Abstract
South African coal-fired power plants (CFPPs) are set in a unique environment and are faced with unique challenges including ageing infrastructure, increased maintenance requirements, and reduced funds. A unique solution is required whereby plant performance can be maintained, or even enhanced, through the use of efficient techniques that utilise the available funds in a cost-effective manner. A simulation-backed model could help improve the effectiveness of operation and minimise downtime. Simulation software has become an intricate part of the operation of modern companies, aiding in decision making, process predictions, scenario investigations, and optimising operations. In order to compare the available CFPP simulation software, six functional evaluation criteria were investigated, namely; training, digital twinning, scenario investigation, optimisation, real-time monitoring, and dynamic analysis. With these criteria in mind, a simulation model was constructed of a South African-based CFPP. The model is based on a semiempirical thermohydraulic model. The results of the simulation were verified against measured plant data and was within 5% accuracy. Correct application of the model contributed towards maintenance scheduling, with an average daily profit per unit of R1.13 million. When extrapolated to all Eskom power stations, this value increases to over R1.6 billion per annum.
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