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Advanced Boiler Control for Biomass and Chemical Recovery Boilers For improved boiler stability and safety, fuel cost efficiency, and environmental compliance,

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Presentation on theme: "Advanced Boiler Control for Biomass and Chemical Recovery Boilers For improved boiler stability and safety, fuel cost efficiency, and environmental compliance,"— Presentation transcript:

1 Advanced Boiler Control for Biomass and Chemical Recovery Boilers For improved boiler stability and safety, fuel cost efficiency, and environmental compliance, using Advanced Control and Optimization strategies and implemented in existing DCSs. Simultaneously Reduces Fuel Costs and Emissions (Particulates, CO 2 ). Advanced Control of Combustion Air and Gas, Steam Drum Level, and Header Pressure. Optimization for Multi-Fuel Firing, Air-Fuel Ratios, and Air Distribution. Multi-fuel Combustion Rate Model. Boiler Master with Load Allocation and Comprehensive Constraint Control. Burner Management and Optimization. Chemical Recovery Boiler Throughput, Consumed Air, and Air Distribution Optimization. Active Control of the Solid Fuel Distribution on the Grate. Grate Cleaning and Restart Optimization. Advanced Boiler Control CIMExcel Software Inc. Slide 1 Woodfeeders Short-term Combustion Long-term Combustion 0 h24 h

2 Advanced Boiler Control Harmac No.9 Power Boiler Hog steam was increased by 60 kpph (180 -> 240 kpph, with a 450 kpph MCR, with hog fuel moisture of 57 %, resulting in a reduction of 15 barrels of oil per hour – from 35 barrels per hour) Port Townsend Paper No.10 Power Boiler During a manual trial, the ABC technology increased the hog steam by 70 kpph (140 -> 210 kpph, with a 250 kpph MCR, with hog fuel moisture of 56 %, resulting in the removal of all 17.5 barrels of oil per hour). During another trial, the particulate matter emissions were reduced by 40% (from the permitted value) during the same hog fuel firing rate. Port Angeles No.8 Power Boiler During a manual trial, the ABC technology increased the hog steam by 30 kpph (70 -> 100 kpph, with a 120 kpph MCR, with hog fuel moisture of 60 %, resulting in the removal of all 8 barrels of oil per hour was removed). Advanced Boiler Control CIMExcel Software Inc. Slide 2

3 Advanced Boiler Control CIMExcel Software Inc. Slide 3 Biomass / Solid Waste - Fuel Boiler Control Loops Superheater Steam Temperature Steam Drum Level Furnace Pressure FD Supply Pressure Auxiliary Fuel Master Primary Fuel Master Auxiliary Air-Fuel Ratio Burner Management and Optimization Auxiliary Air 1 Lead/Lag Auxiliary Air 2 Lead/Lag Auxiliary Fuel Mass Flow Auxiliary Air 1 Mass Flow Auxiliary Air 2 Mass Flow Primary Fuel Feeders Feeder Profiling Feeder Distributors Primary Air-Fuel Ratio Primary / Secondary Distribution Boiler Master / Load Allocation Combustion Rate Model UG1/2 Damper Positioners OF1/2 Damper Positioners Feeder Speed Controllers Feeder Distributor Speed Controllers AA1 Damper Positioner AA2 Damper Positioner Auxiliary Fuel Valve Feedwater Flow Valve FD Fan Speed Controller FD Fan Damper Positioner ID Fan Speed Controller ID Fan Damper Positioner Attemperator Flow Valve Auxiliary Fuel Burners FDS Pressure Setpoint Furnace Pressure Setpoint Boiler Steam Temperature Setpoint

4 Advanced Boiler Control CIMExcel Software Inc. Slide 4 Chemical Recovery Boiler Control Loops Superheater Steam Temperature Steam Drum Level Furnace Pressure FD Supply Pressure Auxiliary Fuel Master BLS Throughput Optimization Auxiliary Air-Fuel Ratio Auxiliary Air Lead/Lag Auxiliary Fuel Mass Flow Auxiliary Air Mass Flow Total Air Control Consumed Air Control Boiler Load Allocation Combustion Rate Model BLS Flow Control Valve Auxiliary Air Damper Positioner Auxiliary Fuel Valve Feedwater Flow Valve FD Fan Speed Controller FD Fan Damper Positioner ID Fan Speed Controller ID Fan Damper Positioner Attemperator Flow Valve Tertiary Air Damper Positioner Secondary Air Damper Positioner Primary Air Damper Positioner FDS Pressure Setpoint Furnace Pressure Setpoint Boiler Steam Temperature Setpoint

5 Combustion Rate Model – Biomass Boiler Advanced Boiler Control CIMExcel Software Inc. Slide 5 CRM Inputs Biomass Combustion Rate: 125 MW CRM calculates the combustion rate of the variable quality biomass fuel during steady and unsteady boiler operation. CRM can determine the Combustion Rate Distribution on the Grate using an array of Thermocouples. CRM is used to optimize the undergrate and overfire air distribution, and to maximize the biomass combustion. Combustion Rate Distribution on the Grate (for each Feeder and front - middle - back locations)

6 Combustion Rate Model – Chemical Recovery Boiler Advanced Boiler Control CIMExcel Software Inc. Slide 6 CRM Inputs Black Liquor Combustion Rate: 150 MW CRM calculates the combustion rate of the variable quality black liquor fuel during steady and unsteady boiler operation. CRM is used to optimize the primary, secondary, and tertiary air distribution, and to increase the steam efficiency.

7 Multi-Fuel Boiler Model and Simulator Advanced Boiler Control CIMExcel Software Inc. Slide 7 for off-line control strategy testing, tuning, checkout, optimization, and for operator training

8 Multi-Fuel Boiler Model and Simulator – First Principles and Empirical Data Model Advanced Boiler Control CIMExcel Software Inc. Slide 8 Babcock& Wilcox Heat Transfer DataSteam Properties Equipment DataBoiler SGS Performance Curves


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