US20170114995A1 - Boiler system controlling fuel to a furnace based on temperature of a structure in a superheater section - Google Patents
Boiler system controlling fuel to a furnace based on temperature of a structure in a superheater section Download PDFInfo
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- US20170114995A1 US20170114995A1 US15/401,852 US201715401852A US2017114995A1 US 20170114995 A1 US20170114995 A1 US 20170114995A1 US 201715401852 A US201715401852 A US 201715401852A US 2017114995 A1 US2017114995 A1 US 2017114995A1
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- Prior art keywords
- temperature
- furnace
- end portion
- tube structure
- boiler system
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F22—STEAM GENERATION
- F22G—SUPERHEATING OF STEAM
- F22G5/00—Controlling superheat temperature
- F22G5/02—Applications of combustion-control devices, e.g. tangential-firing burners, tilting burners
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21C—PRODUCTION OF CELLULOSE BY REMOVING NON-CELLULOSE SUBSTANCES FROM CELLULOSE-CONTAINING MATERIALS; REGENERATION OF PULPING LIQUORS; APPARATUS THEREFOR
- D21C11/00—Regeneration of pulp liquors or effluent waste waters
- D21C11/10—Concentrating spent liquor by evaporation
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21C—PRODUCTION OF CELLULOSE BY REMOVING NON-CELLULOSE SUBSTANCES FROM CELLULOSE-CONTAINING MATERIALS; REGENERATION OF PULPING LIQUORS; APPARATUS THEREFOR
- D21C11/00—Regeneration of pulp liquors or effluent waste waters
- D21C11/12—Combustion of pulp liquors
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
- F01K23/00—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids
- F01K23/02—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled
- F01K23/06—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled combustion heat from one cycle heating the fluid in another cycle
- F01K23/064—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled combustion heat from one cycle heating the fluid in another cycle in combination with an industrial process, e.g. chemical, metallurgical
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F22—STEAM GENERATION
- F22B—METHODS OF STEAM GENERATION; STEAM BOILERS
- F22B35/00—Control systems for steam boilers
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F22—STEAM GENERATION
- F22B—METHODS OF STEAM GENERATION; STEAM BOILERS
- F22B35/00—Control systems for steam boilers
- F22B35/18—Applications of computers to steam boiler control
Definitions
- the present invention relates to a boiler system comprising a controller for monitoring a temperature of a structure in a superheater section and controlling fuel provided to a furnace based on the monitored temperature.
- black liquor which contains almost all of the inorganic cooking chemicals along with lignin and other organic matter separated from the wood during pulping in a digester.
- the black liquor is burned in a recovery boiler.
- the two main functions of the recovery boiler are to recover the inorganic cooking chemicals used in the pulping process and to make use of the chemical energy in the organic portion of the black liquor to generate steam for a paper mill.
- a superheater structure is placed in the furnace in order to extract heat by radiation and convection from the furnace gases. Saturated steam enters the superheater section, and superheated steam exits from the section.
- the superheater structure comprises a plurality of platens.
- a boiler system comprising: a furnace adapted to receive a fuel to be burned to generate hot working gases; a fuel supply structure associated with the furnace for supplying fuel to the furnace; a superheater section associated with the furnace and positioned to receive energy in the form of heat from the hot working gases; and a controller.
- the superheater section may comprise a platen including a tube structure with an end portion and a temperature sensor for measuring the temperature of the tube structure end portion and generating a signal indicative of the temperature of the tube structure end portion.
- the controller may be coupled to the temperature sensor for receiving and monitoring the signal from the sensor.
- the temperature sensor may comprise a thermocouple.
- the controller may monitor the signal from the temperature sensor for rapid changes in temperature of the tube structure end portion. Rapid changes in temperature of the tube structure end portion may be defined by a rapid increase in temperature immediately followed by a rapid decrease in temperature. For example, rapid changes in temperature of the tube structure end portion may be defined by a monotonic increase in temperature of least about 25 degrees F. occurring over a time period of between about one to five minutes and immediately thereafter a monotonic decrease in temperature greater than zero in magnitude occurring over a time period of between about one to ten minutes.
- the controller may increase an amount of fuel supplied by the supply structure to the furnace after the temperature of the tube structure end portion has experienced rapid changes.
- the boiler system may further comprise a temperature measuring device for sensing the temperature of the working gases contacting the superheater section and generating a corresponding temperature signal to the controller.
- the controller may control the amount of fuel provided by the supply structure to the furnace such that the temperature of the working gases is below a threshold temperature until the temperature of the tube structure end portion has experienced rapid changes.
- a boiler system comprising: a furnace adapted to receive a fuel to be burned to generate hot working gases; a fuel supply structure associated with the furnace for supplying fuel to the furnace; a superheater section associated with the furnace and positioned to receive energy in the form of heat from the hot working gases; and a controller.
