Minimization of water consumption under uncertainty for a pulverized coal power plant

Coal-fired power plants are large water consumers. Water consumption in thermoelectric generation is strongly associated with evaporation losses and makeup streams on cooling and contaminant removal systems. Thus, minimization of water consumption requires optimal operating conditions and parameters, while fulfilling the environmental constraints. Several uncertainties affect the operation of the plants, and this work studies those associated with weather. Air conditions (temperature and humidity) were included as uncertain factors for pulverized coal (PC) power plants. Optimization under uncertainty for these large-scale complex processes with black-box models cannot be solved with conventional stochastic programming algorithms because of the large computational expense. Employment of the novel better optimization of nonlinear uncertain systems (BONUS) algorithm, dramatically decreased the computational requirements of the stochastic optimization. Operating conditions including reactor temperatures and pressures; reactant ratios and conditions; and steam flow rates and conditions were calculated to obtain the minimum water consumption under the above-mentioned uncertainties. Reductions of up to 6.3% in water consumption were obtained for the fall season when process variables were set to optimal values. Additionally, the proposed methodology allowed the analysis of other performance parameters like gas emissions and cycle efficiency which were also improved.