U.S. patent number 3,607,117 [Application Number 04/845,353] was granted by the patent office on 1971-09-21 for black liquor recovery boiler combustion and safety control system.
This patent grant is currently assigned to Rust Engineering Company. Invention is credited to Fred Endsley Fuller, Roy Roger Herbst, James Marlin Shaw.
United States Patent |
3,607,117 |
Shaw , et al. |
September 21, 1971 |
BLACK LIQUOR RECOVERY BOILER COMBUSTION AND SAFETY CONTROL
SYSTEM
Abstract
Recovery boiler operation is initiated by a control system
responsive to selected preliminary conditions in the boiler. Once
the boiler is in operation, a combustion system controls the total
amount of air, black liquor, primary fuel and secondary fuel
supplied to the recovery boiler to reduce explosion hazards. Actual
primary and secondary fuel flow rates are added and a fuel-air
demand signal is generated in proportion to the amount of air
required to fully combust both fuels. A black liquor demand signal
is added to the fuel-air demand signal to produce a total air
demand signal which is compared to the actual rate of flow of
combustion air to the boiler. A forced draft controller signal
indicative of any difference between the total air demand and the
actual airflow is applied to a circuit for controlling a forced
draft fan to adjust the total airflow delivered to the boiler,
which air is divided into primary air supplied to the reduction
zone of the boiler and secondary air supplied to the oxidation
zone. The flow of primary air to the reduction zone is
automatically controlled in response to black liquor and primary
fuel flow rates. The flow of secondary air to the combustion zone
is selected automatically in response to the rate of flow of
primary air. In the event certain boiler operation safety limits
are exceeded, safety circuitry overrides the combustion system to
initiate safety procedures which return the boiler operation to
normal or shut down the boiler.
Inventors: |
Shaw; James Marlin (Gardendale,
AL), Herbst; Roy Roger (Birmingham, AL), Fuller; Fred
Endsley (Birmingham, AL) |
Assignee: |
Rust Engineering Company
(Birmingham, AL)
|
Family
ID: |
25295045 |
Appl.
No.: |
04/845,353 |
Filed: |
July 28, 1969 |
Current U.S.
Class: |
422/111; 422/612;
122/448.1; 236/15BD; 236/15R; 423/DIG.3; 110/193; 236/14; 236/15E;
422/185; 422/201; 423/207; 431/12 |
Current CPC
Class: |
F23G
5/50 (20130101); D21C 11/12 (20130101); F23G
7/04 (20130101); Y10S 423/03 (20130101) |
Current International
Class: |
D21C
11/12 (20060101); F23G 7/04 (20060101); F23G
5/50 (20060101); B01j 006/00 (); C01b 017/22 () |
Field of
Search: |
;23/253,277,262,48
;110/22A ;122/448 ;236/14,15B ;431/12 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Tayman, Jr.; James H.
Claims
What is claimed is:
1. In a unit for recovering chemicals from black liquor, said unit
including a combustion chamber having a plurality of combustion
zones, means for supplying black liquor to a first zone of said
chamber, means including a conduit for supplying auxiliary fuel to
at least one other zone of said chamber, and means provided with
separate conduits for supplying air to each of said zones, the
improvement in said unit which comprises:
means for generating a first signal indicative of black liquor
demand;
means in said auxiliary fuel conduit for generating a second signal
indicative of auxiliary fuel being supplied to said chamber;
means for summing the above two signals to generate a third signal
indicative of the total fuel being supplied to the zones of said
chamber;
means responsive to said third signal for controlling said air
supply means to provide a total air supply in excess of that
required to completely combust the black liquor and the fuel
supplied to said chamber;
flow control means responsive to said first signal for delivering
through a first of said conduits a portion of said total air supply
to maintain a reducing atmosphere in the first of said zones so
that a portion of the black liquor remains unburned; and
means responsive to said flow control means for continuously
delivering through said other conduits the remaining portion of
said total air supply to said other combustion zones.
2. A unit according to claim 1 for recovering chemicals from black
liquor, said unit further including:
means responsive to a reduction of the air flow supplied by said
air supply means for interrupting operation of said black liquor
and auxiliary fuel supply means.