- the superheater section may comprise a platen including a tube structure with an end portion and a sensor for measuring the temperature of the tube structure end portion and generating a signal indicative of the temperature of the tube structure end portion.
- the controller may be coupled to the sensor for receiving and monitoring the signal from the sensor and controlling an amount of fuel provided by the supply structure to the furnace based on the signal.
- a process for monitoring a boiler system comprising a furnace for burning a fuel to generate hot working gases, a fuel supply structure for supplying fuel to the furnace, a superheater section comprising a platen including a tube structure with an end portion, and a sensor for measuring the temperature of the tube structure end portion and generating a signal indicative of the temperature of the tube structure end portion.
- the process may comprise monitoring the signal from the sensor, and controlling an amount of fuel provided to the furnace based on the signal.
- Monitoring may comprise monitoring the signal from the temperature sensor for rapid changes in temperature of the tube structure end portion.
- Controlling may comprise increasing an amount of fuel supplied by the supply structure to the furnace after the temperature of the tube structure end portion has experienced rapid changes.
- FIG. 1 is a schematic view of a kraft black liquor recovery boiler system constructed in accordance with the present invention
- FIG. 2 illustrates a portion of a superheater section of the boiler system of FIG. 1 ; wherein tube structures defining platens are illustrated schematically as rectangular structures;
- FIG. 3 illustrates first, second and third tube structures of a platen
- FIG. 4 is an example plot of a tube structure clearing event.
- FIG. 1 illustrates a kraft black liquor recovery boiler system 10 constructed in accordance with the present invention.
- Black liquor is a by-product of chemical pulping in a paper-making process.
- the initial concentration of “weak black liquor” is about 15%. It is concentrated to firing conditions (65% to 85% dry solids content) in an evaporator 20 , and then burned in the recovery boiler system 10 .
- the evaporator 20 receives the weak black liquor from washers (not shown) downstream from a cooking digester (not shown).
- the boiler system 10 comprises a recovery boiler 12 comprising a sealed housing 12 A defining a furnace 30 where a fuel, e.g., black liquor, is burned to generate hot working gases, a heat transfer section 32 and a bullnose 34 in between the furnace 30 and the heat transfer section 32 , see FIG. 1 .
- the boiler system 10 further comprises an economizer 40 , a boiler bank 50 and a superheater section 60 , all of which are located in the heat transfer section 32 , see FIG. 1 .
- the hot working gases resulting from the burning of the fuel in the furnace 30 pass around the bullnose 34 , travel into and through the heat transfer section 32 , are then filtered through an electrostatic precipitator 70 and exit through a stack 72 , see FIG. 1 .
- black liquor instead of natural gas or fuel oil may be used as the fuel in the furnace 30 .
- Vertically aligned wall tubes 130 are incorporated into vertical walls 31 of the furnace 30 .
- a fluid primarily water, passes through the wall tubes 130 such that energy in the form of heat from the hot working gases generated in the furnace 30 is transferred to the fluid flowing through the wall tubes 130 .
- the furnace 30 has primary level air ports 132 , secondary level air ports 134 , and tertiary level air ports 136 for introducing air for combustion at three different height levels.
- Black liquor BL is sprayed into the furnace 30 out of spray guns 138 .
- the black liquor BL is supplied to the guns 138 from the evaporator 20 .
- the injectors 137 and the spray guns 138 define fuel supply structure.
- the economizer 40 receives feedwater from a supply FS.
- the feedwater may be supplied to the economizer 40 at a temperature of about 250° F.
- the economizer 40 may heat the water to a temperature of about 450° F.
- the hot working gases moving through the heat transfer section 32 supply energy in the form of heat to the economizer 40 for heating the feedwater.
- the heated water is then supplied from the economizer 40 to a top drum (steam drum) 52 of the boiler bank 50 , see FIG. 1 .
- the top drum 52 functions generally as a steam-water separator.
- the water flows down a first set of tubes 54 extending from the top drum 52 to a lower drum (mud drum) 56 .
- the water may be heated to a temperature of about 400-600° F.
- a portion of the heated water flows through a second set of tubes 58 in the boiler bank 50 to the upper drum 52 .
- a remaining portion of the heated water in the lower drum 56 is supplied to the wall tubes 130 in the furnace 30 .
- the water flowing through the second set of tubes 58 in the boiler bank 50 and the wall tubes 130 in the furnace 30 may be heated to a saturated state. In the saturated state, the fluid is mainly a liquid, but some steam may be provided.
- the fluid in the wall tubes 130 is returned to the boiler bank 50 at the top drum 52 .
- the steam is separated from the liquid in the top drum 52 .
- the steam in the top drum 52 is supplied to the superheater section 60 , while the water returns to the lower drum 56 via the first set of tubes 54 .
