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

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.
0h
Woodfeeders
Short-term Combustion
Long-term Combustion
24 h
• Simultaneously Reduces Fuel Costs and Emissions (Particulates, CO2).
• 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
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
Biomass / Solid Waste - Fuel Boiler Control Loops
Combustion
Rate Model
Boiler Master /
Load Allocation
Primary
Air-Fuel
Ratio
Auxiliary
Fuel Master
Primary
Fuel Feeders
Auxiliary
Air-Fuel
Ratio
Feeder
Profiling
Burner
Management
and Optimization
Primary /
Secondary
Distribution
Feeder
Distributors
OF1/2
Damper
Positioners
UG1/2
Damper
Positioners
Steam
Drum
Level
Primary
Fuel Master
Feeder
Distributor
Speed
Controllers
Feeder
Speed
Controllers
Advanced Boiler Control
Auxiliary
Air 1
Lead/Lag
Feedwater
Flow
Valve
FDS
Pressure
Setpoint
Furnace
Pressure
Setpoint
Boiler Steam
Temperature
Setpoint
FD Supply
Pressure
Furnace
Pressure
Superheater
Steam
Temperature
Attemperator
ID Fan
FD Fan
Flow
Damper
Damper
Valve
Positioner
Positioner
ID Fan
FD Fan
Speed
Speed
Controller
Controller
Auxiliary
Air 2
Lead/Lag
Auxiliary
Air 1
Mass Flow
Auxiliary
Fuel
Mass Flow
Auxiliary
Air 2
Mass Flow
AA1
Damper
Positioner
Auxiliary
Fuel
Valve
AA2
Damper
Positioner
CIMExcel Software Inc.
Auxiliary
Fuel Burners
Slide 3
Chemical Recovery Boiler Control Loops
Combustion
Rate Model
Boiler Load
Allocation
BLS
Throughput
Optimization
Total Air
Control
Auxiliary
Air-Fuel
Ratio
Steam
Drum
Level
Feedwater
Flow
Valve
Auxiliary Air
Lead/Lag
Consumed
Air Control
Tertiary
Air Damper
Positioner
BLS
Flow Control
Valve
Auxiliary
Fuel Master
Secondary
Air Damper
Positioner
Primary
Air Damper
Positioner
Advanced Boiler Control
FDS
Pressure
Setpoint
Furnace
Pressure
Setpoint
Boiler Steam
Temperature
Setpoint
FD Supply
Pressure
Furnace
Pressure
Superheater
Steam
Temperature
Attemperator
ID Fan
FD Fan
Flow
Damper
Damper
Valve
Positioner
Positioner
ID Fan
FD Fan
Speed
Speed
Controller
Controller
Auxiliary
Auxiliary
Air
Fuel
Mass Flow Mass Flow
Auxiliary Air
Damper
Positioner
Auxiliary
Fuel
Valve
CIMExcel Software Inc.
Slide 4
Combustion Rate Model – Biomass Boiler
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.
CRM Inputs
Biomass Combustion Rate: 125 MW
Combustion Rate Distribution on the Grate (for each Feeder and front - middle - back locations)
Advanced Boiler Control
CIMExcel Software Inc.
Slide 5
Combustion Rate Model – Chemical Recovery Boiler
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.
CRM Inputs
Black Liquor Combustion Rate: 150 MW
Advanced Boiler Control
CIMExcel Software Inc.
Slide 6
Multi-Fuel Boiler Model and Simulator
for off-line control strategy testing, tuning, checkout, optimization, and for operator training
Advanced Boiler Control
CIMExcel Software Inc.
Slide 7
Multi-Fuel Boiler Model and Simulator – First Principles and Empirical Data Model
Babcock& Wilcox Heat Transfer Data
Steam Properties
hg vs Pressure
2.81
0.18
2.81
2.80
0.16
0%
hg (GJ/T)
Fpp, Physical Properties Factor - Crossflow Gas
Babcock & Wilcox Fig 4-12
0.20
5%
0.14
10 %
15 %
2.80
20 %
0.12
2.79
0.10
2.79
0.08
2.78
0
500
1000
1500
2000
2500
3000
30
35
40
Tf, Gas Film Tem perature (degF)
45
50
55
60
Pressure (bar)
Equipment Data
Boiler SGS Performance Curves
ID Fan
Boiler SGS Two Phase Flow
(U = 0.05, 0.10, 0.15,,,, 1.0)
(Uo = 1135 RPM, Po = 13.3 inH2O, Wo = 248 Tph)
22
1.2
21
1.1
20
19
1.0
18
0.9
SGS Recirculation Ratio
17
0.8
P/Po
0.7
0.6
0.5
0.4
16
15
14
13
12
11
10
9
8
0.3
7
0.2
6
5
0.1
4
0.0
0.0
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
1.2
1.3
1.4
Wr, Riser Mass Flow
W/Wo
Advanced Boiler Control
0.1
1.2
CIMExcel Software Inc.
Slide 8