3. A unit according to claim 1 for recovering chemicals from black
liquor, said unit further including:
means responsive to a reduction of the airflow in said other
conduits for interrupting the supply of auxiliary fuel from said
auxiliary fuel supply means to prevent fuel from entering said
chamber in the absence of sufficient air to combust the fuel.
4. A unit for recovering chemicals from black liquor, as recited in
claim 1, in which said unit also comprises, means including a
conduit for supplying auxiliary fuel to said first zone, and which
further comprises:
means in said last recited conduit for generating a fourth signal
indicative of said auxiliary fuel being supplied to the first
zone;
said third signal generated by the summing means being the
summation of said first, second, and fourth signals, and
said flow control means being responsive to said first and fourth
signals.
5. In a chemical process unit for burning black liquor to recover
chemicals, said unit including a chamber having a reduction zone
and an oxidation zone, means for feeding black liquor into said
chamber means for burning auxiliary fuel in said oxidation zone,
and means including a main input line, a first conduit to said
reduction zone and a second conduit to said oxidation zone for
supplying air to said chamber, the improvement in said unit which
comprises:
means for generating a signal indicative of black liquor
demand;
means for comparing said demand signal to the actual flow of black
liquor into said chamber to regulate said black liquor feeding
means;
means in said main input line for generating a signal indicative of
the total air supplied to said chamber;
means responsive to said black liquor demand signal and the actual
flow rate of auxiliary fuel for generating an air demand signal
indicative of the total amount of air necessary to completely
combust said black liquor and auxiliary fuel;
means for comparing said total air signal to said air demand signal
to regulate said air supply means;
air flow control means responsive to said black liquor demand
signal for supplying through said first conduit a first portion of
said total air to said reducing zone to partially combust the black
liquor in said zone; and
means responsive to said air flow control means for continuously
supplying the remainder of said total air through said second
conduit to said oxidation zone to completely combust both said
black liquor and any auxiliary fuel, said remainder being supplied
to said oxidation zone even though no auxiliary fuel is being
burned.
6. A chemical process unit according to claim 5 in which:
said auxiliary fuel burning means includes a plurality of auxiliary
fuel burners each having a wind box for supplying air to said
oxidation zone; and
means are provided for response to a decrease in the air flow in
one of said wind boxes for interrupting the operation of the burner
associated with said one of said wind boxes.
7. A unit for burning black liquor to recover chemicals and produce
heat, said unit including a combustion chamber having a reduction
zone and an oxidation zone, means for supplying primary fuel to
said reduction zone, means for supplying secondary fuel to said
oxidation zone, means for feeding black liquor into said chamber,
and means for supplying air for combustion of the black liquor and
the primary and secondary fuels, the improvement in said unit which
comprises:
means for producing a black liquor demand signal indicative of
desired black liquor flow;
means for comparing said black liquor demand signal to a signal
indicative of actual black liquor flow to control said black liquor
supply means;
means for adding said black liquor demand signal and first and
second signals indicative of the actual primary fuel flow and the
actual secondary fuel flow to produce a total air demand
signal;
air-sensing means responsive to the total actual air flow to said
chamber for producing an actual airflow signal;
first means for comparing said total air demand signal and said
actual airflow signal to generate a signal for controlling said
air-feeding means to supply total air in excess of that required to
completely burn both said fuels and said black liquor;
means for summing said black liquor demand signal and said first
primary fuel signal to produce a primary air demand signal
indicative of the air required to completely combust said primary
fuel and to partially combust said black liquor;
second means for comparing a primary air signal indicative of
actual primary airflow to said primary air demand signal to produce
a primary air control signal;
means responsive to said primary air control signal for
distributing to said reduction zone air to completely combust said
primary fuel and partially combust said black liquor; and
means responsive to said primary air control signal for controlling
the air flow to said oxidation zone to provide excess air in said
oxidation zone to completely burn said primary and secondary fuels
and said black liquor.
8. A unit according to claim 7, in which:
said means for supplying primary fuel includes a primary fuel
header and a plurality of separate primary fuel burners connected
to said header;
said means for supplying air includes a primary air manifold and a
wind box for each of said primary fuel burners;
means are provided for sensing the air flow in said primary
manifold, said sensing means being effective to generate an
override signal in response to reduced airflow in said primary
manifold; and
means are provided for response to said override signal for
interrupting the flow of fuel from said primary fuel header to said
primary fuel burners.