- the upper and lower drums 52 , 56 may be replaced by a single drum, as is known to those skilled in the art, whereby steam is supplied by the single drum to a superheater section.
- the superheater section 60 comprises first, second and third superheaters 62 , 64 and 66 , each of which may comprise between about 20-50 platens 62 A, 64 A and 66 A.
- the platens 62 A, 64 A and 66 A are suspended from the headers 62 B, 64 B, 66 B, 62 C, 64 C and 66 C, which are themselves suspended from overhead beams (not shown) by hanger rods 200 .
- the hot working gases moving through the heat transfer section 32 supply the energy in the form of heat to the superheater section 60 for superheating the steam. It is contemplated that the superheater section 60 may comprise less than three superheaters or more than three superheaters.
- FIG. 3 A platen 62 A from the first superheater 62 is illustrated in FIG. 3 .
- the remaining platens 62 A in the first superheater 62 as well as the platens 64 A and 66 A in the second and third superheaters 64 , 66 are constructed in generally the same manner.
- the platen 62 A may comprise first, second and third separate metal tube structures 160 - 162 , see FIG. 3 .
- the platens are schematically illustrated as rectangular structures, but are defined by tube structures.
- the tube structures 160 - 162 comprise inlet portions 160 A- 162 A, which communicate with the inlet header 62 B and end portions 160 B- 162 B, which communicate with the outlet header 62 C.
- the tube structure inlet portions 160 A- 162 A and end portions 160 B- 162 B are located above a roof 12 B of the boiler housing 12 A, see FIGS. 1 and 3 , while intermediate portions 160 C- 162 C of the tube structures 160 - 162 extend within the boiler housing 12 A and are located within the heat transfer section 32 .
- the tube structures 160 - 162 define pathways through which fluid, e.g., steam, passes from the inlet header 62 B, though the tube structures 160 - 162 and out the outlet header 62 C. It is contemplated that the platen 62 A may have less than or more than three tube structures, e.g., one, two, four or five tube structures.
- the steam is heated to a superheated state in the superheater section 60 .
- cooled liquid water may settle in lower bends of the tube structures 160 - 162 in the platens 62 A, 64 A and 66 A.
- the liquid water prevents steam from passing through the tube structures 160 - 162 .
- the steam moving through the tube structures 160 - 162 functions as a cooling fluid for the metal tube structures 160 - 162 .
- the tube structure may become overheated, especially at an end portion 160 B- 162 B, which may cause damage to the tube structure 160 - 162 .
- start-up of the furnace 30 is monitored by a controller 210 to ensure that the furnace 30 is heated slowly until any liquid water in the tube structures 160 - 162 of the superheater section platens 62 A, 64 A and 66 A has safely evaporated before the furnace 30 is heated to an elevated state.
- a temperature measurement device 170 which, in the illustrated embodiment, comprises an optical pyrometer, may be provided in or near the heat transfer section 32 to measure the temperature of the hot working gases in the heat transfer section 32 and entering the superheater section 60 .
- the temperature measuring device 170 generates a corresponding temperature signal to the controller 210 .
- the temperature sensed by the temperature measurement device 170 provides an indication of the amount of energy in the form of heat being generated by the furnace 30 .
- the controller 210 has verified that liquid water in the tube structures 160 - 162 has been cleared, the amount of fuel provided by the injectors 137 or the spray guns 138 to the furnace 30 is controlled by the controller 210 at a low level.
- the amount of fuel provided by the injectors 137 or the spray guns 138 to the furnace 30 is controlled by the controller 210 such that the temperature of the hot working gases in the heat transfer section 32 and entering the superheater section 60 , as measured by the temperature measuring device 170 , is less than a predefined initial working gas threshold temperature, such as a threshold temperature falling within the range of 800-1000 degrees F. If the temperature of the hot working gases exceeds the threshold temperature, the amount of fuel provided to the furnace 30 is reduced. Once the controller 210 has verified that liquid water in the tube structures 160 has been cleared, then the controller 210 will allow the rate at which fuel is provided to the furnace 30 to increase such that the temperature of the hot working gases entering the superheater section 60 exceeds the threshold temperature.
- a predefined initial working gas threshold temperature such as a threshold temperature falling within the range of 800-1000 degrees F.
- the controller 210 comprises any device which receives input data, processes that data through computer instructions, and generates output data.
- a controller can be a hand-held device, laptop or notebook computer, desktop computer, microcomputer, digital signal processor (DSP), mainframe, server, other programmable computer devices, or any combination thereof.
- DSP digital signal processor
- the controller 210 may also be implemented using programmable logic devices such as field programmable gate arrays (FPGAs) or, alternatively, realized as application specific integrated circuits (ASICs) or similar devices.
