analysis
(PGNAA)

Thermal Nucleus Excited Stable Gamma

Neutron Nucleus Nucleus Ray

3
Principle of Operation: Thermo Scientific CQM

Shielding

Slider Plates Neutron Moderator

/ Reflector

Neutron Shield

NaI Photo-multiplier
Crystal Tube
Cf-252 Neutron
Source

Fission Gamma
Ray Shield

4
4
 Advantages of (PGNAA)
Prompt Gamma Neutron Activation Analysis

ƒ Lowest cost of neutrons

ƒ Lowest radiation while in operation
ƒ Most uniform sensitivity to entire coal cross-section, leading to
superior accuracy
ƒ When coal source is known, has best algorithm for calorific value
determination
ƒ Best reliability—no chance of failure of ionization source
ƒ Most mature online analysis technology
• Thermo Fisher alone has sold more than 600 analyzers in the past
25 years
• Large installed base permits service staff location close to customer

5
 Background on elemental coal analyzers

ƒ Online elemental coal analyzers have been in use for 25

years
• EPRI was an early sponsor
ƒ Analyzers measure
• sulfur
• ash
• moisture
• caloric value
• all major ash constituents
ƒ Analyzer use in power plant applications growing

6
 Utilities are becoming a more significant part
of the analyzer user population

% of Thermo Scientific Coal Analyzers Sales going to Utilities

60%
52%
50%
43% 43%
40%
Percentage

30%

20%

10%
0
0%
1998-2000 2001-2003 2004-2006 2007-present

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 Most utility analyzers are belt analyzers
and are found on bunker feed
Mix of Therm o Scientific Coal Analyzers sold to Utilities since 2000

At the mine--CQM, 14%

At the mine--ECA, 8%

Bunker Feed--ECA, 49%

Receipt monitoring--CQM, 8%

Full-flow 62% Receipt monitoring--ECA, 5%

Sample stream 38%
-----------------------------
Bunker Feed--CQM, 16%
Bunker feed 65%
Receipt monitoring 13%
At the mine 22%

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 Bunker Feed Application

ƒ Accounts for 65% of all Thermo

Scientific utility installations since
2000
ƒ Process goals include
• Boiler optimization
• Emissions compliance
• Ensuring proper sorting between
scrubbed and unscrubbed units
ƒ When there are parallel bunker
feed conveyors the solution can
be
• Two full-flow analyzers
• One sample-stream analyzer, fed
by two primary samplers

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 Receipt monitoring application
Constellation Energy’s C. P. Crane plant in
Maryland
ƒ Installed full-flow analyzer
• Monitors all incoming rail shipments as
conveyed to yard stockpile
• Operator Console located in coal yard
office

Luoyang Longyu power plant in China

• Use an auger sampler to sample each
incoming truck
• Sample increment sent through
sample stream analyzer to determine if
truck is on spec
• Plant saved $375K in six months

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 Two Types of PGNAA Elemental Analyzers

ƒ Sample stream
• Typically flow rates of 2-10 tph
• Primary save stream or secondary
rejects
• Most accurate analyzer in industry
• Constant analysis geometry
Thermo Scientific (formerly Gamma-Metrics) CQM
ƒ Full flow
• Most effective on belt sizes between
30 and 60 inches
• Accuracy best when flow variations
are minimal

Thermo Scientific ECA

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 Choosing between sample stream analyzer (CQM)
and full flow analyzer (ECA)
Any one of the following conditions could tip the scales in favor of
a sample stream analyzer
• Stringent accuracy requirements
• Highly variable belt loading
• Top sizes greater than 4 inches
• Conveyor belt conditions
• Steel corded belts
• Belt sizes of 72 inches and greater
• Installation conditions
• Two parallel belt conveyors, which might be able to share—in a
multiplexed manner—a single sample stream analyzer
• Existing sampling system with which a sample stream analyzer can be
easily integrated

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 Choosing between sample stream analyzer (CQM)
and full flow analyzer (ECA)
Any one of the following conditions could tip the scales in favor of
a sample stream analyzer
• Stringent accuracy requirements
• Highly variable belt loading
• Top sizes greater than 4 inches
• Conveyor belt conditions
• Steel corded belts
• Belt sizes of 72 inches and greater
• Installation conditions
• Two parallel belt conveyors, which might be able to share—in a
multiplexed manner—a single sample stream analyzer
• Existing sampling system with which a sample stream analyzer can be
easily integrated