9. A unit according to claim 8, in which:
said means for supplying secondary fuel includes a secondary fuel
header and a plurality of secondary fuel burners connected to said
secondary fuel header; and
means are provided responsive to an interruption in the air flow
from said air supply means for interrupting the flow of fuel in
both said primary and secondary fuel headers and for discontinuing
the operation of said black liquor feeding means.
10. A unit according to claim 7 in which;
said means for supplying primary fuel includes at least one primary
fuel burner which receives fuel from said primary fuel supply
means;
said means for supplying secondary fuel includes at least one
secondary fuel burner which receives fuel from said secondary fuel
supply means;
said first and second signals are generated in response to the
respective flow of primary and secondary fuel in said primary and
secondary burners;
said air supply means includes a fan having an outlet duct spaced
from said combustion chamber;
said air-sensing means is responsive to the air flow in said outlet
duct for producing said actual air flow signal; and
means are provided for delaying said actual airflow signal prior to
application thereof to said first comparing means to synchronize
said actual air flow signal with said total air demand signal.
11. A system for controlling combustion in a black liquor recovery
unit wherein black liquor is burned to recover chemicals therefrom
and to generate heat for producing steam and wherein primary fuel
is burned for burning down a smelt bed and secondary fuel is burned
for increasing the heat output of the unit, the unit including a
combustion chamber having a reduction zone, an oxidation zone and a
bottom for receiving the smelt bed, the unit further including a
primary fuel burner adjacent said reduction zone, a secondary fuel
burner adjacent said oxidation zone, a primary duct for supplying
primary air to said primary burner, at least one additional duct
for supplying air to said secondary burner and to said chamber, a
fan for supplying combustion air to said primary and additional
ducts and means for feeding black liquor to said chamber; said
system comprising:
means for measuring the flow of primary fuel to said primary burner
to generate a first signal;
means for measuring the flow of secondary fuel to said secondary
burner to generate a second signal;
means for generating a third signal in response to black liquor
flow;
means responsive to said first, second and third signals for
generating a fourth signal indicative of the total air demand of
said unit;
means responsive to the total flow of air supplied by said fan for
generating a fifth signal;
means responsive to said fourth and fifth signals for controlling
said fan to provide a total airflow sufficient to satisfy the total
air demand;
means responsive to said first and third signals for generating a
sixth signal indicative of the amount of primary air required to
fully combust the primary fuel and to partially combust the black
liquor;
means responsive to the primary airflow in said primary duct for
generating a seventh signal indicative of actual primary air
flow;
comparison means responsive to said sixth and seventh signals for
controlling the flow of primary air in said primary duct to provide
the primary air required;
means responsive to said comparison means for regulating the flow
of air to said additional duct so that sufficient air is supplied
to said secondary burner and said oxidation zone of said chamber
for completely burning the secondary fuel and the black liquor;
means for producing an eighth signal indicative of the black liquor
demand of said unit; and
black liquor control means responsive to said third and eighth
signals for regulating said feeding means to supply the desired
amount of black liquor to said chamber.
12. A combustion and safety system in accordance with claim 11, in
which;
means are provided responsive to an interruption in the operation
of said fan for generating a safety control signal; and
safety means are provided responsive to said safety control signal
for turning off said primary and secondary fuel burners, said
safety means being effective to override said black liquor control
means for stopping the flow of black liquor to said chamber.
13. A combustion control system according to claim 11, in
which:
said means for generating said fifth signal measures total air flow
at a selected location spaced from said chamber;
said means for generating said first and second signal measure fuel
flow rates adjacent the respective primary and secondary fuel
burners; and
means are provided for delaying said fifth signal to synchronize
said fourth and fifth signals so that the total air flow
measurement will correspond in time to the measurement of the
primary and secondary fuel flow.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a recovery boiler combustion and
safety control system and, more particularly, to a system for
measuring the total amount of fuel supplied to a black liquor
recovery boiler and automatically controlling the total flow of
combustion air to selected zones of the boiler in response to the
amount of fuel measured.
