This paper presents a comprehensive step-wise methodology for implementing industry 4.0 in a functional coal power plant. The overall efficiency of a 660 MWe supercritical coal-fired plant using real operational data is considered in the study. Conventional and advanced AI-based techniques are used to present comprehensive data visualization. Monte-Carlo experimentation on artificial neural network (ANN) and least square support vector machine (LSSVM) process models and interval adjoint significance analysis (IASA) are performed to eliminate insignificant control variables. Effective and validated ANN and LSSVM process models are developed and comprehensively compared. The ANN process model proved to be significantly more effective; especially, in terms of the capacity to be deployed as a robust and reliable AI model for industrial data analysis and decision making. A detailed investigation of efficient power generation is presented under 50%, 75%, and 100% power plant unit load. Up to 7.20%, 6.85%, and 8.60% savings in heat input values are identified at 50%, 75%, and 100% unit load, respectively, without compromising the power plant’s overall thermal efficiency.
Modern data analytics techniques and computationally inexpensive software tools are fueling the commercial applications of data-driven decision making and process optimization strategies for complex industrial operations. In this paper, modern and reliable process modeling techniques, i.e., multiple linear regression (MLR), artificial neural network (ANN), and least square support vector machine (LSSVM), are employed and comprehensively compared as reliable and robust process models for the generator power of a 660 MWe supercritical coal combustion power plant. Based on the external validation test conducted by the unseen operation data, LSSVM has outperformed the MLR and ANN models to predict the power plant’s generator power. Later, the LSSVM model is used for the failure mode recovery and a very successful operation control excellence tool. Moreover, by adjusting the thermo-electric operating parameters, the generator power on an average is increased by 1.74%, 1.80%, and 1.0 at 50% generation capacity, 75% generation capacity, and 100% generation capacity of the power plant, respectively. The process modeling based on process data and data-driven process optimization strategy building for improved process control is an actual realization of industry 4.0 in the industrial applications.
The emissions from coal power plants have serious implication on the environment protection, and there is an increasing effort around the globe to control these emissions by the flue gas cleaning technologies. This research was carried out on the limestone forced oxidation (LSFO) flue gas desulfurization (FGD) system installed at the 2*660 MW supercritical coal-fired power plant. Nine input variables of the FGD system: pH, inlet sulfur dioxide (SO2), inlet temperature, inlet nitrogen oxide (NOx), inlet O2, oxidation air, absorber slurry density, inlet humidity, and inlet dust were used for the development of effective neural network process models for a comprehensive emission analysis constituting outlet SO2, outlet Hg, outlet NOx, and outlet dust emissions from the LSFO FGD system. Monte Carlo experiments were conducted on the artificial neural network process models to investigate the relationships between the input control variables and output variables. Accordingly, optimum operating ranges of all input control variables were recommended. Operating the LSFO FGD system under optimum conditions, nearly 35% and 24% reduction in SO2 emissions are possible at inlet SO2 values of 1500 mg/m3 and 1800 mg/m3, respectively, as compared to general operating conditions. Similarly, nearly 42% and 28% reduction in Hg emissions are possible at inlet SO2 values of 1500 mg/m3 and 1800 mg/m3, respectively, as compared to general operating conditions. The findings are useful for minimizing the emissions from coal power plants and the development of optimum operating strategies for the LSFO FGD system.
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