Circulating Fluidized Bed Boiler

Optimization Control

Hangzhou HollySys Automation co. LTD

industry experts -- Qian Hua
 Catalogue

1、CFB Principles and Features

2、CFB Control

3、Typical Application of
Coordinated Optimization Control

4、Energy Conservation Prospect

 Corporate Obsession
 DCS system is within low automatic operation ratio, high labor intensity of operator， unstable control
operation parameter 。
 It is not possible to online quantify whether the boiler is operating in an efficient
area , only by the experience and sense of the stoker.
 The coupling between the multi - furnace and multi - machine of the main-pipeline
unit is complex and it is easy to "grab load" .
 When the external load changes, it cannot be adjusted accurately, resulting in large fluctuation of process
parameters 。
 The environmental protection emission index control is not timely, which may easily lead to the excessive
emission being assesse

HollySys with over 20 years experience in the implementation of power projects, in under the guidance of
senior experts in electric power industry technology, in view of process characteristics of the unit system and
main-pipeline unit, integrates the expert strategy, artificial intelligence, big data technology and APC modeling
organic union, developed with characteristic of HollySys HOLLiAS APC software, Effectively solve the problems
of cogeneration enterprises, to solve the boiler combustion optimization and control main-pipeline machine load
distribution and coordination control problem, has successfully used hundreds of sets of results.
 Targeted Solutions
1、how to improve the automatic loop operation ratio, reduce
operator labor intensity ？
2、how to control the key parameter more stable, combustion
even under the red line runs ？ optimization
3、how to realize the automatic running from minimum to full load? control
4、how to improve the boiler efficiency, Achieve the goal of energy
conservation and emission reduction？
5、how to extend boiler life, reduce misoperation?

HOLLiAS APC

1、 How to achieve the automatic operation among the boiler wind

water coal, as well as the coordinated？
2、how to achieve the fully automatic and overcome the coupling
phenomenon between unit and boiler？
3、 How to quickly eliminate and adjust the imbalance between boiler boiler-turbine
steam production and external steam consumption ？ coordinated
4、 How to realize the automatic operation of all boilers without control
interference when the external load changes suddenly ？
5、 How to optimize and overcome the internal and external
disturbance, reduce the heat consumption of the unit ？
CFB Principles 1
 CFB Principles 2

1、 Formation of fluidized bed

1>. Fixed bed: When the air flow rate is not large, the air goes through the
upper part of the bed material gap from the upper, and the height of the bed
material has not changed significantly, the state of bed material is not
fluidized: fixed bed, such as chain furnace.
2>. Boiling bed: When the air velocity continues to increase, small bubbles
gather into larger bubbles and continuously move up through the material
layer and rupture. At this time, the gas-solid two phases are mixed strongly,
such as boiling water, so the state at this time is called : Bubbling bed or
ebullient bed.
3>. Fluidized bed: On the basis of the bubbling bed, the air flow rate
continues to increase. Air bubbles in the bed material are eliminated. The
gas-solid two-phase mixture is more intense and the interface of the
material layer cannot be seen. However, there is still a dense phase area
and lean in the bed. In the phase zone, the bed density in the lower dense
zone is much greater than the bed concentration in the upper dilute phase
zone. The concentration in the middle of the bed during the upward
movement is less than the concentration in the vicinity of the four walls.
The state at this time is called the flow. Beds. This is called: "Boiling
surface flow in the furnace“.
 CFB Principles 3
4>. Gas transport: When the air flow rate increases, the upper and lower
concentrations of the bed material tend to be the same, and the bed
material will be uniformly and rapidly sprayed out of the bed. The fluidization
state at this time is called: jet bed or pneumatic conveying. Such as:
pulverized coal Furnace combustion method.
5>. The state between the fluidized bed and the gas delivery is called a
turbulent bed, and the CFB actually alternates between two states.
 CFB Principles 4

2、What is "fluidization status"?

In 1922, German scientists discovered that when the gas flow enters the container
from bottom to top and is evenly mixed with granular solid material (ø 0-10mm), it no
longer has the characteristics of gas phase material; it no longer has the
characteristics of solid phase material; In many ways it has the properties of a liquid
substance. Therefore, German scientists call this phenomenon a "fluidized state."

Fluidized Fluidized Fluidized

state state
state
Solid phase
Gas-solid
material
mixture

Gas phase material

（More than the Min. fluidization （More than the Min.
（Less than the Min.
wind speed 4-5m / s） fluidizing wind speed）
fluidizing wind speed)
 CFB Principles 5
4、Three major systems of circulating fluidized bed boilers：
①、Material system: New fuel (coal) and desulfurizer are continuously added to the
combustion chamber layer of the furnace. The bed material begins to fluidize, warm
up, burst, crush, and burn under the action of primary air. It is taken out of the
combustion chamber by the smoke wind. The dust is separated and captured by the
separator, and returned to the combustion chamber by the returning equipment,
forming a circulating fluidization process of the ash cycle, which can be simply divided
into the following four stages:
Coal particles are heated and dried → Precipitation and combustion of volatiles →
Expansion and cracking of coal particles → Burning and re-cracking of coke and wear
of carbon particles → Reburning.
②、Wind smoke system: The primary air (about 50% of the total air volume) of the
circulating fluidized bed is blown from the bottom of the hearth bed to promote bed
fluidization and form a reducing combustion atmosphere; secondary air is added at a
certain height, and the secondary wind causes The full combustion of the fuel; high-
pressure air returns the material back to the combustion chamber, forming a
circulation loop.
③、 Steam water system
 CFB Features 1

1. Circulating fluidized bed boilers have become the main

development direction of clean combustion technology
with its advantages of wide fuel adaptation range, direct
desulfurization during combustion, low NO emission,
high combustion efficiency, wide load adjustment range,
and easy utilization of ash residues. Heating, chemical
production and other industries are increasingly used.
2. Due to the complexity and particularity of CFB boiler
combustion, conventional control methods that are
effective for general process control objects have made it
difficult to ensure the realization of the various control
indicators for circulating fluidized bed boilers.
 CFB Features 2