- FPGAs field programmable gate arrays
- ASICs application specific integrated circuits
- a temperature sensor 220 such as a thermocouple in the illustrated embodiment, is provided at the end portion 160 B- 162 B of the tube structure 160 to measure the temperature of the tube structure 160 - 162 at that location, see FIG. 3 .
- the temperature sensors 220 generate corresponding temperature signals to the controller 210 .
- Each tube structure end portion 160 B- 162 B is located near its corresponding outlet header. It is contemplated that a temperature sensor 220 may not be provided for all of the tube structures 160 - 162 in each of the platens 62 A, 64 A and 66 A. However, it is preferred that a temperature sensor 220 is provided for at least one tube structure 160 - 162 in each platen 62 A, 64 A and 66 A.
- a tube structure clearing event Liquid water evaporating in a tube structure 160 - 162 after furnace startup is referred to herein as a “tube structure clearing event.”
- a tube structure clearing event is characterized by rapid changes in temperature at the end portion of the tube structure.
- “rapid changes in temperature” of the end portion 160 B- 162 B of a tube structure 160 - 162 are characterized by the temperature increasing monotonically, rapidly, e.g., over a 1-5 minute period, and significantly, e.g., by a temperature increase of at least 25 degrees F., and immediately thereafter, decreasing monotonically, rapidly, e.g., over a 1-10 minute period, by a temperature magnitude decrease equal to or less than the magnitude of the temperature increase but, in any event, the magnitude of the decrease in temperature is greater than zero.
- FIG. 4 a plot is illustrated corresponding to a measured tube structure clearing event.
- the temperature of a tube structure end portion began to monotonically increase in temperature at about 8075 seconds from about 550 degrees F. to a maximum temperature of about 700 degrees F. at about 8225 seconds.
- the tube structure end portion increased in temperature by about 150 degrees F.
- the temperature of the tube structure end portion immediately began to decrease monotonically to a temperature of about 610 degrees F. at about 8725 seconds.
- the tube structure end portion monotonically decreased in temperature by about 90 degrees.
- the temperature sensors 220 are monitored by the controller 210 for rapid temperature changes, i.e., a rapid increased in temperature immediately followed by a rapid decrease in temperature, indicating that fluid is moving through the entire length of their corresponding tube structures 160 - 162 .
- the controller 210 may cause the injectors 137 or spray guns 138 to increase the amount of fuel provided to the furnace 30 since the temperature of the hot working gases in the heat transfer section 32 and entering the superheater section 60 can safely exceed the predefined initial working gas threshold temperature (800-1000 degrees F. in the illustrated embodiment).
- an “increase in the amount of fuel provided to the furnace” is intended to encompass increasing the rate at which fuel is input into the furnace 30 by either the injectors 137 or the spray guns 138 .
- an increase in the amount of fuel provided to the furnace 30 may result when the injectors 137 increase the rate at which natural gas or fuel oil is input into the furnace 30 ; when the injectors 137 stop inputting natural gas or fuel oil while, at that same time, the spray guns 138 begin inputting black liquor into the furnace 30 at a rate which exceeds the rate at which natural gas or fuel oil was injected into the furnace 30 ; or when the spray guns 138 increase the rate at which black liquor is input into the furnace.
- the controller 210 may generate a message or otherwise indicate to an operator that a tube structure clearing event has occurred and/or request that the operator input a tube structure clearing verification signal. In this embodiment, the controller 210 will not automatically cause the injectors 137 or spray guns 138 to increase the amount of fuel provided to the furnace 30 once all of the temperature sensors 220 have provided signals to the controller 210 indicating that rapid temperature changes have occurred at their corresponding tube structure end portions, as is done by the embodiment discussed above.
- the controller 210 will wait until it receives a verification signal input from the operator, via a keypad, keyboard or other input device, indicating that the operator has verified that a tube structure clearing event has occurred. Only after receiving the verification signal input by the operator will the controller 210 cause the injectors 137 or spray guns 138 to increase the amount of fuel provided to the furnace 30 .
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Abstract
Description
- This invention claims priority to U.S. Ser. No. 14/202,242, filed 1 Mar. 2014, for which Issue Notification was issued by the USPTO on 21 Dec. 2016, indicating invention shall be issued on 10 Jan. 2017 as U.S. Pat. No. 9,541,282, said Application/Patent is hereby incorporated herein in its entirety by the reference.
- The present invention relates to a boiler system comprising a controller for monitoring a temperature of a structure in a superheater section and controlling fuel provided to a furnace based on the monitored temperature.
- In a paper-making process, chemical pulping yields, as a by-product, black liquor, which contains almost all of the inorganic cooking chemicals along with lignin and other organic matter separated from the wood during pulping in a digester. The black liquor is burned in a recovery boiler. The two main functions of the recovery boiler are to recover the inorganic cooking chemicals used in the pulping process and to make use of the chemical energy in the organic portion of the black liquor to generate steam for a paper mill.
