Combustion control method

• US 4,622,922 A
• Filed: 06/10/1985
• Issued: 11/18/1986
• Est. Priority Date: 06/11/1984
• Status: Expired due to Fees

• Current Assignee: Hitachi, Ltd.
• Original Assignee: Hitachi, Ltd.
• Inventors: Sato, Yoshio, Shimada, Yoshihiro, Morooka, Yasuo, Kurihara, Nobuo, Higashi, Toshihiko, Miyagaki, Hisanori, Nishikawa, Mitsuyo, Watanabe, Atsumi, Yokogawa, Atsushi
• Primary Examiner(s): Yuen, Henry C.
• Application Number:
  US06/743,439
• Time in Patent Office: 526 Days
• Field of Search: 110/185, 110/190, 110/263, 110/345, 110/347, 110/346, 431/10, 122/4 D, 122/449
• US Class Current: 122/449
• CPC Class Codes: F23N 1/022 using electronic means
• CPC Class Codes: F23N 2223/40 Simulation
• CPC Class Codes: F23N 2225/08 temperature
• CPC Class Codes: F23N 2225/10 stack temperature
• CPC Class Codes: F23N 2225/16 burner temperature
• CPC Class Codes: F23N 2227/20 Calibrating devices
• CPC Class Codes: F23N 2237/16 secondary air
• CPC Class Codes: F23N 2239/02 Solid fuels
• CPC Class Codes: F23N 5/082 using electronic means
• CPC Class Codes: F23N 5/18 using detectors sensitive to rate of flow of air or fuel

Abstract

A combustion control method wherein manipulated variables or the amounts of fuel and air in at least one combustion zone of a boiler are regulated so that both the amount of nitrogen oxides and the amount of unburned coal in the ash at an outlet of a burner furnace or at least one of them passes the regulation standards and satisfies the requirements for operating a plant. The method is characterized by varying the amounts of fuel and air in performing trial operations on manipulated variables to evaluate the nitrogen oxides at the furnace outlet, the unburned coal in the ash at the furnace outlet and the stability of combustion, and declaring as optimum manipulated variables those amounts of fuel and air used for performing the trial operations which achieve results such that the combustion is found to be stabilized, at least the nitrogen oxides at the furnace outlet satisfy the requirement and the thermal efficiency of the boiler is judged to be at the highest level by a boiler thermal efficiency judging section.

Claims

1. A combustion control method for a furnace, in a boiler, having one or more combustion zones in each of which a burner can be controlled by adjusting the amounts of fuel and air, comprising the steps of:

(a) obtaining a two-dimensional high and low density image having a high and low density regions from a combustion flame and combustion gas in each combustion zone by means of image fiber means and image forming camera means;

(b) estimating for each combustion zone the concentration of NO_x in accordance with the two-dimensional high and low density image obtained from the combustion flame in each combustion zone, and estimating the concentration of NO_x at the outlet of the furnace with the use of the estimated concentration for each combustion zone;

(c) estimating for each combustion zone the amount of unburnt coal in ash in accordance with the two-dimensional high and low density image obtained from the combustion flame in each combustion zone, and estimating the amount of unburnt coal in ash at the outlet of the furnace with the use of the thus estimated amount of unburnt coal in ash;

(d) evaluating the stability of combustion with the use of the two-dimensional high and low density image for each combustion zone;

(e) estimating the thermal efficiency of the boiler upon controlling of the amounts of fuel and air for each combustion zone with the use of a furnace heat transfer model; and

(f) changing the amounts of fuel and air for each combustion zone when the stability of combustion is satisfactory while either one of the estimated concentration of NO_x at the outlet of the furnace and the estimated amount of unburnt coal in ash thereat exceeds the associated limited value, to allow either one of the estimated concentration of NO_x at the outlet of the furnace and the amount of unburnt coal in ash thereat to satisfy the associated limiting condition while to maximize the boiler efficiency.