3. Circulating fluidized bed boilers are characterized by

multivariable, strong coupling, and large inertia. The
particle size of coal is larger than that of pulverized coal
furnaces, especially in the dense phase region at low
temperature and under oxygen combustion. The
combustion process is:
Heat first - release volatiles - heating up – burning
4. Subjects with a change in bed temperature caused by a
primary wind disturbance are characterized by adverse
reactions. The reverse characteristics of oxygen.
 CFB Features 3

变量 CV1 CV2 CV3 CV4 CV5 CV6 CV7 CV8

蒸汽压力 床温 氧量 二氧化硫 床压 炉膛负压 汽包水位 蒸汽温度
MV1 燃料 C S S S M M S/M S/M
MV2 一次风量 S C S S S/M S
MV3 二次风量 S C S
MV4 石灰石量 M C M
MV5 排渣量 M C
MV6 烟气量 C
MV7 给水流量 M C
MV8 减温水量 M S C
DV1 蒸汽流量 S S S/M
• note：C：──Relationship between single input/output variables;
S：──Strong coupling;
M：──Secondary strongest coupling.
 CFB Features 4

 Under a step disturbance

with reduced primary wind,
the bed temperature drops
first, then rises through the
initial position, and finally
rises to its positive steady
state value. This is the
characteristic of a typical
reverse response at zero.

K1 K2
GV1  s   1s
e   e  2 s
1  T1s 1  T2 s
 CFB Features 5

 Load response characteristics

The role of primary air increases the initial response speed of the
combustion system of the CFB boiler; however, due to the large delay
and inertia of the fuel-load characteristics of the CFB boiler, the
adjustment time of the system is relatively long.
 CFB Features summary

Multi-parameter coupling, mutual

interference
Large inertia, large hysteresis
Primary air restriction and inverse
characteristics of bed temperature
Non-linear
 目 录