In the production of pulp, wood chips are cooked in a digester with
white liquor. The active chemicals (sodium hydroxide and sodium
sulfide) in the white liquor separate the lignin from the cellulose
in the wood to provide pulp for paper manufacture. The lignin and
spent chemicals form black liquor which is concentrated in an
evaporator and burned in a black liquor recovery boiler. The
operation of the recovery boiler is effective to recover the
chemicals for reuse in the digester and to produce heat for steam
generation purposes. Thus, safe and properly controlled boiler
operation is essential to the operation of a profitable
papermill.
2. Description of the Prior Art
Notwithstanding the importance of recovery boilers in the operation
of papermills, it has been customary in the past to manually
control the critical aspects of recovery boiler combustion. The
problems faced by boiler engineers in manually controlling recovery
boiler operations may be appreciated when it is understood that
recovery boilers are operated under extremely variable conditions.
For example, even when a recovery boiler is operated as a
base-loaded boiler using black liquor as the only fuel, the airflow
and black liquor flow must be adjusted to maintain a relatively
constant steam output because the chemical composition of black
liquor is variable. Moreover, when an auxiliary primary fuel, such
as gas, is burned in the boiler to melt down the smelt bed, the
flow of primary and secondary air must be regulated according to
the amount of both the black liquor and primary gas inputs.
In addition, to increase the steam output of a recovery boiler, a
secondary fuel, such as gas, may be burned in the boiler. This adds
another variable which must be controlled by the engineer.
In the past, the boiler engineer has been assisted by safety
systems which indicate only whether an auxiliary burner is
operating. Thus, the control of the total combustion air and fuel
requirements of the recovery boiler have been dependent upon the
skill and experience of the boiler engineer. Despite the experience
and efforts of boiler engineers to closely control recovery boiler
operation, accidents have resulted from manual operation of
recovery boilers. The frequency and severity of such accidents lead
the Technical Association of The Pulp and Paper Industry to form a
committee to study recovery boiler operations. The committee
determined that 22 recovery boiler explosions which occurred prior
to 1967 were related to problems in firing auxiliary fuel. This
finding indicates that it is not safe to continue to rely upon
manual control of recovery boiler operations.
In attempting to develop other ways of controlling recovery
boilers, it was recognized that combustion controls have been
provided for power boilers. It is clear, however, that the problems
encountered in recovery boiler operation are significantly
different from those in power boilers. Initially, although there
are no physical barriers between the reduction and oxidation zones
of a recovery boiler, the reduction zone must be maintained in a
deficient air condition, whereas an excess air condition must be
maintained in the oxidation zone.
Further, in power boilers, no residual fuel is maintained in the
boiler. On the other hand, the smelt bed which forms in the
recovery boiler is a source of volatile gas which remains in the
boiler after the black liquor has been supplied. Moreover, power
boiler fuels have easily determined properties of combustion,
whereas black liquor is the result of a variable process and is
used in infinite combination with auxiliary fuels.
Because of these differences, it can be understood that power
boiler control techniques have been found to be unsuitable for
solving the problems encountered in operating black liquor recovery
boilers.
SUMMARY OF THE INVENTION
Research conducted in an endeavor to provide an automatic system
for safely controlling the combustion process in a black liquor
recovery boiler, indicates that prior explosion hazards and
operational problems may be minimized by automatically controlling
the operation of a recovery boiler. During boiler operation, the
total fuel input to the recovery boiler (including the black liquor
input) is related to the supply of air to selected zones in the
boiler by adding a black liquor-air demand signal and a gas-air
demand signal to produce a total air demand signal which is
compared to the actual total combustion air flow to the boiler. A
controller is responsive to the difference between the compared
signals for regulating the total amount of combustion air supplied
to the boiler by a forced-draft fan. The fan supplies the total
mount of combustion air to primary and secondary air manifolds.
Black liquor-air demand and primary gas flow signals are added and
applied to a multiplier circuit which generates a signal indicative
of the primary air demand required to maintain a reducing condition
in the reduction zone. The primary air demand signal is compared to
a signal indicative of the actual primary airflow to produce a
primary air control signal which regulates the flow of air from the
primary air manifold to the reduction zone. The primary air control
signal is also fed to a secondary air control selector which
generates a secondary air control signal for regulating the flow of
secondary air from the secondary manifold to the combustion
zone.
