Boiler Combustion Modeling for Real-Time Control Without Skilled Tuning

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Solution Overview

Problem

Thermal power plants face challenges in achieving optimal combustion efficiency while minimizing emissions, as existing boiler control methods rely heavily on skilled operators and are not easily adaptable for real-time optimization.

Innovation Solution

A boiler control system utilizing an artificial intelligence algorithm for self-learning and modeling, which includes a task manager, pre-processor, modeler, optimizer, and output controller to calculate and apply optimum control values, employing algorithms like PID, MPC, and Genetic Algorithm to optimize combustion based on user-defined priorities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If skilled operators manually adjust combustion parameters based on trial run data, then boiler operation stability is maintained, but combustion optimization is difficult to achieve

Engineering Contradiction:
Improveboiler operation stabilityVSAvoidcombustion optimization capability
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The system employs self-learning algorithms that automatically acquire and analyze boiler operating data, enabling the system to optimize combustion parameters autonomously without relying on skilled operators. The algorithm continuously learns from operational data and automatically adjusts control variables to achieve optimal combustion states.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical adjustment by skilled operators with an automated computational system. The self-learning algorithm processes operating data and calculates optimal control variables, substituting human expertise with an automated intelligence-based control mechanism.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If automatic real-time data acquisition and analysis is implemented, then combustion optimization is improved, but system complexity increases

Engineering Contradiction:
Improvecombustion optimizationVSAvoidcontrol system complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The self-learning algorithm serves multiple functions: it acquires operating data, analyzes combustion states, determines optimal control parameters, and adjusts control variables. This multi-functional approach consolidates what would otherwise require separate systems into a single integrated intelligent controller.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent introduces a self-learning algorithm as an intermediary between raw operating data and control decisions. This algorithm acts as a mediator that processes complex data streams and translates them into optimized control actions, simplifying the overall system architecture.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Productivity

If multiple control targets are optimized simultaneously, then overall combustion efficiency is improved, but calculation time increases

Engineering Contradiction:
Improveoverall combustion efficiencyVSAvoidcalculation time
Core Design Contradiction:
ProductivityVSLoss of time

Solution Approach 1:

The patent divides multiple control targets into distinct groups or categories. The self-learning algorithm processes and optimizes different control variables in an organized sequence, breaking down the complex multi-parameter optimization problem into manageable segments that can be handled efficiently.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The system dynamically adjusts the optimization process based on the interrelationships between control targets. The self-learning algorithm identifies and prioritizes critical control variables, adapting the calculation approach to minimize computation time while maintaining overall combustion efficiency.

Inventive Principle:
Principle #15Dynamics

Data Source

PatentUS11232376B2System and method for optimizing combustion of boiler
Publication Date: 2022.01.25 DOOSAN HEAVY IND & CONSTR CO LTD
  • US11232376B2 patent drawing
  • US11232376B2 patent drawing
  • US11232376B2 patent drawing

AI summary

A system for controlling a boiler apparatus in a power plant to combust under optimized conditions, and a method for optimizing combustion of the boiler apparatus using the same are provided. The boiler control system may include a task manager configured to collect information on a current operating state of a boiler and determine whether to perform a combustion optimization operation for the boiler, a pre-processor configured to preprocess data collected from the boiler and supply the pre-processed data, a modeler configured to create a boiler combustion model on the basis of the pre-processed data received from the pre-processor, an optimizer configured to receive the boiler combustion model from the modeler and perform the combustion optimization operation for the boiler using the boiler combustion model to calculate an optimum control value, wherein the pre-processed data is supplied to the modeler and the optimizer by the pre-processor, and an output controller configured to receive the optimum control value from the optimizer and control an operation of the boiler by reflecting the optimum control value to a boiler control logic.