Boiler Optimization

SmartProcess® Boiler Solution

Emerson’s SmartProcess Boiler is a product used to optimize multi-fuel power boiler processes by increasing the efficiency of the boiler and maximizing the amount of steam produced through burning of least cost fuel (typically waste/alternate fuels such as biomass or off-gases). The SmartProcess Boiler solution provides automatic control for the complete boiler at all times including start-up, and the system allows a multi-fuel boiler to be used as a swing boiler while burning least cost fuel.

1. Makes automatic adjustments to the boiler process to compensate for changing alternate fuel availability and varying fuel caloric value.
2. Provides operators with greatly simplified interface to the boiler process.
3. Automates many functions that are often done manually.
4. Emerson installs mechanical improvements to multi-fuel boiler processes when shortcomings that restrict operation are identified.
5. The objectives of Emerson’s process control and optimization efforts:

• • Burn all available waste gasses, and maximize alternate fuel streams
  • Follow steam load changes while maximizing waste or alternate fuel use
  • Hold Excess Oxygen at 3.0 to 3.5% to maximize efficiency
  • Produce steam at MCR while maintaining emissions within permitted levels
  • Operate boiler in automatic control over 95% of time.

• Companies with sites that have multiple fuels and/or waste gasses gain most benefit from the Smart Process Boiler Solution.
• All industrial boilers.

• Empirical – Reno de Medici with ROI less than 2 years.
• Empirical – TATA Steel Port Talbot.

• Energy cost reduction typically between 1%-3% of boiler fuel costs.

• Giving operators more time to manage the process instead of fighting it.
• Additional functionality such as automatic warm up which in turn leads to a more reliable plant.

Recent European References where Smart Process Boiler has been applied:

• TATA Steel, Port Talbot – 7 boilers, 4 fuels
• Reno De Medici, Blendecques – 1 boiler, 1 fuel
• British Steel, Scunthorpe – 6 boilers, 3 fuels
• Valero, Pembroke Refinery – 7 boilers, 2 fuels
• Agropolychim, Devnya – 2 boilers, 1 fuel (2nd fuel due to be added in 2020)
• Visko Teepak, Lommel – 2 boilers, 2 fuels (start-up due in June 2020)

Please contact Emerson Process Management for more information.