Further, the critical boiler conditions are monitored during boiler
operation. In response to abnormal conditions, a safety system is
effective to return the boiler operation to normal or, in an
emergency, to shut down the boiler.
An object of the present invention is to provide a new and improved
black liquor recovery boiler combustion and safety control
system.
A further object of the present invention resides in a system for
controlling the total flow of air and fuel to a black liquor
recovery boiler.
Another object of the present invention is to automatically
maintain a reducing condition in a first zone of a recovery boiler
and an excess air condition in a second zone in accordance with
varying demand for a number of different fuel inputs to the
boiler.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of the present invention may be appreciated
upon reference to the following description of the preferred
embodiment when taken in conjunction with accompanying drawings, in
which:
FIG. 1 is a schematic elevational view of a black liquor recovery
boiler for use with the control system of the present
invention;
FIG. 2 is a chart illustrating the relationship between recovery
boiler startup controls, combustion controls and override controls
of the control system of the present invention; and
FIG. 3 is a schematic diagram of the control system illustrating
selected structural elements of the recovery boiler shown in FIG.
1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings wherein like reference characters are
used throughout to designate like elements, the illustrative and
preferred embodiment of the present invention is shown in FIG. 1
including a chemical recovery unit, such as a boiler 10. The boiler
10 extends vertically from a base 12 for a height of up to 15
stories, for example, and is provided with a reduction zone A at
the lower end thereof and an oxidation zone B spaced upwardly from
the reduction zone A. The zones A and B are in open communication
relative to each other to facilitate the upward flow of products of
combustion to an exhaust stack 14 under the operation of an induced
draft fan 15.
The walls of the boiler 10 are lined with steam generating tubes 16
of a boiler heat exchange system which includes additional heat
exchanger tubes 18 located at the upper end of the boiler 10. A
mixture of steam and water (at saturation temperature for the
particular pressure at which he boiler unit is the flows upwardly
through the tubes 16 and 18 to a header 20. The boiler 10 may be
operated to produce steam at a pressure of 875 lbs. per sq. inch
and superheated to a desired value, such as 825.degree. F. The
steam is supplied from the header 20 to a desired point of use
within the papermill.
In the normal operation of the boiler 10, black liquor which has
been evaporated in the Kraft process to a desired density (such as
a 50-65 percent solids content), is sprayed into the boiler 10
through nozzles 22 at a suitable pressure and temperature. Most of
the sprayed liquor particles fall to the bottom 24 of the boiler 10
in counterflow to the products of combustion rising from the
reduction zone A. The falling particles are dried and form a pile
or smelt bed 26. Preheated primary air is supplied to the reduction
zone A through primary wind boxes 28 in amounts sufficient to
produce a reducing atmosphere or condition therein. The residual
chemicals from the black liquor flow through a spout 30 to a
receiving tank 32 for reuse in the Kraft process. The combustible
materials in the products of combustion which rise from the smelt
bed 26 are burned with preheated secondary air which is supplied to
the boiler 10 through secondary wind boxes 34. The temperature in
the reduction zone A is generally in the range of 2,1000
-2,200.degree. F., whereas the products of combustion leave the
combustion zone B at about 1,700.degree. F.
The total flow of combustion air to the boiler 10 is provided by a
forced draft fan 36 having vanes 38 which are effective to vary the
total air flow at constant blower speed. The fan 36 supplies
combustion air through a duct 40 to a primary air manifold 42 and a
secondary air manifold 44. The flow of primary air to the primary
wind boxes 28 is controlled by vanes 46 in the manifold 42, whereas
the flow of secondary air to the wind boxes 34 is controlled by
vanes 48.
In the operation of the boiler 10 under normal conditions, black
liquor is the only fuel supplied to the boiler 10. However, when
the boiler is started up, auxiliary fuel is supplied through a
nozzle 50 of primary burners 52 and is burned in the boiler 10. For
purposes of illustration, the auxiliary fuel described herein will
be gas, but it should be understood that other fuel, such as fuel
oil, may be used as the auxiliary fuel. After the burning primary
gas has initiated combustion of the black liquor, the gas supply is
shut off. During the burning of the primary gas, primary air is
supplied to the reduction zone A through the primary wind boxes 28
for complete combustion of the primary gas.