- In a kraft recovery boiler, a superheater structure is placed in the furnace in order to extract heat by radiation and convection from the furnace gases. Saturated steam enters the superheater section, and superheated steam exits from the section. The superheater structure comprises a plurality of platens.
- In accordance with a first aspect of the present invention, a boiler system is provided comprising: a furnace adapted to receive a fuel to be burned to generate hot working gases; a fuel supply structure associated with the furnace for supplying fuel to the furnace; a superheater section associated with the furnace and positioned to receive energy in the form of heat from the hot working gases; and a controller. The superheater section may comprise a platen including a tube structure with an end portion and a temperature sensor for measuring the temperature of the tube structure end portion and generating a signal indicative of the temperature of the tube structure end portion. The controller may be coupled to the temperature sensor for receiving and monitoring the signal from the sensor.
- The temperature sensor may comprise a thermocouple.
- The controller may monitor the signal from the temperature sensor for rapid changes in temperature of the tube structure end portion. Rapid changes in temperature of the tube structure end portion may be defined by a rapid increase in temperature immediately followed by a rapid decrease in temperature. For example, rapid changes in temperature of the tube structure end portion may be defined by a monotonic increase in temperature of least about 25 degrees F. occurring over a time period of between about one to five minutes and immediately thereafter a monotonic decrease in temperature greater than zero in magnitude occurring over a time period of between about one to ten minutes.
- The controller may increase an amount of fuel supplied by the supply structure to the furnace after the temperature of the tube structure end portion has experienced rapid changes.
- The boiler system may further comprise a temperature measuring device for sensing the temperature of the working gases contacting the superheater section and generating a corresponding temperature signal to the controller.
- The controller may control the amount of fuel provided by the supply structure to the furnace such that the temperature of the working gases is below a threshold temperature until the temperature of the tube structure end portion has experienced rapid changes.
- In accordance with a second aspect of the present invention, a boiler system is provided comprising: a furnace adapted to receive a fuel to be burned to generate hot working gases; a fuel supply structure associated with the furnace for supplying fuel to the furnace; a superheater section associated with the furnace and positioned to receive energy in the form of heat from the hot working gases; and a controller. The superheater section may comprise a platen including a tube structure with an end portion and a sensor for measuring the temperature of the tube structure end portion and generating a signal indicative of the temperature of the tube structure end portion. The controller may be coupled to the sensor for receiving and monitoring the signal from the sensor and controlling an amount of fuel provided by the supply structure to the furnace based on the signal.
- In accordance with a third aspect of the present invention, a process is provided for monitoring a boiler system comprising a furnace for burning a fuel to generate hot working gases, a fuel supply structure for supplying fuel to the furnace, a superheater section comprising a platen including a tube structure with an end portion, and a sensor for measuring the temperature of the tube structure end portion and generating a signal indicative of the temperature of the tube structure end portion. The process may comprise monitoring the signal from the sensor, and controlling an amount of fuel provided to the furnace based on the signal.
- Monitoring may comprise monitoring the signal from the temperature sensor for rapid changes in temperature of the tube structure end portion.
- Controlling may comprise increasing an amount of fuel supplied by the supply structure to the furnace after the temperature of the tube structure end portion has experienced rapid changes.
- While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the present invention will be better understood from the following description in conjunction with the accompanying Drawing Figures, in which like reference numerals identify like elements, and wherein:
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FIG. 1 is a schematic view of a kraft black liquor recovery boiler system constructed in accordance with the present invention; -
FIG. 2 illustrates a portion of a superheater section of the boiler system ofFIG. 1 ; wherein tube structures defining platens are illustrated schematically as rectangular structures; -
FIG. 3 illustrates first, second and third tube structures of a platen; and -
FIG. 4 is an example plot of a tube structure clearing event. - In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration, and not by way of limitation, specific preferred embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and that changes may be made without departing from the spirit and scope of the present invention.
