Boiler Soot Blowing Control Using Heat Absorption Feedback
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Solution Overview
Problem
Current methods for controlling soot blowing in fuel burning boilers are inconsistent and inefficient, often leading to excessive soot deposits or excessive energy consumption, due to reliance on ad hoc practices, sensitive first principle methods, and data-intensive empirical models.
Innovation Solution
A statistical process control system that collects and analyzes heat absorption data to adjust soot blowing operations, setting limits and recalibrating based on actual heat absorption measurements, providing consistent and uniform control independent of flue gas temperature disturbances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If ad hoc soot blowing practices are used, then operational simplicity is maintained, but soot blowing consistency and boiler efficiency deteriorate
Solution Approach 1:
The patent implements a feedback mechanism where heat absorption measurements are continuously monitored and used to adjust soot blowing operations. The system compares actual heat absorption values against target values and automatically adjusts soot blower operation to maintain optimal heat absorption, ensuring consistent and reliable soot blowing performance while maintaining operational simplicity through automated control.
2Measurement precision
If first principle based methods are used to control soot blowing, then theoretical accuracy is improved, but sensitivity to flue gas temperature disturbances and data requirements increase
Solution Approach 1:
The patent extracts the essential control function from complex first principle models by directly measuring heat absorption as a standalone parameter. Instead of using complex models that require multiple input parameters (flue gas temperature, steam flow, etc.), the system directly measures heat absorption and uses this single extracted parameter to control soot blowing, eliminating the need for extensive data collection and reducing sensitivity to disturbances in individual parameters.
3Reliability
If excessive soot blowing is applied, then soot deposit removal is improved, but energy consumption and steam wastage increase
Solution Approach 1:
The system uses feedback control to adjust soot blowing intensity based on actual heat absorption measurements. When heat absorption is within target range, soot blowing is reduced or stopped, preventing excessive energy consumption and steam wastage. When heat absorption deviates from target, soot blowing is activated or intensified only to the extent needed to restore optimal heat absorption, ensuring efficient energy and steam utilization.
Solution Approach 2:
The patent applies partial action by using only the amount of soot blowing necessary to achieve target heat absorption rather than continuous or excessive soot blowing. The system determines the minimum required soot blowing intensity based on heat absorption measurements, applying just enough cleaning action to maintain efficiency without wasting energy or steam on unnecessary blowing operations.
4Use of energy by moving object
If inadequate soot blowing is applied, then energy consumption is reduced, but heat transfer efficiency and boiler output deteriorate
Solution Approach 1:
The feedback control system continuously monitors heat absorption and activates soot blowing only when heat absorption deviates from target values, ensuring that soot blowing is applied only when necessary to maintain boiler efficiency and output. This prevents both excessive and inadequate soot blowing, optimizing the balance between energy consumption and productivity.
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 ensures reliable and efficient soot blowing operations by reducing data requirements, minimizing errors, and maintaining boiler efficiency while minimizing energy costs and preventing permanent fouling.
Implementation Method 1
the use of soot blowers to remove soot encrustations accumulated on boiler surfaces through the creation of mechanical and thermal shock
Implementation Method 2
the use of soot blowers to remove soot encrustations accumulated on boiler surfaces through the creation of mechanical and thermal shock
Implementation Method 3
use various types of soot blowers to spray cleaning materials through nozzles
Implementation Method 4
heat absorption data for a heat exchange section of a boiler
Data Source
AI summary
A statistical process control system employs a consistent soot blowing operation for a heat exchange section of, for example, a fuel burning boiler, collects heat absorption data for the heat exchange section and analyzes the distribution of the heat absorption data as well as various parameters of the heat absorption distribution to readjust the soot blowing operation. The statistical process control system may set a desired lower heat absorption limit and a desired upper heat absorption limit and compare them, respectively, with an actual lower heat absorption limit and an actual upper heat absorption limit to determine the readjustment to be made to the soot blowing operation. Alternatively, the statistical process control system may be used to determine permanent slagging of the heat exchange section.