In the event the demand for steam exceeds that which can be
supplied by burning the available black liquor, auxiliary fuel,
such as secondary gas or fuel oil, is supplied to nozzles 54 of
secondary burners 56. Secondary air sufficient to complete the
combustion of the secondary gas is supplied through the secondary
manifold 44.
In the past, the supply of black liquor, primary and secondary
fuels and air has been controlled manually. However, such manual
control has often been unsatisfactory, especially when auxiliary
fuels are burned in conjunction with the black liquor. In
particular, 22 black liquor recovery boiler explosions have been
attributed to problems in manually controlling such boilers during
auxiliary fuel burning. Accordingly, the present system for
automatically controlling recovery boiler operation makes it
possible to minimize the conditions which have in the past
contributed to such explosions.
Referring now in general to FIG. 2, the system of the present
invention is shown including a boiler startup circuit 60 which
includes a series of circuits which are responsive to certain
initial conditions in the boiler 10. Completion of the startup
circuit 60 initiates a boiler purge cycle controller 62. The purge
cycle places the zones A and B in condition for operation of the
primary burners 52, whereupon the primary burners 52 are ignited by
a starter 64. The primary burners 52 are effective to heat the
boiler 10 and to initiate sustained ignition of black liquor which
is sprayed into the boiler 10 from the nozzles 22. A primary burner
check circuit 66 is responsive to the establishment of burner flame
at the primary burners 52 to permit continued flow of black liquor
and primary gas under the control of a combustion control system 70
shown in detail in FIG. 3.
The system 70 controls the operation of the boiler 10 and is
responsive to a burner override circuit 72 which monitors the
operation of the individual burners 52 and 56. The system 70 is
also responsive to an emergency protection circuit 74 to effect
boiler shutdown.
Referring now in detail to FIG. 2, the boiler startup circuit 60 is
shown including a check circuit 76 which is completed in response
to selected boiler precipitator and evaporator temperatures, for
example. In response to the completion of the circuit 76, a circuit
78 is energized for starting the induced draft fan 15. The fan 15
is effective to produce a desired pressure, such as 2 inches W.G.,
in the boiler 10. In response to such pressure, a circuit 80
energizes a circuit 82 to initiate operation of the forced draft
fan 36. The circuit the circuit 82 renders the purge cycle
controller circuit 62 effective. The circuit 62 is completed in
response to 60 The circuit percent primary air flow in the primary
manifold 42 and, for example, the sensing of predetermined pressure
in gas headers 88 and 89 (FIG. 3) which supply gas to the burners
52 and 56. The completed circuit 62 initiates a purge cycle for a
selected time period, such as 5 minutes, so that no volatile gases
or other fuel remains in the boiler 10.
At the end of the purge cycle, the circuit 62 initiates operation
of the starter 64 and the primary burner check circuit 66. In the
event burner flames are not established within a selected time
period, such as 6 minutes, the check circuit 66 is effective to
interrupt the flow of primary gas by closing a primary gas header
valve 84 and a secondary gas header valve 86 (see FIG. 3). Further,
the check circuit 66 recycles the purge cycle controller circuit 62
to require a complete purge cycle before the primary burners 52 are
reignited.
In the event burner flames are established at the primary burners
52 within the 6-minute time period, the check circuit 66 is
satisfied and permits operation of the boiler 10 under the control
of the system 70.
Referring now in detail to FIG. 3, when the boiler 10 has reached a
temperature sufficient to initiate ignition of black liquor, a
black liquor pump 90 is started to supply black liquor to the
nozzles 22. As soon as sustained ignition of the black liquor
occurs, the flow of primary gas may be discontinued for operation
of the boiler 10 with black liquor as the only fuel.