2. A combustion control method as set forth in claim 1, wherein said high density areas of said two-dimensional high and low density image are defined as oxidization flame regions each having a gravity center and are formed at two different regions divided by the center axial line of said burner for each combustion zone, and said concentration of NO_x at the outlets of said furnace upon steady state combustion is estimated by use of a model using, as variables, an NO_x reduction value for each burner which is estimated from at least one of three kinds of values consisting of the positions of the gravity centers of said oxidization flame regions, the distance between said gravity centers of said oxidization flame regions and the degree of shape of said oxidization flame regions, an air ratio for each burner an averaged burner air ratio for each combustion zone and an amount of fuel for each combustion zone.

3. A combustion control method as set forth in claim 1, wherein said high density areas of said two-dimensional high and low density image are defined as oxidization flame regions each having gravity center and are formed at two differenct regions divided by the center axial line of said burner for each combustion zone, and the amount of unburnt coal in ash at the outlet of the furnace upon steady state combustion is estimated by use of a model using, as variables, the index of unburnt coal in ash estimated from at least one of four kinds of values consisting of the positions of the gravity centers of said oxidization flame regions, the distance between the gravity centers of said oxidization flame regions and burner primary air amount for each combustion zone, an after-air amount, a furnace air ratio and an averaged burner air ratio.

4. A combustion control method as set forth in claim 1, wherein said two-dimensional high and low density image provides the area of combustion flame region and the area of a high brightness region, and said stability of combustion is evaluated by use of a model using, as a variable, the ratio of the area of the combustion flame and the area of the high brightness region.

5. A combustion control method as set forth in claim:

1, wherein said high density regions of said two-dimensional high and low density image are defined as oxidization flame regions each having a gravity center and are formed at two different regions divided by the center axial line of said burner for each combustion zone, and said safety of combustion is evaluated by use of a model using, as a variable, at least one of the following kinds of values, the positions of the gravity centers of said oxidization flame regions, the distance between the gravity centers of the oxidization flame regions, the thickness of the oxidization flame regions, an averaged brightness of the oxidization flame region and timed fluctuations in said values of said kinds.

6. A combustion control method as set forth in claim 1, wherein the total value of an input heat and a combustion generated heat and the total value of amounts of heat absorbed by fluid in heat transfer pipes in the furnace are obtained by use of furnace heat transfer physical models for estimating the temperature of combustion gas, the temperature of heat transfer pipe metal and the temperature of fluid in the heat transfer pipes, for each combustion zone, with the use of the amount of supplied fuel and air as input values for each combustion zone, to thereby obtain the thermal efficiency in the form of a ratio of the latter to the former.

7. A combustion control method as set forth in claim 1, wherein the total value of an input heat and a combustion generated heat and the total value of amounts of heat absorbed by the furnace heat transfer pipe metals are obtained by use of furnace heat transfer models for estimating the temperature of combustion gas, the temperature of the heat transfer pipe metal and the temperature of fluid in the heat transfer pipes for each combustion zone, with the use of the amount of supplied fuel and air as input values for each combustion zone, to thereby estimate the thermal efficiency in the form of a ratio of the latter to the former.

8. A combustion control method as set forth in claim 1, wherein there are provided a model for predicting the concentration of NO_x at the outlet of the furnace and a model for predicting the amount of unburnt coal in ash thereat to carry out the trial and error operation for the amounts of fuel and air for each combustion zone in order to determine optimum amounts of fuel and air for each combustion zone, and the control amounts of trial and error operation for fuel and air are internally changed to repeat the trial and error operation until prediction values obtained by these models satisfy the restrictions imposed on the concentration of NO_x and the amount of unburnt coal in ash at the outlet of the furnace, thereby to actually control the amounts of fuel and air for each combustion zone with the use of the control amounts of trial and error operation, as optimum values, which satisfy either of said restrictions and which allow the thermal efficiency to be maximum.

9. A combustion control method as set forth in claim 8, wherein the concentration of NO_x for each combustion zone is at first predicted from the control amounts of trial and error operation for fuel and air for each combustion zone by use of a multiple regression model, and the prediction value of concentration of NO_x at the outlet of the furnace is obtained with the use of the thus obtained prediction value of concentration of NO_x for each combustion zone.

10. A combustion control method as set forth in claim 8, wherein at first the amount of unburnt coal in ash is predicted from the control amounts of fuel and air by use of a multiple regression model to determine the prediction value of amount of unburnt coal in ash at the outlet of the furnace.

