Improving Heat Rate Efficiency at Illinois Coal-Fired Power Plants

Heat Rate
Improvements at
Illinois Coal-Fired
Power Plants
Jim Ross
Manager, Division of Air
Pollution Control
Illinois EPA
1
Building Block 1
2
BB#1
Heat
Rate/Efficiency
Improvements at
Coal-Fired EGUs
Coal-fired EGUs take actions to
increase the heat rate/efficiency by
6% so that generate more electricity
while burning same amount of coal
Step 2
Heat Rate (HR) = the efficiency of conversion from coal input to
Heat Rate (HR) = the efficiency of conversion from coal input to
energy output
energy output
HR = F/E
HR = F/E
F = heat energy input supplied by coal in Btu
F = heat energy input supplied by coal in Btu
E = energy output from the EGU in kWh
E = energy output from the EGU in kWh
The efficiency is calculated by dividing the equivalent Btu
content of a kWh of electricity (which is 3,412 Btu) by the heat
rate. For example, if the heat rate is 10,140 Btu/kWh, the
efficiency is 34%.
Heat content of coal = mmBtu/ton of coal (varies by coal type)
Heat content of coal = mmBtu/ton of coal (varies by coal type)
The amount of coal used to generate electricity depends on the
The amount of coal used to generate electricity depends on the
efficiency
efficiency
 or 
 or 
heat rate
heat rate
 of the EGU and the 
 of the EGU and the 
heat content
heat content
 of the
 of the
coal.
coal.
EGU efficiencies/heat rates vary by type and size of EGU, age
EGU efficiencies/heat rates vary by type and size of EGU, age
of EGU, coal type, emission controls, and other factors.
of EGU, coal type, emission controls, and other factors.
 
 
What is Heat Rate?
3
changes can be made that increase the efficiency
changes can be made that increase the efficiency
of an EGU in converting coal to energy.
of an EGU in converting coal to energy.
Less amount of coal burned to produce an
Less amount of coal burned to produce an
amount of electricity
amount of electricity
Desirable because results in less pollution per
Desirable because results in less pollution per
amount of coal burned = less carbon intensity
amount of coal burned = less carbon intensity
The 
The 
lower the heat rate the better
lower the heat rate the better
, i.e., more
, i.e., more
power is produced per amount of coal burned
power is produced per amount of coal burned
(since generation is in denominator)
(since generation is in denominator)
Lower heat rate = higher efficiency
Lower heat rate = higher efficiency
Why Heat Rate Improvements?
Why Heat Rate Improvements?
4
1.
Reviewed several studies, in particular 2009 Sargent and
Reviewed several studies, in particular 2009 Sargent and
Lundy examined 
Lundy examined 
specific 
best practices and equipment
upgrades
, including 
upgrades to boilers, steam turbines,
and control systems
….. 
4 to 12 percent improvement
possible
2.
Reviewed historical heat rate data. Identified several “data
apparent” instances where an EGU's heat rate experienced a
substantial improvement in a short time—presumably
because of 
equipment upgrades
 installed at that point in
time…. 
3 to 8 percent possible
Conclusion
:
  “strong basis for considering heat rate
improvement as a meaningful potential approach to reducing
the carbon intensity of generation at individual affected
fossil fuel-fired EGUs.”
USEPA Basis for Heat Rate Improvement
USEPA Basis for Heat Rate Improvement
5
2 
2 
principal areas of analysis:
1.
Best Practices:
 
improvements that
could be achieved by reducing
heat rate variability at individual
coal-fired EGUs through
adoption of 
best practices for
operation and maintenance
2.
Equipment Upgrades:
improvements that could be
achieved through further
equipment upgrades
Heat Rate Improvement
Heat Rate Improvement
Areas and Amounts
Areas and Amounts
6
1.
Best Practices to operating and maintenance procedures:
assessed variability in hourly gross heat rates of approximately
900 individual coal-fired EGUs from 2002 to 2012
Found 
heat rate variability
 relative to average heat rates and
deviations generally result in performance worse than the
optimal heat rates…(reduce variability improve heat rate)
1.3 percent to 6.7 percent potential for improvement in the
average heat rate of entire fleet of coal-fired EGUs
Conclusion: 
“reasonable estimate for purposes of developing state-
specific goals is that affected coal-fired steam EGUs on average could
achieve a four percent improvement in heat rate through adoption of
best practices to reduce hourly heat rate variability”
………
HR Improvements (cont.)
7
4%
2. Equipment Upgrades:
evaluated potential opportunities through specific
upgrades identified in the 2009 Sargent & Lundy
study
implementation of full subset of appropriate
opportunities at a single EGU could be expected to
result in heat rate improvement of ~ 
4 percent
recognize that this may overstate the average
equipment upgrade opportunity across all EGUs
because some EGUs may have already
implemented some of these upgrades - on average
across the fleet of affected EGUs, only 
1/2
 of the full
equipment upgrade opportunity remains
8
HR Improvements (cont.)
HR Improvements (cont.)
½ x 4% = 
2%
1. Best Practices = 4%
1. Best Practices = 4%
2. Equipment Upgrades = 2%
2. Equipment Upgrades = 2%
Total Potential for Heat Rate
Total Potential for Heat Rate
Improvement = 
Improvement = 
6%
6%
Building Block 1
9
Docket ID No. EPA-HQ-OAR-
2013-0602
GHG Abatement Measures
USEPA Technical Support
Document (TSD)
10
1)
Minimizing heat loss is the
greatest factor affecting the loss of
efficiency
2)
Equipment refurbishment
3)
Plant upgrades
4)
Improved operations and
maintenance schedules
How Improve?
11
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Heat rate improvements at coal-fired power plants in Illinois are crucial for enhancing energy conversion efficiency, reducing carbon intensity, and minimizing pollution. By increasing the heat rate/efficiency by 6%, these plants can generate more electricity while burning the same amount of coal. The concept of heat rate, its calculation, and the reasons for pursuing heat rate improvements are explained. Studies have shown that upgrades and best practices can lead to significant improvements in heat rate, offering a promising avenue for lowering carbon intensity in power generation.


