SmartProcess® Boiler
Emerson's SmartProcess® Multi-Fuel Boiler solution optimizes boiler operations by minimizing steam header pressure deviations and maximizing the combustion of less expensive fuels. The solution increases boiler efficiency by reducing the level of combustion air while meeting all emission constraints. SmartProcess® Multi-Fuel Boiler also helps eliminate the need for manual operator interventions.
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Improvement Highlights
- Reduced natural gas usage rate by 75%.
- Increased bark burning by 16%.
- Increased boiler steam production by 3.5%.
- Documented savings of over $1.5M per year.
- Typical payback in 3 to 6 mo.
Objectives/Benefits
Maintain operations at or above best-in-class performance levels:
- Generate 90% of steam with biomass fuels.
- Hold excess oxygen below 3.5% to maximize unit efficiency.
- Produce steam at MCR while maintaining emissions within permitted levels.
- Maintain carbon ash under 10%.
- Operate boiler in full automatic control over 95%.
SmartProcess® Multi-Fuel Boiler functionality includes:
- Full automatic boiler control
- Separate control masters for each fuel in boiler
- Btu-based firing with real-time adjustment for biomass fuel quality
- Real-time optimizer
- Enhanced operator interface
Multi-Fuel Boiler Operational Challenges
Multi-Fuel Power Boilers are used in the Pulp and Paper industry to provide cost effective steam for process use and on-site electrical generation. Operation of a Multi-Fuel Boiler is significantly more difficult than running a unit fired with only fossil fuels. The more common issues include:
- Widely variable BTU content of fuel
- Biomass moisture variability
- Wide variety of biomass particle sizes
- Incomplete combustion
- Inadequate air system volume
- Poor boiler emissions performances
Multi-Fuel Boiler operations must be optimized so that steam and electricity are produced for the least cost possible. |
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