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FIG. 1 illustrates a kraft black liquorrecovery boiler system 10 constructed in accordance with the present invention. Black liquor is a by-product of chemical pulping in a paper-making process. The initial concentration of “weak black liquor” is about 15%. It is concentrated to firing conditions (65% to 85% dry solids content) in anevaporator 20, and then burned in therecovery boiler system 10. Theevaporator 20 receives the weak black liquor from washers (not shown) downstream from a cooking digester (not shown). - The
boiler system 10 comprises arecovery boiler 12 comprising a sealedhousing 12A defining afurnace 30 where a fuel, e.g., black liquor, is burned to generate hot working gases, aheat transfer section 32 and abullnose 34 in between thefurnace 30 and theheat transfer section 32, seeFIG. 1 . Theboiler system 10 further comprises aneconomizer 40, aboiler bank 50 and asuperheater section 60, all of which are located in theheat transfer section 32, seeFIG. 1 . The hot working gases resulting from the burning of the fuel in thefurnace 30 pass around thebullnose 34, travel into and through theheat transfer section 32, are then filtered through anelectrostatic precipitator 70 and exit through astack 72, seeFIG. 1 . It is noted that when thefurnace 30 is initially fired, another fuel other than black liquor, such as natural gas or fuel oil, may be provided to thefurnace 30 viainjectors 137. Once thefurnace 30 has reached a desired temperature, black liquor instead of natural gas or fuel oil may be used as the fuel in thefurnace 30. - Vertically aligned
wall tubes 130 are incorporated intovertical walls 31 of thefurnace 30. As will be discussed further below, a fluid, primarily water, passes through thewall tubes 130 such that energy in the form of heat from the hot working gases generated in thefurnace 30 is transferred to the fluid flowing through thewall tubes 130. Thefurnace 30 has primarylevel air ports 132, secondarylevel air ports 134, and tertiarylevel air ports 136 for introducing air for combustion at three different height levels. Black liquor BL is sprayed into thefurnace 30 out ofspray guns 138. The black liquor BL is supplied to theguns 138 from theevaporator 20. Theinjectors 137 and thespray guns 138 define fuel supply structure. - The
economizer 40 receives feedwater from a supply FS. In the illustrated embodiment, the feedwater may be supplied to theeconomizer 40 at a temperature of about 250° F. Theeconomizer 40 may heat the water to a temperature of about 450° F. The hot working gases moving through theheat transfer section 32 supply energy in the form of heat to theeconomizer 40 for heating the feedwater. The heated water is then supplied from theeconomizer 40 to a top drum (steam drum) 52 of theboiler bank 50, seeFIG. 1 . Thetop drum 52 functions generally as a steam-water separator. In the embodiment illustrated inFIG. 1 , the water flows down a first set oftubes 54 extending from thetop drum 52 to a lower drum (mud drum) 56. As the water flows down thetubes 54, it may be heated to a temperature of about 400-600° F. From thelower drum 56, a portion of the heated water flows through a second set oftubes 58 in theboiler bank 50 to theupper drum 52. A remaining portion of the heated water in thelower drum 56 is supplied to thewall tubes 130 in thefurnace 30. The water flowing through the second set oftubes 58 in theboiler bank 50 and thewall tubes 130 in thefurnace 30 may be heated to a saturated state. In the saturated state, the fluid is mainly a liquid, but some steam may be provided. The fluid in thewall tubes 130 is returned to theboiler bank 50 at thetop drum 52. The steam is separated from the liquid in thetop drum 52. The steam in thetop drum 52 is supplied to thesuperheater section 60, while the water returns to thelower drum 56 via the first set oftubes 54. - In an alternative embodiment (not shown), the upper and
lower drums - In the embodiment illustrated in
FIG. 2 , thesuperheater section 60 comprises first, second andthird superheaters platens platens inlet header platens platens outlet header platens headers hanger rods 200. The hot working gases moving through theheat transfer section 32 supply the energy in the form of heat to thesuperheater section 60 for superheating the steam. It is contemplated that thesuperheater section 60 may comprise less than three superheaters or more than three superheaters. - A
platen 62A from thefirst superheater 62 is illustrated inFIG. 3 . The remainingplatens 62A in thefirst superheater 62 as well as theplatens third superheaters platen 62A may comprise first, second and third separate metal tube structures 160-162, seeFIG. 3 . InFIG. 2 , the platens are schematically illustrated as rectangular structures, but are defined by tube structures. The tube structures 160-162comprise inlet portions 160A-162A, which communicate with theinlet header 62B and endportions 160B-162B, which communicate with theoutlet header 62C. The tubestructure inlet portions 160A-162A and endportions 160B-162B are located above aroof 12B of theboiler housing 12A, seeFIGS. 1 and 3 , whileintermediate portions 160C-162C of the tube structures 160-162 extend within theboiler housing 12A and are located within theheat transfer section 32. The tube structures 160-162 define pathways through which fluid, e.g., steam, passes from theinlet header 62B, though the tube structures 160-162 and out theoutlet header 62C. It is contemplated that theplaten 62A may have less than or more than three tube structures, e.g., one, two, four or five tube structures. - The steam is heated to a superheated state in the