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  1. Heat Rate Improvements at Illinois Coal-Fired Power Plants Jim Ross Manager, Division of Air Pollution Control Illinois EPA

  2. Building Block 1 Step 2 Building Block Goal (lbs % Reduced Cumulative % CO2/MWh) BB#1 Heat Rate/Efficiency Improvements at Coal-Fired EGUs Baseline 1,895 1 2 3 4 1,784 6% 6% Total 6% Coal-fired EGUs take actions to increase the heat rate/efficiency by 6% so that generate more electricity while burning same amount of coal 2

  3. What is Heat Rate? Heat Rate (HR) = the efficiency of conversion from coal input to energy output HR = F/E F = heat energy input supplied by coal in Btu E = energy output from the EGU in kWh The efficiency is calculated by dividing the equivalent Btu content of a kWh of electricity (which is 3,412 Btu) by the heat rate. For example, if the heat rate is 10,140 Btu/kWh, the efficiency is 34%. Heat content of coal = mmBtu/ton of coal (varies by coal type) The amount of coal used to generate electricity depends on the efficiency or heat rate of the EGU and the heat content of the coal. EGU efficiencies/heat rates vary by type and size of EGU, age of EGU, coal type, emission controls, and other factors.

  4. Why Heat Rate Improvements? changes can be made that increase the efficiency of an EGU in converting coal to energy. Less amount of coal burned to produce an amount of electricity Desirable because results in less pollution per amount of coal burned = less carbon intensity The lower the heat rate the better, i.e., more power is produced per amount of coal burned (since generation is in denominator) Lower heat rate = higher efficiency

  5. USEPA Basis for Heat Rate Improvement Reviewed several studies, in particular 2009 Sargent and Lundy examined specific best practices and equipment upgrades, including upgrades to boilers, steam turbines, and control systems .. 4 to 12 percent improvement possible 1. Reviewed historical heat rate data. Identified several data apparent instances where an EGU's heat rate experienced a substantial improvement in a short time presumably because of equipment upgrades installed at that point in time . 3 to 8 percent possible 2. Conclusion: strong basis for considering heat rate improvement as a meaningful potential approach to reducing the carbon intensity of generation at individual affected fossil fuel-fired EGUs.

  6. Heat Rate Improvement Areas and Amounts 2 principal areas of analysis: 1. Best Practices: improvements that could be achieved by reducing heat rate variability at individual coal-fired EGUs through adoption of best practices for operation and maintenance 2. Equipment Upgrades: improvements that could be achieved through further equipment upgrades

  7. HR Improvements (cont.) Best Practices to operating and maintenance procedures: 1. assessed variability in hourly gross heat rates of approximately 900 individual coal-fired EGUs from 2002 to 2012 Found heat rate variability relative to average heat rates and deviations generally result in performance worse than the optimal heat rates (reduce variability improve heat rate) 1.3 percent to 6.7 percent potential for improvement in the average heat rate of entire fleet of coal-fired EGUs Conclusion: reasonable estimate for purposes of developing state- specific goals is that affected coal-fired steam EGUs on average could achieve a four percent improvement in heat rate through adoption of best practices to reduce hourly heat rate variability 4%

  8. HR Improvements (cont.) 2. Equipment Upgrades: evaluated potential opportunities through specific upgrades identified in the 2009 Sargent & Lundy study implementation of full subset of appropriate opportunities at a single EGU could be expected to result in heat rate improvement of ~ 4 percent recognize that this may overstate the average equipment upgrade opportunity across all EGUs because some EGUs may have already implemented some of these upgrades - on average across the fleet of affected EGUs, only 1/2 of the full equipment upgrade opportunity remains x 4% = 2%

  9. 1. Best Practices = 4% 2. Equipment Upgrades = 2% Total Potential for Heat Rate Improvement = 6% Building Block 1

  10. Docket ID No. EPA-HQ-OAR- 2013-0602 GHG Abatement Measures USEPA Technical Support Document (TSD)

  11. How Improve? Minimizing heat loss is the greatest factor affecting the loss of efficiency Equipment refurbishment Plant upgrades Improved operations and maintenance schedules 1) 2) 3) 4)

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