1、CFB Principles and Features

2、CFB Control

3、Typical Application of
Coordinated Optimization Control

4、 Energy Conservation Prospect

 Boiler Combustion Optimization
Control Key Subsystem

fuel supply
regulation
Wind and
1 smoke system

air supply induced air

regulation regulation

APC

2 steam and
feed water desuperheating
water system regulation
regulation
 CFB Boiler Control 1
1.CFB boiler operation ：
Diligent operation, fine tune!
Diligent operation: require timely operation, to avoid deviation after expansion operation!
Fine tune: It is required that the amount of each operation can not be too large, not too fast and too
fierce!
(1). Operation principle of high temperature and high pressure CFB boiler:
Set the load with the wind and set the temperature with coal.
(2). Operation principle of secondary air:
The distribution of the temperature field of the furnace is adjusted according to the differential
pressure of the floating section and the outlet temperature of the furnace, and the oxygen content
of the flue gas is used as a reference control amount.
(3). Bed differential pressure operation: (take 490t/h) as an example:
The ratio of the bed differential pressure to the static layer height is approximately 11.76 Pa/mm.
The bed pressure measurement points are generally arranged at 200-225 mm above the air
distribution plate, and the resistance of the Habao cloth is generally 6000-8000 Pa. The resistance
is 2500-3500Pa, generally 13000-15000Pa for shanghai Boiler, Dongfang Boiler, and Jinan Boiler,
and the empty bed resistance is 5000-6000Pa.
The bed differential pressure of the 130~280t/h Wuxi boiler plant is generally 6000-9000Pa.
 CFB Boiler Control 2
(4). Fly Ash Carbon Content Control
The fly ash contains high carbon content, and the bed pressure is properly reduced;
As the secondary air volume increases, the carbon content of fly ash decreases;
First, the ratio of secondary air is 6/4→4/6.
For each 3% reduction in carbon content of fly ash, boiler efficiency increases by 1%.
(5). Fuel particle size
High cycle ratio CFB - can use coarser fuel
Low cycle ratio CFB - can use smaller diameter fuel;
Low-volume, high-ash fuels are easier to use than smaller-size fuels;
High-volatile fuels tend to use coarser-grained fuels;
(6). Adjustment of the amount of combustion air
The higher concentration of oxygen in the furnace is beneficial to the burn-out of carbon
particles. The carbon content of fly ash decreases, whereas the carbon content increases.
Under the condition that sufficient amount of combustion air is ensured, the rigidity of
secondary air is increased to enhance the mixing of secondary air and solid particles, and
special attention should be paid to increasing the secondary air volume in the upper layer.
 CFB Boiler Control 3
(7). Bed temperature adjustment;
The bed temperature is too low, carbon content in fly ash increases, boiler
efficiency decreases, as the bed temperature rises, the carbon content of fly
ash decreases, and the combustion efficiency increases.
Low bed temperature solution:
a. Adjust the gap of the crusher and reduce the fuel particle size.
b. Increase the amount of secondary air, reduce the amount of secondary air;
c. Operation is mainly achieved by changing the fuel quantity and the primary
and secondary air ratios and the circulating ash quantity.
(8). Return device control:
The return air pressure is too high, causing the back-feed device to be
reversed, paying particular attention to the gradient of the return air pressure
gradient from the bottom up, one to prevent the formation of a strong oxidation
zone in the top, and the other to prevent relatively large particle size The
bottom of the feed back device is coked.
 CFB Boiler Control 4
2.CFB boiler control strategy:
The control principle of a high temperature separation CFB boiler:
Set the load by air, adjust the temperature with coal (bed temperature),
supply oxygen (secondary air and oxygen content of flue gas), induce wind
pressure (furnace negative pressure), and also specify the following control
principles:
Bed temperature control principle
Bed temperature is a function of load, high load high bed temperature, low
load low bed temperature, and average bed temperature should be
controlled at 880-920°C during load changes
Bed pressure control principle:
Bed pressure is a function of load, high load high bed pressure, low load
low bed pressure, and with load changes, bed pressure should be controlled
at 6.0-14 Kpa.
 CFB Boiler Control 5
3. Boiler bed temperature control characteristics analysis:
1>. Effect of load change on bed temperature:
The effect of load change on the bed temperature: the load is high, the bed temperature
setting should be high; the load is low, the bed temperature setting should be low; the bed
temperature is a function of the load;
2>. Effect of Coal Change on Bed Temperature:
The effect of coal variety on bed temperature is more complicated. When the coal type
deteriorates, the DCS thermal load command system should appropriately increase the
amount of coal and air volume; when the coal types become better, the DCS thermal load
command system should appropriately reduce the amount of coal and air volume. the way is:
(1). It is determined through on-site commissioning.
(2). It is possible to optimize the calculation of coal consumption and coal calorific value
online in time, and then adjust the coal supply and primary air volume of the entire
combustion system by changing the heat load command.
3>.The effect of primary air volume on bed temperature:
The change in bed temperature is relatively sensitive to primary air volume. Once the air
volume increases, the bed temperature increases first and then decreases. Conversely, when
the primary air volume decreases, the bed temperature decreases first and then increases.
This is the reverse characteristic of a wind.
 CFB Boiler Control 6
4. Analysis of Control Characteristics of Primary Airflow in Boilers
The control of primary air volume is very important for the circulating fluidized bed boiler to work
normally.
(1). The primary air volume is a function of the load, and the primary air volume changes with the
load;
(2). In the low load stage, the primary air volume is controlled, and in the high load stage, the
secondary air volume is mainly controlled;
(3). 。 The control of the uniformity of the fluidized state should avoid the consequences of large
primary air volume deviations on both sides, uneven fluidization, bed leakage, and local coking.
(4). Avoiding excessive fluidization causes increased boiler wear, shortened maintenance
intervals, and reduced boiler life. Unit consumption increases!
5. Analysis of Control Characteristics of Secondary Airflow in Boiler
The control of secondary air is mainly to ensure that the combustibles get further oxygen-
enriched combustion in the dilute phase zone (suspension section). The control of secondary air
meets two requirements at the same time:
(1). Rigidity of secondary air: Select the appropriate secondary air pressure head to control the
gradient distribution of the temperature field in the hearth to ensure that the upper and lower
temperature difference of the hearth is controlled at ≯20°C, otherwise it will cause water wall
The uneven heating of the lower heating surface reduces the combustion efficiency of the boiler
and increases the carbon content of the fly ash.
(2). Using the oxygen correction method to control and adjust the secondary air volume.
 Scope and Content of
Optimize and Coordinate Control
The implementation of boiler optimization control is mainly divided into four parts, including
optimization of boiler operation, optimization of boiler combustion control, and optimization of
coordination of boiler steam turbines.
1. Boiler operation optimization is the inspection and discovery of problems in process, operation
and control, giving guidance opinions and process, operational problems and suggestions for
improvement.
2. The optimization of boiler combustion control is mainly aimed at the modeling and control logic
optimization of the boiler monomer control loop, automatically identifying changes in fuel calorific
value and pressure changes, and meeting and achieving long-term automatic and stable operation
of the combustion. The contents of each section include:
①Boiler monomer automatic circuit includes: automatic feed water (drum water level),
desuperheated water automatic (main steam temperature), automatic coal volume, induced draft
automatic (negative pressure), automatic air supply (air supply volume), automatic furnace
temperature, etc.
②Combustion optimization debugging: automatic optimization of coal quantity, identification and
correction of calorific value, multivariable predictive control, automatic optimization and optimization
of air supply, optimization of induced draft control, and other control optimization strategies
3. Coordinated control: Automatically coordinated control of load and pressure using DEB direct
energy balance. The boiler automatically follows the turbine mode adjustment. Master control
automatically distributes load to multiple boilers.
 Optimization Control Content
Drum water level (main water supply) control problems and improve the program
The main feedwater control loop is a three-fluid cascade control, which controls the
drum water level by adjusting the main feedgate opening; vice-control feedwater flow,
main control drum water level, main steam flow as the main feed-forward signal,
directly correct the water flow
The automatic circuit is set with input conditions and cutting conditions. When the
conditions are not available, the automatic control is limited; when the control valve
fault, signal failure, and the deviation of the water level from the target value are large,
the cutting is automatically performed. When the water level is in abnormal conditions,
the water level fluctuates, causing the water level (high and low II) to be eliminated
manually because the water level automatic control direction is correct. After manual
removal, the manual operation direction is the same, but the operation workload is
increased, so the general Manual removal is not required. Manual operation is only
performed when it is dangerous.
In order to avoid the saturation of the integral, the secondary tune deviation limits the