superheater section 60. Prior to boiler/furnace start-up, cooled liquid water may settle in lower bends of the tube structures 160-162 in theplatens end portion 160B-162B, which may cause damage to the tube structure 160-162. - In the present invention, start-up of the
furnace 30 is monitored by acontroller 210 to ensure that thefurnace 30 is heated slowly until any liquid water in the tube structures 160-162 of thesuperheater section platens furnace 30 is heated to an elevated state. - A
temperature measurement device 170, which, in the illustrated embodiment, comprises an optical pyrometer, may be provided in or near theheat transfer section 32 to measure the temperature of the hot working gases in theheat transfer section 32 and entering thesuperheater section 60. Thetemperature measuring device 170 generates a corresponding temperature signal to thecontroller 210. The temperature sensed by thetemperature measurement device 170 provides an indication of the amount of energy in the form of heat being generated by thefurnace 30. Until thecontroller 210 has verified that liquid water in the tube structures 160-162 has been cleared, the amount of fuel provided by theinjectors 137 or thespray guns 138 to thefurnace 30 is controlled by thecontroller 210 at a low level. That is, in the illustrated embodiment, the amount of fuel provided by theinjectors 137 or thespray guns 138 to thefurnace 30 is controlled by thecontroller 210 such that the temperature of the hot working gases in theheat transfer section 32 and entering thesuperheater section 60, as measured by thetemperature measuring device 170, is less than a predefined initial working gas threshold temperature, such as a threshold temperature falling within the range of 800-1000 degrees F. If the temperature of the hot working gases exceeds the threshold temperature, the amount of fuel provided to thefurnace 30 is reduced. Once thecontroller 210 has verified that liquid water in thetube structures 160 has been cleared, then thecontroller 210 will allow the rate at which fuel is provided to thefurnace 30 to increase such that the temperature of the hot working gases entering thesuperheater section 60 exceeds the threshold temperature. - The
controller 210 comprises any device which receives input data, processes that data through computer instructions, and generates output data. Such a controller can be a hand-held device, laptop or notebook computer, desktop computer, microcomputer, digital signal processor (DSP), mainframe, server, other programmable computer devices, or any combination thereof. Thecontroller 210 may also be implemented using programmable logic devices such as field programmable gate arrays (FPGAs) or, alternatively, realized as application specific integrated circuits (ASICs) or similar devices. - Preferably, for each of the tube structures 160-162 in the
platens temperature sensor 220, such as a thermocouple in the illustrated embodiment, is provided at theend portion 160B-162B of thetube structure 160 to measure the temperature of the tube structure 160-162 at that location, seeFIG. 3 . Thetemperature sensors 220 generate corresponding temperature signals to thecontroller 210. Each tubestructure end portion 160B-162B is located near its corresponding outlet header. It is contemplated that atemperature sensor 220 may not be provided for all of the tube structures 160-162 in each of theplatens temperature sensor 220 is provided for at least one tube structure 160-162 in eachplaten - Liquid water evaporating in a tube structure 160-162 after furnace startup is referred to herein as a “tube structure clearing event.” Such a tube structure clearing event is characterized by rapid changes in temperature at the end portion of the tube structure. In the illustrated embodiment, “rapid changes in temperature” of the
end portion 160B-162B of a tube structure 160-162, as measured by acorresponding temperature sensor 220, are characterized by the temperature increasing monotonically, rapidly, e.g., over a 1-5 minute period, and significantly, e.g., by a temperature increase of at least 25 degrees F., and immediately thereafter, decreasing monotonically, rapidly, e.g., over a 1-10 minute period, by a temperature magnitude decrease equal to or less than the magnitude of the temperature increase but, in any event, the magnitude of the decrease in temperature is greater than zero. - In
FIG. 4 , a plot is illustrated corresponding to a measured tube structure clearing event. As shown inFIG. 4 , the temperature of a tube structure end portion, as measured by acorresponding temperature sensor 220, began to monotonically increase in temperature at about 8075 seconds from about 550 degrees F. to a maximum temperature of about 700 degrees F. at about 8225 seconds. Hence, over a time period of about 150 seconds, the tube structure end portion increased in temperature by about 150 degrees F. After reaching the maximum temperature at about 8225 seconds, the temperature of the tube structure end portion immediately began to decrease monotonically to a temperature of about 610 degrees F. at about 8725 seconds. Hence, over a time period of about 500 seconds, the tube structure end portion monotonically decreased in temperature by about 90 degrees. - Hence, the
temperature sensors 220 are monitored by thecontroller 210 for rapid temperature changes, i.e., a rapid increased in temperature immediately followed by a rapid decrease in temperature, indicating that fluid is moving through the entire length of their corresponding tube structures 160-162. In the illustrated embodiment, once all of thetemperature sensors 220 have provided signals indicating that rapid temperature changes have occurred at their corresponding tube structure end portions, thecontroller 210 may cause theinjectors 137 orspray guns 138 to increase the amount of fuel provided to thefurnace 30 since the temperature of the hot working gases in theheat transfer section 32 and entering thesuperheater section 60 can safely exceed the predefined initial working gas threshold temperature (800-1000 degrees F. in the illustrated embodiment). - An “increase in the amount of fuel provided to the furnace” is intended to encompass increasing the rate at which fuel is input into the