In the system shown in FIG. 3, the steam demand of the paper mill
is used to set a black liquor flow demand controller 100 which
generates a black liquor demand signal 102 which is indicative of
the flow of black liquor required to meet the steam demand of the
papermill. The signal 102 is applied to a first comparison circuit
104 which compares the signal 102 and a signal 106 which is
indicative of the actual black liquor flow rate through the nozzles
22. The magnetic field in a flow meter 108 is varied according to
the velocity of black liquor there through to generate the signal
106. The signal 106 from the flow meter 108 may be in millivolts or
the corresponding milliampere value for application to the
comparison circuit 104.
The comparison circuit 104 may be an integral operational amplifier
having a potentiometer (not shown) in the signal 106 input circuit
to provide gain and reset rate based upon boiler response so that
the control system 70 is stable. The circuit 104 compares the
signals 102 and 106 to produce a black liquor flow control signal
110 which is used to control the flow rate of black liquor, such as
by positioning a valve (not shown) or by regulating the black
liquor pump 90. The signal 110 is applied across an interlock
switch 112 which is connected to the burner override circuit
72.
The black liquor demand signal 102 is also applied to a first
summing circuit 120. An orifice plate 122 is provided upstream from
the primary gas nozzles 50 to produce a primary gas flow signal 124
which, after processing in a standard manner, is indicative of and
varies linearly with primary gas flow to the nozzles 50.
The summing circuit 120 algebraically adds the signals 102 and 124
and produces a primary fuel demand signal 126 which is applied to a
multiplier circuit 128. The multiplier circuit 128 has a manually
adjustable gain which can be set according to the applicable
fuel-to-air ratio to produce a primary air demand signal 130 which
is indicative of the amount of air required to completely burn the
primary gas and to partially burn the black liquor.
The primary air demand signal 130 and a signal 132 indicative of
the actual flow of primary air are compared by a second comparison
circuit 134. The signal 132 is generated by a flow sensor which
includes an orifice plate 136 mounted in the primary manifold 42
downstream from the vanes 46. The flow sensor also includes
standard circuitry to produce the signal 132 linearly with respect
to the flow of primary air.
The circuit 134 generates a primary air control signal 136 which is
converted to linear motion by a transducer 138 to adjust the
position of the vanes 46 so that the desired amount of primary air
is supplied to the primary wind boxes 28.
Because the reduction zone A is supplied with less air than is
required for complete combustion of the black liquor, excess air is
supplied to the combustion zone B under the control of the primary
air control signal 136. In particular, in response to the signal
136, a bias selector circuit 140 generates a secondary air signal
142 which is converted to linear motion by a transducer 144 to
adjust the vanes 48 at the entry to the secondary wind boxes 34 to
supply excess air to the combustion zone B. The bias selector
circuit 140 may be adjusted to vary the ratio of primary to
secondary air in accordance with desired changes in the amount of
excess air, for example.
The total airflow to the boiler 10 from the forced draft fan 36 is
determined in response to the total amount of fuel supplied to the
boiler 10. Thus, the primary gas flow signal 124 and a signal 150
indicative of the flow rate of secondary gas from the secondary
burners 56 are applied to a second summing circuit 152 to develop a
signal 154 representing the total gas flow. The signal 150 is
generated in the same manner as the signal 124 by a flow rate
sensor having orifice plates 156 so that the signal 150 varies
linearly with secondary gas flow.
A multiplier circuit 158 converts the total gas flow signal 154 to
a signal 160 corresponding to the air demand for complete primary
and secondary combustion. The signal 160 and the black liquor
demand signal 102 are added by a third summing circuit 162 to
generate a signal 164 which is indicative of the total air demand
of the boiler 10.
The actual airflow provided by the forced draft fan 36 is sensed by
a flow rate sensor having an orifice plate 170 so that a signal 172
which varies linearly with total air flow is produced. Because the
orifice plate 170 is mounted in the duct 40 upstream from the
location of the orifice plates 122 and 136, the signal 172 is
applied to a time delay circuit 174 to delay the signal 172 to
account for the time difference between taking the gas and air flow
measurements. The delayed signal 172 is applied to a comparator
circuit 176 along with the signal 164. The comparator circuit 176
is similar to the circuit 104 and responds to the difference
between the signals 164 and 172 to produce a control signal 178
which operates a total airflow regulator 180. The regulator 180
operates a transducer 182 to adjust the vanes 38 of the fan 36 to
provide the required total air demand to the boiler 10.