If none of these are issues, a full flow analyzer should be sufficient

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Full Stream Analyzer Accuracy Compared with Sample Stream
Analyzer Accuracy

Full flow
analyzer

~ 15 -50%

Sample Left-to-right Varying belt Vertical

stream sensitivity loading sensitivity
analyzer variance variance

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 Accuracy comparison: sample stream vs. full flow
Arch Mountain Laurel CQM: Lab vs. Analyzer Ash
Comparison
August 2007

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RMSD = 0.46%
Standard Error of the Estimate = 0.35%
10
Laboratory Ash (Wt. %)

6
Arch Mountain Laurel ECA: Lab vs. Analyzer Comparison
August 2007
4
12
RMSD = 0.51%
2 Standard Error of the Estimate = 0.44%
10

0
0 2 4 6 8 8 10 12
Laboratory

Analyzer Ash (Wt. %)

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When flow is consistent and belt is fully
loaded, the accuracy difference is 4

slight; in this example 2

• 20% worse Standard Error of the 0

Estimate 0 2 4 6
Analyzer
8 10 12

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 The critical importance of
analyzer and reference system accuracy

Upper limit = 0.8 Seemingly modest

differences in accuracy
0.8
RMSD = 0.03
can lead to huge profit
0.7
Setpoint = 0.74 differences
0.6 • Assume
RMSD = 0.04
0.5 Setpoint = 0.72 • 5 mtpy clean coal
Probability

burned
0.4
• $10/ton cost
0.3
differential
0.2
• 0.6% sulfur
0.1 • 1.8% sulfur
0
8 8.5 9 9.5 10
% sulfur 10.5 11 11.5 12
% Ash • Annual savings
associated with 0.03%
RMSD rather than
0.04% = $833,000

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The analyzer value pyramid

Proper
selection
of set point
based upon
actual performance

Regular lab vs.

analyzer calibrations to
ensure optimal calibration

Do a thorough calibration
during commissioning

Install it in the best location,

with a sampling system located
on the same process stream

Choose the right analyzer

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The analyzer value pyramid

Proper
selection
of set point
based upon
actual performance

Regular lab vs.

analyzer calibrations to
ensure optimal calibration

Do a thorough calibration
during commissioning

Choose the right location to install

Choose the right analyzer

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The analyzer value pyramid

Proper
selection
of set point
based upon
actual performance

Regular lab vs.

analyzer calibrations to
ensure optimal calibration

Calibrate thoroughly
during commissioning

Choose the right location to install

Choose the right analyzer

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The analyzer value pyramid

Proper
selection
of set point
based upon
actual performance

Check calibration
regularly

Calibrate thoroughly
during commissioning

Choose the right location to install

Choose the right analyzer

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The analyzer value pyramid

Use
Applications
Software for
added value

Check calibration
regularly

Calibrate thoroughly
during commissioning

Choose the right location to install

Choose the right analyzer

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 Utility Applications Software

ƒ COBOS Automated Blending from Thermo Scientific

ƒ Coal yard Quality and Silo Tracking from the Engineering
Consulting Group
ƒ Boiler optimization and profit maximization from Black & Veatch

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COBOS from Thermo Fisher

ƒ Up to six sources
ƒ Up to three control parameters
ƒ Cost minimization algorithm
subject to achieving min’s &
max’s on control variables
ƒ Batch or continuous, with
adjustable recovery rate from
deviations
ƒ Feeder constraints
ƒ Adjusts for varying delays from
feeders
ƒ Auto adjustment in analyzer
assumptions (e.g., MAF Btu)
based upon feed proportions

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 ECG’s AccuTrack Objectives

ƒ Fuel Tracking Objectives:

ƒ Track incoming coal tons and fuel spec from Mine to Yard to Bunker to
Burner
ƒ Forecast Blending to meet Operational and Economic Objectives
ƒ Track Chemistry to Avoid Boiler Upsets while Maintaining Consistent
Emissions
ƒ Provide Operators with Early Warning Advisory Information

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 AccuTrack Operator Advisory Screen

When?

What?
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Black & Veatch: Predicting Performance Based on Coal Quality

• Holistic view
• Takes market
conditions into
account
• Overall goal is
profit maximization
• Model is dynamic,
learning from actual
effects of different
coal qualities

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Questions and Comments

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