Boiler Slag Control via Burner Air-Fuel Ratio Adjustment
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Solution Overview
Problem
Fossil-fuel fired boiler systems face issues with slag formation at specific locations, leading to equipment damage, increased operational costs, and downtime due to reduced thermal efficiency and inefficient use of slag reducing compounds.
Innovation Solution
A control system utilizing temperature, CO, and slag detection sensors to identify areas with excessive slag formation, adjusting the air-fuel ratio and air-fuel mass flow of specific burners to decrease slag formation, and strategically delivering slag reducing compounds to affected areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If slag reducing compounds are used to decrease slag formation, then slag formation rate decreases, but operational cost increases due to usage of costly additives
Solution Approach 1:
The system applies slag reducing compounds selectively to specific burners that contribute to slag formation at predetermined locations, rather than uniformly to all burners. The controller determines which burners are responsible for slag formation based on sensor data and applies additives only to those specific burners, optimizing cost efficiency while maintaining effectiveness.
Solution Approach 2:
The system uses sensors (temperature sensors, CO sensors, and slag detection sensors) to continuously monitor boiler conditions and provides feedback to the controller. The controller adjusts slag reducing compound application based on real-time feedback about slag thickness, temperature levels, and CO levels, ensuring additives are used only when and where needed.
2Manufacturing precision
If comprehensive sensor monitoring and control adjustments are implemented, then slag formation control precision improves, but device complexity increases
Solution Approach 1:
The system divides the boiler into multiple predetermined locations and associates specific burners with specific locations. The controller determines which burners contribute to slag formation at which locations and adjusts air-fuel ratios and additive application on a per-burner basis, rather than controlling the entire boiler as a single unit.
Solution Approach 2:
The system uses the boiler's own operational parameters (temperature, CO levels, slag thickness) as feedback to automatically adjust its own operation. The controller modifies air-fuel ratios and additive application based on sensor data from the boiler itself, enabling self-regulation without external intervention.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively reduces slag formation rates at predetermined locations, enhancing thermal efficiency, minimizing downtime, and optimizing the use of slag reducing compounds by targeting specific areas of high impact.
Implementation Method 1
receiving a first plurality of signals from a plurality of temperature sensors disposed in the boiler system... determining a plurality of temperature levels at a first plurality of locations in the boiler system based on the first plurality of signals
Implementation Method 2
receiving a second plurality of signals from a plurality of CO sensors disposed in the boiler system... determining a plurality of CO levels at the first plurality of locations based on the second plurality of signals
Implementation Method 3
receiving a third plurality of signals from a plurality of slag detection sensors disposed in the boiler system... determining a plurality of slag thickness levels at the first plurality of locations based on the third plurality of signals
Implementation Method 4
increasing an A/F ratio of at least one burner of the second plurality of burners, to decrease the rate of slag formation at the second plurality of locations
Data Source
AI summary
A system and a method for decreasing a rate of slag formation at predetermined locations in a boiler system are provided. The boiler system has a plurality of burners, a plurality of slag detection sensors, a plurality of temperature sensors and a plurality of CO sensors disposed therein. The system determines locations within the boiler system that have relatively high slag thickness levels utilizing the plurality of slag detection sensors and then adjusts A/F ratios or mass flows of burners affecting those locations, or adds slag reducing additives to the burners affecting those locations, to decrease a rate of slag formation at the locations, utilizing signals from the plurality of slag detection sensor, the plurality of temperature sensors, and the plurality of CO sensors.