Inferential Pulverized Fuel Flow Sensing in Coal Mill
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Solution Overview
Problem
Traditional load line control strategies for coal pulverizers fail to account for the dynamics of coal pulverizing and transport processes, leading to suboptimal energy consumption and inaccurate measurement of pulverized fuel flow, which is difficult and expensive to measure directly.
Innovation Solution
Implementing an inferential sensing system using differential pressure sensing within a coal mill to estimate recirculated coal load and pulverized fuel flow, combined with a model-based approach and a Kalman filter to stabilize and optimize coal pulverizing and transport processes, allowing for fine-tuning of mill operation and combustion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional load line control strategy is used, then mill operation reliability is maintained, but energy consumption increases and measurement accuracy decreases
Solution Approach 1:
The patent replaces direct mechanical measurement of pulverized fuel flow with an inferential sensing system using differential pressure sensors and a Kalman filter algorithm. This substitution allows for accurate flow measurement without the complexity and energy consumption of direct measurement systems, while maintaining reliability through model-based estimation.
Solution Approach 2:
The patent introduces differential pressure sensors as intermediary measurement points that indirectly measure pulverized fuel flow. By measuring pressure differences at strategic locations and using a Kalman filter to process these intermediate measurements, the system achieves accurate flow estimation without directly measuring the fuel flow itself, reducing energy consumption.
2Reliability
If traditional load line control strategy is used, then conservative operation is ensured, but measurement precision of pulverized fuel flow deteriorates
Solution Approach 1:
The patent replaces inadequate direct measurement methods with an inferential sensing system based on differential pressure measurements and Kalman filter algorithms. This substitution provides precise pulverized fuel flow measurement by processing intermediate pressure signals through a mathematical model that accounts for system dynamics.
Solution Approach 2:
The patent implements a feedback control system using the Kalman filter to continuously estimate pulverized fuel flow based on differential pressure measurements. The estimated flow information is fed back to the control system, enabling precise measurement and dynamic adjustment of mill operation to maintain optimal performance.
3Measurement precision
If direct measurement of pulverized fuel flow is implemented, then measurement accuracy improves, but device complexity and cost increase
Solution Approach 1:
The patent uses differential pressure sensors as intermediary measurement devices that are simpler and less expensive than direct pulverized fuel flow measurement systems. By measuring pressure differences at accessible locations and using a Kalman filter to infer fuel flow from these intermediate measurements, the system achieves high measurement accuracy without complex direct measurement equipment.
Solution Approach 2:
The patent substitutes complex mechanical direct measurement systems with a combination of simple differential pressure sensors and a mathematical estimation algorithm. This substitution dramatically reduces device complexity and cost while maintaining or improving measurement accuracy through the use of the Kalman filter to process the pressure signals.
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
This approach enables accurate estimation and control of pulverized fuel flow, optimizing coal milling and combustion processes by stabilizing recirculated load and dynamically responding to changes in coal mill operation, thereby reducing energy consumption and improving combustion efficiency.
Implementation Method 1
sensing a differential pressure between two locations within a fuel path of the coal mill
Data Source
AI summary
The subject mater herein relates to coal mills and, more particularly, inferential pulverized fuel flow sensing and manipulation within a coal mill. Various embodiments provide systems, methods, and software to manipulate a primary air flow rate and a coal feed rate into a coal mill to produce a target pulverized fuel flow. Some embodiments include sensing a differential pressure between two or more locations within a coal mill to estimate a recirculated load of coal at one or more stages within the coal mill.