main tune output, uses the mass balance method to carry on the fuzzy control,
prevents the main steam flowrate and the feedwater flowrate from deviating
excessively, adjusts not in time, limits the main tune output at the same time. The
machine big data analysis and self-learning get the target value and range of the water
supply flow and limit the fluctuation of the feedwater flow.
 Optimization Control Content
The main steam temperature (minus warm water) control problems and the
solution perfecting
All of them were changed to cascade control, and the outlet temperature of the
two-stage superheater was controlled by adjusting the opening of the two-stage
attemperating water valve. The main regulating valve control superheater
temperature, the secondary regulating valve control attemperator outlet
temperature (after water spraying). The temperature target after water spraying
is obtained by big data analysis and self - learning. The temperature reduction
adjustment of the front and rear two levels is divided into left and right sides,
and the control scheme of the left and right sides is the same. The limitation of
steam temperature and dryness after water spraying is introduced, ensure no
overspray. According to the temperature control situation, the feedforward
signal of sub-adjustment is connected to the field after the comprehensive
optimization judgment of the main steam flow, coal volume, air volume and flue
gas tail temperature is introduced. Meanwhile, in order to avoid integral
saturation, the minor deviation limits the output of the main tone.
Through load coal, air volume, large amount of data analysis, forecast
attemperation water regulator opening range, limit the adjusting range, avoid
valve open too much and too low.
 Optimization Control Content
Furnace negative pressure(induced air) control problems and solution
improvement
Optimization of logic: Negative pressure limits the air supply (the summary of
primary wind and secondary wind) and coal, interlocking, when the furnace
pressure high, limit the adding of wind and coal; otherwise limit the reducing of
wind and coal. Introduce and optimize the air feed forward logic, the amount of
air is controlled directly in advance according to the amount of coal; According
to the change of air supply, feedforward controls the air supply (feedforward is
based on machine self - learning and self - correction), which can meet the
response speed of variable working condition and variable load quickly, at the
same time make the adjusting stable and fine ，reduce the negative pressure
sate, operation on the critical line, reduce the single consumption of auxiliary
machine.
The induced air should also be analyzed by large data of load and coal volume,
forecast the opening range of the induced air, limit the adjusting range, avoid
the regulating valve over-drive and under-drive.
 Optimization Control Content
Oxygen content (secondary wind)control solution improvement
Oxygen content needs to be identified by analyzing incomplete combustion
components of flue gas. The first is whether the oxygen content target is
appropriate, and the second is whether the oxygen content measurement is
accurate. Finding the right oxygen target is critical. We need to perfect the feed
wind control system, according to load, boiler oxygen, total air supply and total fuel
volume (mainly heat value) signal , automatic identification and learning to predict
the amount of wind , through cascade PID, adjust the fan frequency conversion ,
The stability and sufficiency of the combustion system are guaranteed by
decoupling control of the deviation of air supply and oxygen supply. The air supply is
proportional to the amount of coal. When the thermal value of coal changes, the
total air supply is corrected by the amount of oxygen.
优化控制部分内容介绍
The air supply and coal are function relations, When the amount of coal entering the
boiler is high, the amount of air required is high, but it must be studied and
corrected by the thermal value of coal. When the thermal value of coal is high, the
amount of air required is high, otherwise the air is reduced. There are two function
modules of self - learning and identification for air supply, relationship between load
and air volume, between coal volume and air volume, each have 50%. The load
accounts for 60% and the coal accounts for 40% in fluidized bed boiler.
 Optimization Control Content
Primary wind control solution improvement
The primary air volume is limited by the minimum fluidized air volume, The
required primary air volume is predicted by automatic identification and
learning, The primary fan damper or frequency conversion is adjusted by
cascade PID, The stability and sufficiency of the combustion system are
ensured by the primary air volume correction of the bed temperature
deviation. Primary air volume is proportional to coal volume and load.
Primary air volume is a function of coal quantity and load, When the amount
of coal entering the boiler is high ，the required primary wind will be high.
The primary air volume has two functions for self-learning and identification,
relationship between load and air volume, between coal volume and air
volume, the load accounts for 70% and the coal accounts for 30% in fluidized
bed boiler.
 Optimization Control Content
CFB boiler temperature(bed temperature)control solution improvement
Change the amount of coal according to the boiler temperature target, boiler
temperature is a function of load , no need to run the settings, automatically adjust the
boiler temperature and the amount of fuel entering the boiler according to the load
target, at the same time, introduce the prediction control of bed temperature by big data
analysis, introduce the boiler temperature change rate control, introduced the pressure
change rate and time control of steam drum, introduce a fast pullback algorithm etc. in
short, that is multi-variable predictive control using some advanced techniques and
algorithms. Through the prediction, with the boiler temperature control target and the
coal quantity control target, the boiler can operate automatically, safely and stably,
because the forecast can respond to the change of load quickly, no human intervention
and adjustment is required without equipment and instrument malfunction (stable
operating condition load range), no automatic operation, all manual operation according
to the needs of the load adjustment.
When the load fluctuates and the coal value fluctuates greatly, the operation is frequent
and large, it is necessary to perfect the optimal control solution of coal quantity, make
automatic control solution of coal quantity. According to total operation, automatic adjust
the total amount of coal supplied to the boiler is given, steady load. By predicting the
amount of coal and coordinating control, there is no need for operation intervention,
automatic adjustment and operation.
 Optimization Control Content
Coal quantity control solution improvement
It is necessary to perfect the coal quantity control solution, make automatic control
solution of coal quantity, according to the total operation, Set the total amount of coal
supplied to the boiler for automatic adjustment, steady load. When the amount of coal
fluctuates, the amount of coal will be automatically corrected to ensure the total amount
of coal in the furnace remains unchanged.
Boiler load and coal volume need to be self - learned and identified, calculate the
amount of coal required for the current load automatically, According to the load
deviation and pressure deviation, the predicted amount of coal is corrected. The wind,
water and coal of the boiler are controlled and adjusted synchronously according to the
forecast.
CFB boiler and bed pressure automatic control
Bed pressure is a function of load, High load need high bed pressure, low load need
low bed pressure. Low load for a long time (automatically correct and increase the bed
pressure when below the load target), When the load exceeds the maximum load,
Automatic correction and reduction of bed pressure target. The relation between bed
pressure and load ，through the machine self-learning, automatically calculates the
bed pressure required for the current load. The bed pressure target tracks the actual
value when manually mode, when automatic mode, manual non- disturbing
interference bed pressure target, Modifications are made on the basis of the original
target.
 Optimization Control Content
Machine and furnace coordination control solution improvement
According to the actual situation on site, there are two plans: The first is to
adjust the pressure of the steam turbine （ Stabilize the turbine throttle
pressure, the efficiency of the steam turbine is the highest), Coordinated
control of direct balance of DEB energy of boiler regulating power (load).
Steam turbine DEH control hand over to boiler automatic control, pressure
target of steam turbine is determined according to parameters target of steam
turbine. The second solution is automatic power adjustment of the steam
turbine, boiler adjusts pressure automatically, This is the fastest way to
respond to external loads. You can choose a suitable way from the two ways to
automatically run according to the operation requirements. Boiler load is
divided into manual setting and automatic setting, if load mode, manual load
given; if constant pressure mode, the pressure target before the machine is
given manually. Only after coordinated control, the coupling and interaction
between boiler and steam turbine be solved, operate more stably, economically
and safely.
Steam turbine control solution improvement
It's relatively simple compared to a boiler, and it's not explained here.
 MACS Schematic Diagram of Combustion
Optimization Control System
The combustion process of boiler is an extremely complex chemical process and
physical heat transfer process, the control of the amount of fuel, the amount of air
supply and the amount of induced air supply have the characteristics of strong coupling,
non-linearity, variability and large hysteresis. Therefore, the control of the whole
combustion system must be coordinated to ensure the stability of boiler load, pressure,
oxygen content, temperature and negative pressure.

