Model based control for advanced PID combustion controllers in WtE plants

Transkript

1 Model based control for advanced PID combustion controllers in WtE plants Dr.-Ing. Ragnar Warnecke and Volker Müller GKS, Germany

2 GKS - Waste-to-Energy Section - 2

3 26,00 24,00 Firing Capacity Diagram GKS Schweinfurt GKS "2006" Rev Shortterm Overload Capacity 110% 2' 1' Important to meet the given capacity data Fuel Capacity [MW] 22,00 100% 2 1 Area of normal Operation 20, ,00 16,00 6' 67% 4' 5' 14, % 12, ,00 60% 100% 110% 8, Fuel Throughput [kg/h] Auxillary burners Good combustion control system necessary 3

4 Manipulable Variables: 18! 4

5 Kinds of Combustion Control Systems Combustion Control Systems (CCS) PID Fuzzy Control (FC) Neuronale Artificial Network (NN) Model Controlled (MC) Conventional Advanced Model Predictive Control (MPC) Fuzzy Support Neuronal Statistic Net Model Based 5

6 Decision matrices Control systems: PID FC NN MPC Arguments: Experience of GKS control engineer Acceptance of GKS operators Physical/chemical/technical understanding by GKS staff Reference situation of the suppliers in WtE-plants Changes by GKS possible (without others) Perspective in the future Companies: Arguments: SAR, Dingolfing Babcock-Noell, Würzburg Thyssen-Krupp, KH-Automation, Fuldabrück References in WtE-plants Competence in discussion (controller/proce ss engineering) Flexibility for integration of MBC Detail solutions Price

7 Integration of CC into DCS Linie 11 Linie 12 Linie 13 Bus-System CS 275 Engeneering-Station Gateway Gateway Gateway AS: PCS7 + ES Profi-bus Hydraulic-system control AS: PCS7 + Server Hydraulic-system control Profi-bus AS: PCS7 + Server Hydraulic-system control Office-network Profi-bus Remote-maintenance 7

8 Overview new advanced combustion control system 8

9 Plant limits and base tables 9

10 Comparison of Data number of values [%] ,8-12,6-11,4-10,2-9 -7,8-6,6-5,4-4,2-3 -1,8-0,6 0,6 1,8 3 4,2 5,4 6,6 7,8 9 10,2 11,4 12,6 13,8 15 deviation actual value of steam production to set point [%] new combustion control system old combustion control system number of values [%] ,2 1 1,8 2,6 3,4 4,2 5 5,8 6,6 7,4 8,2 9 9,8 10,6 11,4 12, ,8 14,6 15,4 16, ,8 18,6 19,4 20 CO concentration [mg/m³] new combustion control system old combustion control system 10

11 Extended Bed Height (< 0,5 % of operation time) 1.400,00 100, ,00 90,00 80, ,00 800,00 600,00 400,00 200,00 70,00 60,00 50,00 40,00 30,00 20,00 10,00 FR Z 1 FR Z 2 FR Z 3 FR Z 4 FR Z 5 Kessel Eintritt Feurerraumtemp. Kesseldecke ohne Offset SW FD Menge L11 L11 Frischdampfmenge 02 Gehalt RG Kesselaustritt tr. CO RG K ATR Loss of efficiency and burden of environment! 11

12 Idea: Model for Combustion Chamber 12

13 Model Structure 13

14 Combustion model 14

15 Connection of Model to CCS via OPC 15

16 Bed height from Model Beispielhafter Schichthöhenverlauf über 12 Stunden (vom Modell gerechnet) : Heizwert Zone 1 Zone 2 Zone 4 Zone 3 16

17 Bed height + manipulated Variable Extended bed height with instable combustion was avoided! 17

18 Summary OPC connection works Model data are very good validated with real plant Control signals of bed height are sent to CCS Interpretation of the deviation of real data and model data shows very good results GKS will use the signal to avoid male operation during extended bed height (caused by severe waste fluctuation) 18

19 Objectives: Primary objectives: Advanced-PID combustion control deliver excellent results For cases with strongly different waste a model can deliver sufficient data to avoid problems in combustion Overall objectives: Advanced-PID systems increase efficiency of plants and reduce emissions Avoiding instabilities in combustion by MBC coupling eliminate efficiency loss and environmental burden A combustion model deliver an enlarged understand of the processes 19

20 Economic Goals for Products For the Combustion Control System (CCS): The Advanced-PID got new structured overview Dynamic function plans are now integrated Extended weighting table with more variables are included in the CCS Advantages by the model: Model is available for coupling with CFD and CCS Operation with parallel Model is possible Pre-adjustment of CCS is possible offside the plant (= faster commissioning) Avoiding of failures during operation at the plant by pre-adjustment 20

21 Economic and Ecologic Goals for GKS About 5 % less CO About 3 % more throughput (5.000 t/a) Much better understanding of the processes Chlorine trap: about 25 % decreased corrosion 21