Still referring to FIG. 3, it may be understood that under normal
operating conditions, the system 70 will regulate the process of
combustion in the boiler 10 by relating the total fuel input to the
boiler to the total air demand. In the event, however, that a
failure occurs in equipment which is critical to the safe operation
of the boiler 10, the burner override circuit 72 will sense the
failure and initiate protective action. In particular, if during
the operation of the primary burners 52 there is a loss of primary
air pressure in the manifold 42, a sensor 200 senses this condition
and energizes a primary burner protection circuit 202 which is
effective to close a valve 84 in the primary gas header 88. Closure
of the valve 84 interrupts the flow of primary gas to all of the
primary burners 52 to avoid the accumulation in the boiler 10 of
unburned gas. The system 70 responds to the interruption of primary
gas flow by reducing the amplitude of the primary fuel demand
signal 126 and reducing the total airflow to the boiler 10.
As shown in FIG. 3, the circuit 72 includes secondary burner
protection in the form of sensors 208 mounted on each secondary
wind box 34. In the event the pressure is lost in a particular wind
box 34, the adjacent sensor 208 energizes a burner control circuit
210 which is effective to close a secondary burner valve 212
associated with the burner 56 in the particular wind box 34 which
lost air pressure. The orifice plate 156 in the respective burner
56 responds accordingly and initiates combustion control changes in
the system 70.
The secondary burner protection also includes a switch 218 which is
responsive to a closed position of the vanes 48 upstream from the
secondary wind boxes 34. Upon actuation, the switch renders the
circuit 210 effective to close the secondary gas header valve 86 to
interrupt secondary gas flow to all of the burners 56. As described
above, the orifice plates 156 in all of the burners 56 respond to
the interruption of secondary gas flow and initiate required
combustion control changes in the system 70.
The burner override circuit 72 is also effective to sense the loss
of power to the induced draft fan 15. As shown in FIG. 2, in
response to this condition, the circuit 72 renders the forced draft
fan control circuit 82 effective to shut down the forced draft fan
36. Referring again to FIG. 3, the shutting down of the forced
draft fan 36 renders a fuel control circuit 222 effective to close
the primary gas header valve 84, a secondary gas header valve 220,
and a main header valve (not shown) to interrupt the flow of gas to
the boiler 10. Further, the circuit 222 opens the interlock switch
112 to interrupt operation of the black liquor pump 90.
Accordingly, in the event either or both the forced draft fan 36
and the induced draft fan 15 become ineffective, the circuit 72
will prevent the continued supply of fuel to the boiler 10.
When the forced draft fan 36 becomes inoperative such that there is
a loss of air pressure in the duct 40, a sensor 230 is effective to
render the circuit 222 effective to close the valves 84 and 220 and
the main header valve and to open the switch 112.
As described above, the burner protection override circuit 72
automatically initiates certain safety operations. On the other
hand, the emergency protection override circuit 74 may be manually
operated in the event an emergency condition develops. Upon
actuation of the circuit 74 by a push button, for example, the
circuit 74 is effective to open the switch 112 to stop the black
liquor flow to the nozzles 22. Further, gas flow is interrupted,
for example, by energizing the circuit 222 which closes valves 84
and 220. To exhaust combustible materials from the boiler 10, the
circuit 74 also renders the induced draft fan circuit 78 effective
to operate the induced draft fan 15 at minimum speed.
The circuit 74 also prevents fresh air from entering the boiler by
closing the primary air vents 46 and the secondary air vents 48
through the operation of an interlock 240. Also, the forced draft
fan 36 is shut down by the circuit 74 through a signal which is
applied to the circuit 82.
As a result of the emergency operations controlled by the circuit
74, the introduction into the boiler 10 of combustible materials
(air, gas and black liquor) is discontinued and products of
combustion which may be produced by the smelt bed 26 are removed
from the boiler 10 by the induced draft fan 15.
It is to be understood that the above-described arrangements are
simply illustrative of the application of the principles of this
invention. Numerous other arrangements may be readily devised by
those skilled in the art which will embody the principles of the
invention and fall within the spirit and scope thereof.
* * * * *