Project reference: UPM Schongau

Optimization of the fluidized bed boiler HKW 2

The challenge

The manual operation of the fluidized bed boiler CHP 2 led to numerous operator interventions and an uneven boiler output due to fluctuating fuel qualities.

Objective

The aim of the project was to implement an intelligent, higher-level fire power control (FPC) system to stabilize operation, reduce emissions and relieve the plant operators.

Approach:
A preliminary study (pre-check) has identified annual optimization potential of at least €240,000 through the use of a modern Advanced Process Control (APC) concept. The EPOC® Suite was selected as a customized solution for control optimization.

Advantages of the EPOC® Suite

Smoothing of boiler output and avoidance of load drops.

Increased automation with reduced manual intervention.

Optimization of fuel flexibility and stabilization of steam management.

Compliance with emission limits for CO and NOx.

Increased efficiency through reduced gas consumption, caking and cleaning downtime.

Implementation

Project phases

Pre-Check: Initial assessment of potential and coordination of objectives.

Potential study:
Detailed analysis and concept development of FPC.

Implementation:
Engineering, delivery, commissioning and adjustment of the FPC using the EPOC® Boiler module.

Completion:
The implementation of the EPOC® Suite marks a significant step toward stable, low-emission and economically optimized boiler opteration. The long-term cooperation offers additional potential for further optimization, particularly in fuel management.

Results

Significant increase in steam production

More renewable electricity

Less natural gas

CO2-savings

Additional revenue

No negative impact on emissions

The use of the EPOC® Suite supports:

Even combustion, constant firebox temperatures

Dynamic adaption to changing fuel compositions

Maximizing steam producion

Minimization of gas consumption in CHP 2

Reduction of boiler scale deposits

Miximizing travel time through precise firing

Permantent compliance with legal emission limits

Increasec degree of automation, minimization of manual intervention

UPM GmbH, Schongau; ca. 400 Mitarbeiter

EPOC® Boiler

Diagramm Dampfmenge EPOC Conenga Group

Vergleich Dampfmengenschwankungen, Mehrproduktion

EPOC Monitoring

Customer testimonial

“The potential for optimizing control technology in process plants often remains untapped. With the EPOC® Suite and the in-depth know-how of CONENGA’s experts in the field of “Model Predictive Control”, we have seized this potential in our fluidized bed power plant and can look forward to significant CO2savings and an increase in the amount of live steam.”