计划与调度

实时优化
(RTO)
优化控制
先进过程控制
(APC)

分散控制系统
(DCS)
 HollySys HOLLiAS APC
Core Technology

Decoupling 8 1 Predictive
Control Control

Coordination 7 2 Fuzzy
Control Control
HOLLiAS APC

Core Technology
6 3
Artificial Soft-Measuring
Intelligent Technology

5 4
Automatic Big data
Optimization Self-learning
Techniques
 Combustion Optimization Key Technology(1)
-Adaptive Optimization Controller

Multivariable adaptive optimization controller (HiaP) is developed based on

mathematical control theory, which is similar to the traditional PID control idea,
but its performance is much higher than the traditional PID, with multivariable
input, parameter model online adaptive, high computational efficiency , Can be a
good solution to the adaptive changes in coal regulation.
 Combustion Optimization Key Technology(2)
-Artificial Intelligent Control
Artificial Intelligent control technology includes two functions as follow:
(1) Overcoming the problems of non-linear control and large dead zone of equipment and
insensitive reaction of actuator, etc., it solves the problem of on-site equipment being
automatically put into operation due to defects and abnormality of equipment characteristics.
(2) Intelligent imitation artificial automatic acceleration function, simulate manual operation,
make the system overshoot and then pull back quickly, which greatly shortens response time
and solves the problem of lag of combustion system reaction.
 Combustion Optimization Key Technology(3)
- Blowing-in Regulation

Traditional New
Blowing-in Blowing-in
Control bad Control
good

Adopt Conventional PID Adopt Automatic Optimization Control

1. Great influence by accuracy of 1. The air supply is calculated

oxygen signal dynamically by the optimization mode
2. The amount of wind adjustment with 2. Optimized air distribution adapts to
quality of coal varies not timely changes in coal quality automatically
3. Control stability is poor 3. Not affected by the accuracy of

4. Boiler efficiency cannot guarantee oxygen signal

4. Ensure the boiler operates at high
efficiency
 Combustion Optimization Key Technology(4)
- Automatic Optimization
There is an optimum oxygen content in the combustion process that minimizes q2 + q4.
Based on this theory, we put an automatic optimization model into the system and start the
optimization procedure automatically when the calorific value of coal is relatively stable.
According to the preset optimization step and optimization time, we can finish the optimization
process, And then find the best coal ratio K1 coefficient, utilize optimization coefficient K to
amend the air supply control loop, making the highest boiler efficiency. When the coal species
change, making the coal heat value exceeds the relatively stable area, the system will
automatically start the optimization program again.
 Combustion Optimization Key Technology(5)
- Induced draft Fan Regulation

 Reliability of traditional induced draft fan regulation is bad, Automatic input is

difficult and with high risk, labor intensity for Manual regulation is high:
① Set auto-tuning system instructions to limit self-switching algorithm;
② Set the transient / steady-state area to suppress the system's natural
vibration;
③ Set self-balancing system for the bilateral fans load (current);
④ Use feedforward loop expert strategy to eliminate internal and external
disturbances quickly.
Furnace Pressure Combustion Combustion Regulation
Item Reliability
Fluctuation Stability Sufficiency Time

Traditional Induced
Bad △120Pa Average Average 32S
Draft Fan Regulation

New Induced Draft

Good △ 50Pa Good Good 20S
Fan Regulation
 Combustion Optimization Key Technology(6)
-Running Mode

Single Furnace Can not decoupling control, easy to

1 Automatic Mode disturb each other

Running Pressure Coordination Mode

Mode
2 Control Mode Decoupling control between boiler
and steam turbine automatic, load
Load Control optimal distribution
3 Mode

10

9.9
单位：MPa
9.8
单炉模式
协调模式
9.7

9.6

9.5

Area Chart about Boiler Main Steam Pressure of Single Furnace Mode and Coordination Mode
 Combustion Optimization Key Technology
Prediction Control

 When combustion system is in relative steady state and comply with the
conditions as below:
 The deviation between set value and measured value of main steam pressure is less than
0.02MPa;

 The deviation between set value and measured value of main steam flow is less than 2t/h;

 The deviation between set value and measured value of boiler oxygen content is less than 0.5%;

 When comply with all the conditions above, the system automatically memorizes the current main
steam flow and coal quantity, and automatically calculates the predicted unit coal mass gas
production rate F0, and F0 is dynamic data of continuous rolling optimization. Via the unit of coal
gas production rate F0 ,it will guide coal quantity control, not only to ensure the stability of the
system steady-state regulation, but also increases the system response to external load fast.
 Forecast coal volume correction, pressure deviation, load deviation correction.
Combustion Optimization and Coordination
Control Communication Structure Diagram
 Schematic Diagram of Original
DCS Logic Implementation

Feed water flow instruction

Optimal new APC
control system Feed coal instruction
control
based on
predictive Valve opening instruction
control
Feed water
flow instruction
Feed coal
OPC Communication Track Input/ instruction
each other removal Steam Valve
opening instruction
Valve opening
instruction
DCS Tradition Feed coal
AGC control instruction
system in Feed water
DCS flow instruction
 Single Boiler Optimization
Configuration List
1、System Software list
Qua
Seq. Name Model Unit Vendor
ntity
1 Operating system Windows 7（pre-install） Set 1 Mircrosoft
HOLLiAS-MACS V653 automatic control
2 Control software Set 1 HollySys
system software
Combustion optimization control
3 Application software Set 1 HollySys
package: HOLLiAS MACS-OPT V1.1.3
Communication Hollias Comm V2（Including independent
4 Set 1 HollySys
software authorization）
Optimized software SimuRTS V6 registered software
5 Pcs 1 HollySys
authorization authorization
Engineer station HOLLiAS MACS V6.5.3 Software engineer
6 Pcs 1 HollySys
authorization station dongle
 Single Boiler Optimization
Configuration List
2、System hardware list
Qua
Seq. Name Model Unit Vendor
ntity
Optimize and Tower workstation/T5810 series
1 communicate standards Set 1 DELL
server hosts /Intel Xeon E5/4G/500G SATA 7.2k/DVDRW
2 Display 23'‘ WLCD/E2316H Set 2 China
Dual screen
3 Removable, vertical installation Pcs 1 China
display stand

