Case studies

Combustion control of a biomass plant of BioMa Energie AG

Project goals:

Setup of a new combustion control on a B&R 2005 system control using an Intouch visualization.

Delivered services:

• Development of the control concept
• Programming of the combustion control in B&R Automation Studio
• Commissioning
• Visualization 
• Optimization of the parameters

Results:

• Customized combustion control setup to maximize the yield of fuel
• Automatic minimization of the fume gas losses by using an emission driven O_2-control.
• Reduction of the fluctuations of the combustion chamber's temperature

Optimization of the combustion control of the biomass power plant of BioEnergie Kufstein, Austria

Project goals:

Optimization of the existing combustion control for reducing the emissions while cutting the fluctuations of the live steam quantity, the combustion chamber's temperature and the concentration of O₂ in the fume gases.

• Optimization of the combustion for minimizing emissions (CO and NOx)
• Increase of the combustion's degree of efficiency

Plant's data:

• Thermal power: 28,4 MW
• P_el of the turbine: 6,925MW
• Live steam pressure: 64bar
• Live steam temperature: 450°C
• Live steam quantity: 30 t/h

Delivered services:

• On-site analyse of the parameters
• Development of a a new control concept for secondary air injection
• Planning and development of an optimized combustion control

Results:

• Integration of an automated combustion control
• Improved combustion on the grate

Optimization of the power generation at the paper mill Mondi Frantschach GmbH

The project's goals were the optimization of a fluidized bed plant (bark boiler) for mimimizing the need of external energy and increasing the plant's degree of efficiency.

Obtained results:

• Savings in external power by a conventional control modification > 2 GWh/a
• Total power savings on site: 7,5GWh
• Increased steam generation of 3,5%
• Reduction of  flue gas losses of the bark boiler > 10%
• Increase of power generation of 3,5%
• Reduction of fluctuations of the boiler by 20%
• > EUR 800.000 savings by reduced external power acquisition
• ROI < 3 months

Optimization of the combustion control of a fluidized bed waste boiler of the district heating company, Vienna

The project's goals were an increase of waste throughput and the reduction of steam generation fluctuations by implementing a model based combustion control.

Results:

• Increase of the average waste throughput by 3,5%
• Reduction of fuel oil consumption for auxiliary firing by 30%
• Reduction of fluctuations of the steam quantity by 40%
• Reduction of steam pressure fluctuations by 50%
• Reduction of flue gas losses by 5%
• Reduced emission of CO (and CO-peaks) by 25%
• Reduction of fluctuations of the temperature of the combustion chamber by 30%
• Project duration: 10 months

Parental control system for the steam network of a toxic waste incineration plant, Fernwärme Wien (district heating of Vienna) 

The project's goal were an increase of power generation and the minimization of the dependence on external energy. 

Results:

• Realized steam pressure stability: +/- 1%
• Increase of the steam's degree of efficiency by 5%
• ROI < 18 months

Control of a peak load boiler of a biomass district heating plant at EnergieComfort Tannheim GmbH

Project's goals:

Minimization of the fuel oil consumption by performing a system integration of a B&R APROL process control system into the existing control set. We developed a solution fully satisfying the customer using X20 controllers and a Profibus-DP connection.

Plant data:

• Performance of the bi9omass boiler: 2,5 MW thermal
• Performance of the fuel oil boiler: 3 MW thermal

Results:

• Savings of fuel oil of > 15% on all days with comparable external temperature.
• Very short project duration of < 14 days on site.
• ROI < 6 months

Development and integration of a model-predictive, smart combustion control of a 100MW biomass power plant at wodego GmbH, Neumarkt, Germany

Project tasks:

• Development and integration of a model predictive combustion control for maximum performance and operating reliability
• Connection of a advanced process control-PC running IPCOS model predictive control to an existing Siemens S5 system control via an INAT OPC server. 

Delivered services:

• Development and integration of the model based combustion control
• Planning and engineering of a fuel input measurement system
• Commissioning and optimization of the combustion control
• Implementation of several parental limiting controls

Results:

• CO-emissions cut by 50%
• Homogenization of the steam production by 30%
• Reduction of the fluctuations of the combustion chamber's temperature by 30%
• ROI < 12 months

Process and control engineering services for projects on power plants

INP Germany & INP Austria

Tasks:

• Optimization of the plant's efficiency by developing and integrating a parental fuzzy logic control for a waste disposal system composed of 6 steam boiler and 2 steam turbines
• Combustion control for a roller grate plant (public services of Prague)
• Smart control for a fluidized bed combustion system fueled by sludge of heterogeneous fuel value

Delivered services:

• Development of control concepts
• Development and commissioning of fuzzy logic controllers
• Parental control for boiler and turbine plants
• Programming of flow charts for S7-software
• Commissioning of combustion controls
• Performance optimization of system controls

Results:

• Successful and fast commissioning
• Increased both performance and operational reliability

Optimierung Feuerleistungsregelung Biomasseanlage
BioEnergie Kufstein

Aufgabenstellung:

Ziel ist die Optimierung der bestehenden Feuerleistungsregelung für einen emissionsarmen Betrieb der Biomassefeuerung bei minimalen Schwankungen der Frischdampfmenge, der Feuerraumtemperatur und des O₂-Gehaltes im Rauchgas.

• Optimierung der Feuerungsführung für minimale Emissionen (CO und NO_x)
• Optimierung des Feuerungswirkungsgrades
• Stabilisierung der Ausbrandlinie auf dem Rost

Anlagendaten:

• Feuerungswärmeleistung: 28,4MW
• P_el Turbinengenerator: 6,925MW
• Frischdampfdruck: 64bar
• Frischdampftemperatur: 450°C
• Frischdampfmenge: 30t/h

Leistungen VOIGT+WIPP Engineers:

• Parameteranalyse vor Ort
• Konzepterstellung für neue Sekundärlufteindüsung
• Planung und Konzept für optimierte Feuerungsregelung
• Erstellung einer automatischen Feuerlageregelung

Projekterfolge:

• Stabilisierung der Ausbrandlinie der Biomasse auf dem Rost
• Einhaltung der Emissionsgrenzwerte
• Maximierung der Dampfproduktion