11. A combustion control method as set forth in claim 1, wherein detection is made such that the difference between the measured value of concentration of NO_x at the outlet of the furnance and the predicted value thereof exceeds an allowable value, and the multiple regression model for predicting the concentration of NO_x for each combustion zone is reconstituted by a multiple regression analysis method with the use of the estimated value of concentration of NO_x which is estimated from the two-dimensional high and low density image for each combustion zone, in accordance with the actual control amounts of fuel and air for each combustion zone.

12. A combustion control method as set forth in claim 9, wherein detection is made such that the difference between the measured amount of unburnt coal in ash at the outlet of the furnace and the prediction value of the amount of unburnt coal in ash at the outlet of the furnace exceeds an allowable value, and the multiple regression model for predicting the amount of unburnt coal in ash for each combustion zone is reconstituted by a multiple regression analysis method with the use of the estimated value of amount of unburnt coal in ash which is estimated from the two-dimensional high and low density image for each combustion zone, in accordance with the actual control amounts of fuel and air for each combustion zone.

13. A combustion control method as set forth in claim 1, wherein optimum control amounts of fuel and air for each combustion zone are searched and determined by the simplex method for obtaining the maximum point of the thermal efficiency of a boiler.

14. A combustion control method as set forth in claim 13, wherein when the search for optimum control amounts of fuel and air to determine the maximum point of the boiler efficiency is carried out at first time, fuel distribution to all combustion zones is maintained constant to search and determine the amount of air which maximized the boiler efficiency, and by holding the above-mentioned condition the fuel distribution which maximized the boiler efficiency is then searched and determined, thereby the distributions of air and fuel which maximize the boiler efficiency are determined as optimum control amounts.

15. A combustion control method as set forth in claim 6, wherein coefficients used for the furnace heat tranfer models are compensated for such that the respective difference values, for each combustion zone, between the estimated value of temperature of combustion gas estimated from the two-dimensional high and low density image of combustion gas and the estimated value of the temperature-of combustion gas obtained by use of the associated model, between the measured value of the temperature of the heat transfer pipe metal and the estimated value of the temperature of heat transfer pipe metal obtained by use of the associated model, and between the measured value of the temperature of fluid in an outlet of the heat transfer pipes outlet and the estimated value of the temperature of fluid in the outlet of the heat transfer pipes obtained by use of the associated model are decreased.

16. A combustion control method as set forth in claim 7, wherein coefficients used for the furnace heat transfer models are compensated for such that the respective difference values, for each combustion zone, between the estimated value of the temperature of combustion gas estimated from the two-dimensional high and low density image of combustion gas and the estimated value of the temperature of combustion gas obtained by use of the associated model, between the measure value of the temperature of the heat transfer pipe metal and the estimated value of the temperature of heat transfer pipe metal obtained by use of the associated model, and between the measured value of the temperature of fluid in an outlet of the heat transfer pipes outlet and the estimated value of the temperature of fluid in the outlet of the heat transfer pipes obtained by use of the associated model are decreased.

17. A combustion control method as set forth in claim 6, wherein in the furnace heat transfer model, the rate of combustion of fuel fed to each combustion zone is calculated as a function of the temperature of the combustion flame for each combustion zone which is estimated with the use of a high temperature bicolor thermometer in accordance with the two-dimensional high and low density image of combustion flame.

18. A combustion control method as set forth in claim 7, wherein in the furnace heat transfer model, the rate of combustion of fuel fed to each combustion zone is calculated as a function of the temperature of the combustion flame for each combustion zone which is estimated with the use of a high temperature bicolor thermometer in accordance with the two-dimensional high and low density image of combustion flame.

19. A control combustion method as set forth in claim 1, wherein the boiler heat transfer efficiency is calculated by use of the furnace heat transfer model for estimating the temperature of fluid in heat transfer tubes of the boiler for each combustion zone with the use of, as input values, the estimated value of the temperature of combustion gas estimated from the two-dimensional high and low density image of combustion gas for each combustion zone and the measured value of the temperature of the heat transfer tube metal, in addition to the feed amount of fuel and air for each combustion zone.