4 Gigabit PCI-E Broadcom: Gigabit, RJ45 port，PCI-E x1 Pcs 1 China

network card
5 UTP CAT5e Unassembled 30m Pair 1 China
6 Power DistributorBull five-hole row Pcs 1 China

7 loudspeaker box
active loudspeaker /R1000TC/ Pair 1 China
220VAC/16W/ SNR:80dB
 Combustion Optimization and
Coordinated Control Communication
Scope of Application:
The existing DCS system software and hardware are third-party brand. This method is
recommended. The original DCS system can also be used if its HollySys own system.
It has a wide range of applications and is easy to regulate and unify.
Hardware Implementation Method:
1. Add a new optimization control server/OPC server.
2. The signal needed for optimizing the control system is transmitted bidirectionally
through the OPC protocol.
Software implementation Method:
1. Install OPC client software on the original DCS system.
2. Add the optimized control switching interface program and signal assignment
program in the original DCS system.
3. All the optimization coordination control algorithms are implemented in the
optimization control server.
 Combustion Optimization
- Technical Specifications
The specific technical indicators of the optimized control system are as follows:
(1) During the normal operation of the unit, the usage of the optimized control system
shall not be lower than 95% (the process system does not have the self-control
condition and does not count), and the labor intensity of production is reduced;
(2) After the control optimization system is put into operation, the stability of key
process parameters such as load, main steam pressure, steam drum water level,
main steam pressure (temperature), oxygen amount, and negative pressure can
be improved, and the deviation (fluctuation amplitude) of key process parameters
can be reduced more than 30%.
(3) After the implementation of combustion optimization and "card edge" control, the
thermal efficiency of the unit is improved, and the unit efficiency is increased by an
average of 1% or more than before the implementation;
(4) To achieve automatic control optimization of boiler operating conditions and loads,
and quickly respond to changes to the external load requirements, so as to achieve
a safe, stable and economical operation.
(5) Establish a boiler operation safety protection system with fault diagnosis and
automatic switching function. When the main instrument and equipment failure
occurs in the boiler system, it can automatically switch without interruption, and
conduct live voice alarm.
(6) Establish statistics on over-limitation and over-time statistical parameters for
boilers according to class, and calculate the efficiency automatically.
 Combustion Optimization
- Control Index
Parameter Unit Steady State Load Change Indicator
index （＜3%Pe/min）
Main steam flow T/h △2 △4

Main steam pressure MPa △0.08 △0.15

Boiler oxygen % △0.4 △0.8

Furnace negative pressure Pa △30 △50

Drum level mm △10 △20

Main steam temperature ℃ △2.5 △5

Coal quantity T/h △2 △4

Other parameters and indicators

 目 录

1、CFB Principles and Features

2、CFB Control

3、Typical Application of
Coordinated Optimization Control

4、 Energy Conservation Prospect

 Combustion Optimization
Application Cases

Typical applications include:

1. Unitization circulating fluidized bed boiler Optimized control;
2. Unitization subcritical drum boiler optimization control;
3. Unitization supercritical dc boiler Optimized control;
4. Unitization supercritical dc boiler Optimized control;
5. Piping-main circulating fluidized bed boiler Optimized control;
6. Piping-main Optimized control of coal-fired boilers;
7. Piping-main Optimized control of gas boilers;
8. Piping-main waste furnace Optimized control;
9. Biomass combustion Optimization control etc.
 Optimal Control and Coordinated
Control of Typical Project List
No. User Boiler Capacity Turbine Capacity
Guohua hulunbeier power generation co. LTD 2*2000t/h 2*660MW
1
Shaoguan Pingshi Power Plant(B Plant) 1024t/h 300MW
2
Fujian Longyan Power Generation Co. Ltd. 1024t/h 300MW
3
Datang Liaoning Dianbing Power Generation Co. Ltd. 1024t/h 300MW
4
Ningxia Guohua Ningdong Power Generation Co. Ltd. 1100t/h 330MW
5
Shenhua Shendong Xinjiang Midong Thermal Power Plant 1024t/h 300MW
6
Shenhua Shendong Salaqi Power Plant 1100t/h 330MW
7
Shenhua Zhunneng Ganshi Power Plant 1100t/h 330MW
8
Datang Wuan Power Generation Co. Ltd. 1100t/h 330MW
9
Fujian Longyan Power Generation Co. Ltd. 4*440t/h 4*135MW
10
Shenhua Yangguang Co. Ltd. 2*440t/h 2*135MW
11
Shenhua Xibaode Power Plant 2*440t/h 2*135MW
12
Shanxi Shendong Dianta Power Plant 2*450t/h 2*135MW
13
 Optimal Control and Coordinated
Control of Typical Project List
No. User Boiler Capacity Turbine Capacity
Liaoning datang fuxin thermal power plant 4*470t/h 2*50MW+1*30MW
14
Huadian group xinjiang kashgar thermal power boiler
4*220/h 4*50MW
15 optimization
Xinjiang zhongtai chemical thermoelectric boiler optimization 3*440t/h 3*135MW
16
Xinjiang turpan power plant Optimization of boiler and AGC 2*480t/h 2*135MW
17
Sinopec group Shanghai gaoqiao thermoelectric main-pipe
6*220t/h 3*25MW+2*50MW
18 coordination and optimization
Sinopec group chongqing chuanwei petrochemical
thermoelectric boiler 2*460t/h 2*25MW
19 optimization
Chongqing dalkai thermoelectric boiler
2*260t/h CFB 2*25MW
20 optimization
Hangzhou Hongshan Thermal Power Boiler Optimization and
3*150t/CFB 2*25MW
21 Mother Tube Coordination Control Project
CJ (Shenyang Seagate) Biotechnology Co., Ltd. Boiler
4*90t/hCFB Heating
22 Optimization Project
Shandong Qiyuan Thermal Power Boiler Optimization
4*130t/hCFB
23 (Yousheng: SUPCON DCS)
Heilongjiang Pengcheng biochemical boiler optimization 3*60t/hCFB Heating
24
 Optimal Control and Coordinated
Control of Typical Project List
No. User Boiler Capacity Turbine Capacity

