Common Boiler Feedwater Header for IGCC Plant Reliability

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Solution Overview

Problem

Integrated gasification combined cycle (IGCC) power plants with multiple trains face operational disturbances and increased costs due to the need for additional piping and hardware to manage varying flow rates and conditions of boiler feedwater between parallel trains, affecting the reliability and efficiency of syngas heaters and coolers.

Innovation Solution

A system that combines boiler feedwater from multiple steam generators into a common header, allowing for independent control of flow rates based on operational criteria, reducing the impact of disturbances and optimizing the operation of syngas heaters and coolers through a controller that adjusts flow rates in response to temperature, pressure, and other conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If additional piping and hardware are added to manage varying flow rates and conditions of boiler feedwater between parallel trains, then the reliability and efficiency of syngas heaters and coolers are improved, but the capital expenditures and device complexity increase

Engineering Contradiction:

Improvereliability of syngas heaters and coolersVSAvoidpiping and hardware requirements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines boiler feedwater from multiple steam generators into a common header, merging previously separate piping systems. This reduces the number of independent piping lines and hardware components needed to manage feedwater distribution, thereby reducing capital expenditures and device complexity while maintaining the ability to supply multiple syngas heaters and coolers reliably

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The common boiler feedwater header serves multiple functions: it distributes feedwater to multiple steam generators, accommodates varying flow rates from different trains, and provides a centralized point for flow rate management. This multi-functional design eliminates the need for separate dedicated piping for each train, reducing overall system complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If additional piping and hardware are added to manage varying flow rates and conditions of boiler feedwater between parallel trains, then the availability of IGCC power plants is improved, but the capital expenditures increase

Engineering Contradiction:

Improveavailability of IGCC power plantsVSAvoidcapital expenditures

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By merging feedwater systems into a common header, the patent reduces the total amount of piping and hardware that needs to be manufactured and installed, directly reducing capital expenditures while maintaining plant availability through improved flow management

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If flow rates of boiler feedwater are independently controlled based on operational criteria, then the efficient operation of syngas heaters and coolers is maintained, but the control system complexity increases

Engineering Contradiction:

Improveefficient operation of syngas heaters and coolersVSAvoidcontrol system requirements

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The controller monitors operational criteria such as temperature, pressure, and flow rates from multiple steam generators and automatically adjusts feedwater flow distribution. This feedback mechanism enables efficient operation of syngas heaters and coolers by responding to changing conditions, while the automated control reduces the need for complex manual intervention systems

Inventive Principle:

Principle #23Feedback

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enhances the reliability and availability of IGCC power plants by reducing the impact of operational upsets and asymmetrical loading, minimizing equipment and piping requirements, and maintaining efficient operation of syngas heaters and coolers, thereby lowering capital expenditures.

Implementation Method 1

a common boiler feedwater configured to combine the first boiler feedwater and the second boiler feedwater to produce a common boiler feedwater

Methodology Applied

Scientific EffectFluid mixing:

Implementation Method 2

a heater configured to receive the common boiler feedwater to heat a gas

Methodology Applied

Scientific EffectHeat transfer:

Data Source

PatentUS9163827B2System and method for using boiler feedwater

Publication Date: 2015.10.20 AIR PROD & CHEM INC

AI summary

A system includes a first steam generator configured to generate a first boiler feedwater, a second steam generator configured to generate a second boiler feedwater, a common boiler feedwater configured to combine the first boiler feedwater and the second boiler feedwater to produce a common boiler feedwater, and a heater configured to receive the common boiler feedwater to heat a gas.