<p>Heat and power stations are often in need of optimizations. A simulation model is a tool for findingways to optimize the plant. The scope of this diploma work is to develop a simulation model ofBoiler 5 at Mälarenergi AB. Boiler 5 is a circulated fluidized bed boiler that was taken into service inyear 2001. Among the included parts in the boiler are cyclone, convection part andINTREX-chambers. The software that was used for the simulation was SimTech’s IPSEpro. IPSEprois a heat and mass balance software for steady state calculations. The program comes with a set ofmodules in a library called APP_lib which contains modules such as preaheaters, pump, boiler andturbine stages. The user can however design own modules in the Model Development Kit, since thelibrary code is open source. The development of the simulation model started with an updating of anold model from year 2003. Values provided from Foster Wheeler where then used to make the modelcalculate in a right way. Thereafter some calculations of the super heaters’ heat transfer coefficientswere made. The coefficients were then translated into IPSEpro’s own programming language ModelDescription Language, and were put into the model’s modules. The results were compared with realvalues from the plant’s system. It showed that the calculated values needed more investigations to bemore accurate. The conclusion was that the final model needs more equations to describe the plant in amore realistic way.</p>

Heat and power stations are often in need of optimizations. A simulation model is a tool for findingways to optimize the plant. The scope of this diploma work is to develop a simulation model ofBoiler 5 at Mälarenergi AB. Boiler 5 is a circulated fluidized bed boiler that was taken into service inyear 2001. Among the included parts in the boiler are cyclone, convection part andINTREX-chambers. The software that was used for the simulation was SimTech’s IPSEpro. IPSEprois a heat and mass balance software for steady state calculations. The program comes with a set ofmodules in a library called APP_lib which contains modules such as preaheaters, pump, boiler andturbine stages. The user can however design own modules in the Model Development Kit, since thelibrary code is open source. The development of the simulation model started with an updating of anold model from year 2003. Values provided from Foster Wheeler where then used to make the modelcalculate in a right way. Thereafter some calculations of the super heaters’ heat transfer coefficientswere made. The coefficients were then translated into IPSEpro’s own programming language ModelDescription Language, and were put into the model’s modules. The results were compared with realvalues from the plant’s system. It showed that the calculated values needed more investigations to bemore accurate. The conclusion was that the final model needs more equations to describe the plant in amore realistic way.

Bibliography: p. 61. / Issued also as a Master of Science thesis in the Dept. of Electrical Engineering, 1968. / M.I.T. Project DSR 70054. Research Grant NSFC-472.

Superheaters suffer large material loss during combustion of waste and biomass, causing a short life time for these expensive components. During combustion, corrosive ash particles are formed and erosion is caused by circulating bed material and sand particles, all contributing to the material loss. This study examines whether corrosion or erosion has the largest effect on this material loss by investigating two superheaters in loop seal during biomass and waste combustion of an 85 MW, Circulating Fluidized Bed (CFB) boiler in Händelö. The samples were investigated by SEM/EDX and XRD with regard to material loss and corrosion products. The superheaters have different thermal conditions since the material temperature in the first superheater that the steam passes is lower than in the one that comes after. In this report, a model to determine the tube temperature in steam boiler superheaters is also described due to the fact that the local tube temperature is of great importance of condensation of corrosive gases such as KCl and NaCl. Material loss was significantly greater on the cooler superheater compared with the warmer. The material temperatures on the outside of the tubes, were calculated to be about 574 °C for the cooler superheater and about 617°C for the warmer superheater. Overall, all analyzes showed low levels of corrosive substances, although there was a certain corrosion tendency, which indicates that material loss of the superheaters is caused by corrosion-assisted erosion. Lower material temperature of the superheater resulted in a higher degree of condensation of corrosive species such as alkali chlorides, which might have accelerated the erosion. The conclusion is that the dominant mechanism of material loss on the superheaters is erosion.

The focus of this thesis is the development and implementation of a neural network model predictive controller to be used for controlling the integrated recycle heat exchanger (Intrex) in a 300MW circulating fluidized bed (CFB) boiler. Discussion of the development of the controller will include data collection and preprocessing, controller design and controller tuning. The controller will be programmed directly into the plant distributed control system (DCS) and does not require the continuous use of any third party software. The intrexes serve as the loop seal in the CFB as well as intermediate and finishing superheaters. Heat is transferred to the steam in the intrex superheaters from the circulating ash which can vary in consistency, quantity and quality. Fuel composition can have a large impact on the ash quality and in turn, on intrex performance. Variations in MW load and airflow settings will also impact intrex performance due to their impact on the quantity of ash circulating in the CFB. Insufficient intrex heat transfer will result in low main steam temperature while excessive heat transfer will result in high superheat attemperator sprays and/or loss of unit efficiency. This controller will automatically adjust to optimize intrex ash flow to compensate for changes in the other ash properties by controlling intrex air flows. The controller will allow the operator to enter a target intrex steam temperature increase which will cause all of the intrex air flows to adjust simultaneously to achieve the target temperature. The result will be stable main steam temperature and in turn stable and reliable operation of the CFB.