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Examples of Typical Applications and Successes
The following case studies describe applications of StatSoft’s technologies to coal-fired cyclone and wall-fired furnaces. The data driven (data mining) approach to plant optimization is equally successful with other common types of furnace designs, manufacturing, and different fuels (coal, gas, etc.), and it is applicable to other types of key operational performance indicators (e.g. urea injection/ammonia slip, ultrasonic leak detection, etc.).
Optimize Operations
Increase Flame Temperatures
Problem: Optimization of a coal burning 300 MW multi-cyclone unit for consistent high flame temperatures; increase the flame temperatures to avoid forming slag, burning fuel oil, etc.
Solution: Analyze twelve months of three-minute historical data using StatSoft’s proprietary data-driven (data mining) methodologies; Identify optimized control parameter settings for Stoichiometric Ratios (S.R.), Coal flows, Primary Air, Tertiary Air, Split Secondary Air Damper Flows, etc.
Results: After dialing in StatSoft optimized settings, flame temperatures immediately responded (strongly), resulting in more stable and higher flame temperatures (cleaner combustion)
Note: The flame temperature at some of the cyclones had been abnormally and critically low for several days, requiring the burning of fuel oil (at a substantial cost) and intermittent shut-downs; flame temperatures recovered almost immediately after StatSoft’s optimized control settings were applied.
PPPR Screenshot, Line Graph, Time vs. Flame Temperature
PPPR Screenshot, Standard vs. Optimized Comparison Chart, Optimization of Flame Temperature
PPPR Screenshot, Scatterplot, Multiple Variables vs. Time
Improve Efficiency and Performance of Your Equipment
Problem: Optimize performance and reliability of ongoing operations; stabilize and improve flame temperatures of an 85 MW coal-burning multicyclone unit.
Solution: Apply StatSoft’s proprietary data-driven (data mining) methodologies to consistently increase flame temperatures under a variety of loads.
Results: Flame temperatures increased consistently across all cyclone burners, leading to more reliable operations.
Note: Even though the flame temperatures had been within satisfactory limits, StatSoft’s optimized control settings improved temperatures further and beyond historical values.
Stabilize Operations
Problem: Optimization of a 400 MW coal-fired DRB-4Z burner for consistent and robust low NOx operations; avoid excursions, expensive downtime
Solution: Apply StatSoft’s methodologies to reduce both the average NOx and variability (control variability, then target process for better performance); optimized solution allows burner to operate consistently under normally occurring (external) variability in load, coal quality, etc.
Results: After dialing in StatSoft optimized settings, flame temperatures immediately responded (strongly), resulting in more stable and higher flame temperatures (cleaner combustion)
Note: Optimized settings for combinations of control parameters not only resulted in lower NOx, but also greater robustness, i.e. consistently lower NOx emissions with less variability (no excursions) were achieved over continued operations at low load.
PPPR Screenshot, Scatterplot, NOx Under Low Load
PPPR Screenshot, Standard and Optimized Comparison Chart, NOx under low load
Reduce Emissions (NOx, CO)
Problem: Optimization of a 400 MW coal-fired DRB-4Z burner for low-NOx operations under low load (50-175 MW).
Solution: Apply StatSoft proprietary data-driven (data mining) technologies to historical data; identify optimized parameter settings (changes to air flows); results consisted of a set of specific (achievable) input parameter ranges that could be implemented easily into the existing DCS (digital control system).
Results: After optimization, NOx emissions under low-load operations were then comparable to NOx emissions under higher loads.
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Contact StatSoft Power Solutions for more information about our services, software solutions, and recent success stories.
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e-mail: info@StatSoftPower.com