Jiangsu Jingshen salt thermal power boiler optimization 1*2CFB 1*25MW

25

Shandong Weihai Thermal Power Boiler Optimization and Multiple steam

3*240t/h CFB
26 Mother Tube Co-ordination Control turbines

Shandong Luxi Chemical Thermoelectric #2 Boiler

480t/h 135MW
27 Optimization
Shandong Luxi Chemical Thermoelectric #3 Boiler
680t/h 135MW
28 Optimization
Shandong Luxi Chemical Thermoelectric #4 and #5 Boiler
2*680t/h 135MW
29 Optimization

Shandong Dongyue Thermal Power Boiler Optimization and

240t/h CFB
30 Mother Tube Coordinated Control 60MW

Shandong Quanlin Thermal Power Boiler Optimization and

3*130t/hCFB
31 Mother Tube Coordination Control 2*25MW
Indonesia (Wuxi Guolian Indonesia Optimization Project)
3*130t/hCFB
32 Boiler Optimization 2*25MW

Heilongjiang Bei'an Thermal Power Generation CFB Boiler 2*130t/h CFB

33 Optimization (For Siemens DCS) 2*25MW
 Optimal Control and Coordinated
Control of Typical Project List
No. User Boiler Capacity Turbine Capacity
Heilongjiang Fujin Thermal CFB Boiler Optimization (For
34 2*130t/h CFB 2*25MW
Siemens DCS)
Cangzhou Zhongtie Phase II Mother Tube Coordinated Control
35 2*240t/h CFB 2*25MW
Boiler Optimization

36 Heilongjiang Haotian Corn Thermal Power Boiler Optimization 75t/h CFB 12MW
Shandong Jingbo Hengfeng Thermal Power Boiler
37 130t/h CFB 2*25MW
Optimization
Shandong Jingbo Hengfeng Thermal Power Boiler
38 240t/h 2*50MW
Optimization
Cangzhou Zhongtie Phase III Mother Tube Coordinated Co-
38 2*300t/h 2*60MW
firing boiler combustion optimization
Cangzhou Chengre Longhai Thermal (Haixing) Heating Boiler
40 2*150t/h
Optimization

41 Jilin Gongzhuling Longsheng Thermal Boiler Optimization 4*200t/h CFB 2*30MW

Sanning Petrochemical Urea Plant Thermal Power Boiler

42 Optimization and Mother Tube Coordinated Control 2*75t/h CFB 25MW
Yangzhou Hengqi Coal Gas Optimization and Coordinated
43 240t/h
Control 65MW
 Optimal Control and Coordinated
Control of Typical Project List
No. User Boiler Capacity Turbine Capacity

Jiangxi Jiujiang Petrochemical Thermal Power CFB Boiler

44 2*220t/h 50MW
Control Optimization
Dongguan Kewei Environmental Protection Waste Boiler
45 3*60t/h 2*25MW
Optimization Control
Guangda Environmental Protection (Ningbo) Waste Boiler
46 1*60t/h 25MW
Optimization Control
Zhejiang Juhua Thermal Power #10 Unit Optimization Control 30MW Extraction –
47 280t/h
(For Emerson) Back Pressure Type
Dongguan Jiulong Hailong Thermal Power #4 Unit 30MW Extraction –
48 280t/h
Optimization and Mother Tube Coordinated Control Condensing Type

49 Hebei Xinxing Cast-tube Gas Boiler Optimization and Mother

Tube Coordinated Control 240t/h 65MW

50 Guangdong Shao Steel Thermal Power Coal Gas Boiler

Optimization and Mother Tube Coordinated Control 4*240t/h 65MW
51 Jiyuan Iron & Steel Coal Gas Boiler Optimization 280t/h 80MW
52 Jiulong Quanzhou Phase II Boiler Optimization 380t/h CFB 80MW
 Optimal Control and Coordinated
Control of Typical Project List

No. User Boiler Capacity Turbine Capacity

Chongqing Liwen Paper Thermal Power Boiler

53 Optimization and Mother Tube Coordinated Control 480t/h CFB 65MW
Hebei Puyang Iron & Steel Coal Gas Boiler Optimization
54 and Mother Tube Coordinated Control 4*240t/h 4*65MW
Hulunbeir Donneng Chemical Industry Co., Ltd. CFB
55 Boiler Optimization Control 240t/h CFB 65MW
Heilongjiang Suihua Xiangyu Jingu Biochemical Boiler 2*45MW Extraction –
56 Optimization Control 3*260t/h CFB Back Pressure Type
Hulunbeir Shengtong Sugar Boiler Optimization and
57 Coordinated Control 130t/h CFB 50MW
Baling Petrochemical Boiler Optimization and 25MW Extraction –
58 Coordinated Control 260t/h Back Pressure Type
Case 1: Coordinated Control
Management Center (6 boilers)
 Case 1: Pressure Comparison Before
and After Optimization and Coordination

before：main-pipe pressure after： main-pipe pressure

fluctuate up to 0.31MPa fluctuate reduce to 0.08MPa

Reduce range is ：74.2%

 Case 1: Coordinated Control
Mode 8 Hour Trend

4 boilers are put into coordinated control at the same time:

： the main-pipe pressure run as critical line, main-pipe pressure
fluctuation less than 0.083MPa
案例2：协调控制管理中心(4台锅炉)
Case 2: coordinated control management center (4 boilers)
案例2：优化控制界面（CFB锅炉）
Case 2: Optimized control interface (CFB boiler)
 案例2：手动控制时母管压力趋势
Case 2: main-pipe pressure trend during manual control