furnace 30 by either theinjectors 137 or thespray guns 138. Hence, an increase in the amount of fuel provided to thefurnace 30 may result when theinjectors 137 increase the rate at which natural gas or fuel oil is input into thefurnace 30; when theinjectors 137 stop inputting natural gas or fuel oil while, at that same time, thespray guns 138 begin inputting black liquor into thefurnace 30 at a rate which exceeds the rate at which natural gas or fuel oil was injected into thefurnace 30; or when thespray guns 138 increase the rate at which black liquor is input into the furnace. - In accordance with a further aspect of the present invention, once all of the
temperature sensors 220 have provided signals to thecontroller 210 indicating that rapid temperature changes have occurred at their corresponding tube structure end portions, thecontroller 210 may generate a message or otherwise indicate to an operator that a tube structure clearing event has occurred and/or request that the operator input a tube structure clearing verification signal. In this embodiment, thecontroller 210 will not automatically cause theinjectors 137 orspray guns 138 to increase the amount of fuel provided to thefurnace 30 once all of thetemperature sensors 220 have provided signals to thecontroller 210 indicating that rapid temperature changes have occurred at their corresponding tube structure end portions, as is done by the embodiment discussed above. Instead, thecontroller 210 will wait until it receives a verification signal input from the operator, via a keypad, keyboard or other input device, indicating that the operator has verified that a tube structure clearing event has occurred. Only after receiving the verification signal input by the operator will thecontroller 210 cause theinjectors 137 orspray guns 138 to increase the amount of fuel provided to thefurnace 30. - While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
Claims (20)
Priority Applications (2)
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US15/401,852 US20170114995A1 (en) | 2014-03-10 | 2017-01-09 | Boiler system controlling fuel to a furnace based on temperature of a structure in a superheater section |
US16/568,890 US20200003410A1 (en) | 2014-03-10 | 2019-09-12 | Boiler system controlling fuel to a furnace based on temperature of a structure in a superheater section |
Applications Claiming Priority (2)
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US14/202,242 US9541282B2 (en) | 2014-03-10 | 2014-03-10 | Boiler system controlling fuel to a furnace based on temperature of a structure in a superheater section |
US15/401,852 US20170114995A1 (en) | 2014-03-10 | 2017-01-09 | Boiler system controlling fuel to a furnace based on temperature of a structure in a superheater section |
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US14/202,242 Continuation US9541282B2 (en) | 2014-03-10 | 2014-03-10 | Boiler system controlling fuel to a furnace based on temperature of a structure in a superheater section |
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US16/568,890 Continuation US20200003410A1 (en) | 2014-03-10 | 2019-09-12 | Boiler system controlling fuel to a furnace based on temperature of a structure in a superheater section |
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US15/401,852 Abandoned US20170114995A1 (en) | 2014-03-10 | 2017-01-09 | Boiler system controlling fuel to a furnace based on temperature of a structure in a superheater section |
US16/568,890 Abandoned US20200003410A1 (en) | 2014-03-10 | 2019-09-12 | Boiler system controlling fuel to a furnace based on temperature of a structure in a superheater section |
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US16/568,890 Abandoned US20200003410A1 (en) | 2014-03-10 | 2019-09-12 | Boiler system controlling fuel to a furnace based on temperature of a structure in a superheater section |
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US8381690B2 (en) | 2007-12-17 | 2013-02-26 | International Paper Company | Controlling cooling flow in a sootblower based on lance tube temperature |
US9927231B2 (en) * | 2014-07-25 | 2018-03-27 | Integrated Test & Measurement (ITM), LLC | System and methods for detecting, monitoring, and removing deposits on boiler heat exchanger surfaces using vibrational analysis |
US10060688B2 (en) | 2014-07-25 | 2018-08-28 | Integrated Test & Measurement (ITM) | System and methods for detecting, monitoring, and removing deposits on boiler heat exchanger surfaces using vibrational analysis |
PL3172520T3 (en) | 2014-07-25 | 2019-07-31 | International Paper Company | System and method for determining a location of fouling on boiler heat transfer surface |
CN109058971B (en) * | 2018-05-04 | 2020-08-14 | 四川通普科技有限公司 | NB-IoT-based boiler operation monitoring system |
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Also Published As
Publication number | Publication date |
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CA2941377A1 (en) | 2015-09-17 |
EP4345372A3 (en) | 2024-05-22 |
US9541282B2 (en) | 2017-01-10 |
EP3117037A1 (en) | 2017-01-18 |
CA2941377C (en) | 2018-06-26 |
WO2015138321A1 (en) | 2015-09-17 |
PL3117037T3 (en) | 2024-06-17 |
EP3117037B1 (en) | 2024-02-21 |
US20200003410A1 (en) | 2020-01-02 |
EP4345372A2 (en) | 2024-04-03 |
EP3117037C0 (en) | 2024-02-21 |
US20150253003A1 (en) | 2015-09-10 |
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