手动控制时：母管压力波动达0.17MPa
Manual control: mian-pipe pressure fluctuation up to 0.17MPa
 案例2：手动控制时母管压力趋势
Case 2: main-pipe pressure trend during
coordination control

协调控制时：母管压力波动仅0.05MPa
coordinated control: main-pipe pressure fluctuation is only 0.05MPa
案例3 多炉多机循环流化床协调控制
Case 3 multi - furnace multi - machine
circulating fluidized bed coordination control
案例3 多炉多机循环流化床协调控制
Case 3 multi - furnace multi - machine
circulating fluidized bed coordination control
泉林热电3*130t/h CFB
Quanlin thermoelectricity 3*130t/h CFB
东岳热电240t/h CFB
昊天玉米热电75t/h CFB
Haotian corn thermo 75t/h CFB
京博恒丰热电130t/h CFB
Beijing hengfeng thermal power 130t/h CFB
京博恒丰热电130t/h CFB
Beijing hengfeng thermal power 130t/h CFB
燃烧优化与协调控制鉴定报告
Combustion optimization and coordination
control appraisal report
燃烧优化与协调控制鉴定报告
Combustion optimization and coordination
control appraisal report(2*1000MW)
燃烧优化与协调控制鉴定报告
Combustion optimization and coordination
control appraisal report
燃烧优化与协调控制鉴定报告
Combustion optimization and coordination
control appraisal report
 发明专利
Patent for Invention
 发明专利
Patent for Invention
 发明专利
Patent for Invention
 目 录

1、CFB Principles and Features

2、CFB Control

3、Typical Application of
Coordinated Optimization Control

4、 Energy Conservation Prospect

 Optimization and Coordination
Solve Key Problems
 1、 How to improve the rate of automatic circuit, reduce the operator's labor
intensity?
 2、 How to make the important parameter control more stable, even runs on
critical line?
 3、 How to improve boiler efficiency and achieve the purpose of energy saving
and emission reduction ?
 4、 How to realize simultaneous full automation of multiple boilers, overcome
the phenomenon of "seesaw" ?
 5、 How to respond accurately and quickly to sudden changes in external loads ?
 6、 How to optimize the distribution of the load change of the whole system and
reduce the heat consumption of the unit ?

HollySys MACS Combustion optimization control software and CCS

Intelligent main-pipe coordinated control software will solve above
problems well.
 Energy Conservation Prospect
 1. Energy conservation and efficiency

 After optimized operation of circulating fluidized bed boiler:

 ① Direct energy conservation efficiency ；

 ② Reduce auxiliary machine unit consumption ；

 ③ Reduce boiler wear

 ④ Parameter stability, improve the metal life of boiler ；

 ⑤ Lay the foundation for reduction of people and increase efficiency ；

 ⑥ Automatic rate is high, the maintenance level of equipment is

increased 。

 Energy saving is absolute, energy saving amount is relative

 Responding to external interference requires sacrificing boiler efficiency ；

 Taking boiler efficiency as the main factor will reduce the response to load

 Give consideration to two or more things.

 Energy Conservation Prospect
2. Use 280 tons boiler as an example, illustrate the benefits:
when reduce the control error of main steam temperature 5℃ and increase the
allowed operating temperature 5℃ for each, The improvement of heat consumption
of the unit is 0.103％~ 0.107%. reduce the control error of main steam pressure,
every increase of 0.1 Mpa, the heat consumption of the unit can be improved about
0.0467％. The combined heat consumption of the two terms is reduced to 0.15％.
In accordance with environmental requirements , reducing the oxygen content of flue
gas by 1% can improve the heat consumption of the unit by about 0.215%.
If a single boiler consumes about 150,000 tons of coal annually.
①. The steam yield of tons of coal can save 2Kg of coal (At 200 tons per hour, 300
days per year), this translates into savings of about 2,880 tons of standard coal per
year, the price of standard coal at market price can be estimated at 500 yuan/ton, this
would save about 1.44 million yuan (720,000 yuan if halved) in annual fuel costs.
②. Reduce the accident downtime and improve the unit availability. It is assumed that
the annual accumulative operation is one more week, which is calculated by 200
tons/hour, that is 33,600 tons of extra steam annually, and by 100 yuan/ton, the
annual economic benefit of additional steam is 3.36 million yuan.
 Energy Conservation Prospect
 ③.Reduce the thermal stress of the transient process under the sharp change of
load to protect the equipment and extend the service life. The unit cost is
assumed to be 500 million yuan, the design life is 30Y, and the extended life of
1Y is equivalent to the economic benefit of reducing equipment consumption of
16.67 million yuan . As a 30-day average, savings in equipment costs are about
550,000 yuan per year.

 ④. Reduce the single consumption of the auxiliary machine, save 1000 degrees
of electricity per day, operate 300 days per year, save 3000000 degrees of
electricity per year.

 ⑤. The optimization improve the operation stability of the boiler and extend the
life cycle of the unit. reduce emissions, The equipment management level is
improved, the personnel ability is improved, the social benefit is obvious.

 ⑥. The working intensity can be reduced and the worker can do other meaningful
work such as inspection.
 Summary
 We have rich debugging experience and mature solution for the control of
circulating fluidized bed boiler

 We have a unique algorithm and solution for the control of multi-furnace and
multi-unit main-pipe control boilers

 We not only have mature control solution, but also have advanced APC
predictive control software. Which could be embedded, could be hanged
outside!

 We can bring abundant economic and social benefits to users

Thank you for your always
attention and support to
HollySys!

www . HollySys . com

HANGZHOU HollySys AUTOMATION CO.,LTD

Address：No. 1, north road 19, xiasha economic Address：No. 2, disheng middle road, Beijing
and technological development zone, Hangzhou economic and technological development zone
Postcode：310018 Postcode ：100176
Telephone：0571-81633600 Telephone ：010-58981000
Fax：0571-81633700 Fax：010-58981100