Steam Header Optimization
Header pressure control and boiler load master, reduces header variability, stabilises whole plant
Process Control
Technology description
SmartProcess™ Header
Emerson’s SmartProcess Header is a product used to automatically control and optimize the operation of a Steam Distribution System, coordinating control of all steam headers.
It enables:
- prioritization of the headers and maximizes steam to turbines if they are present
- control of the link between the users of heat (processes) and the heat input devices (Recovery, Power and/or HRSG Boilers), in order for steam headers to equalize at a state that is optimal
- cost effective electrical/steam balance.
Key features
- The inter-header pressure reducing stations (PRS) and steam vent losses are minimized.
- The internal power generation is maximized.
- Supply of steam as the process demands is maintained.
- Localised header pressure changes and equalization delays are minimized.
- Entire heat balance rather than individual header balance.
Application fields
- Best suited to plants with multiple boilers and steam headers but can also be applied with good results to plants with multiple boilers feeding just one header
- Steam headers
Business case
Calculated business case
Assuming a 5% increase in internal power generation is achieved (as per section 11 of this document) on a typical MCPD size plant with 30 MW of electrical power generation available, the power increase would be 1.5MW. Assuming cost of electrical power import is 60 EUR/MWH, this equates to a potential sustainable financial benefit of 90 EUR/h or 2160 EUR/day or ~ 65K EUR/month or ~ 750K EUR/year).
CO2 impact / Energy cost reduction
- Typically 5%-20% energy cost reduction in let down and vented steam coupled with a 5% increase in internal power generation
Non-energy benefits
- Increased tolerance to plant upsets maintaining overall process production levels
- Reducing operator effort particularly in response to plant upset
Technology deployed by
Recent European References where Smart Process Header Optimisation has been applied:
- TATA Steel, Port Talbot – 3 steam headers
- British Steel, Scunthorpe – 2 steam headers
- Valero, Pembroke Refinery – 2 steam headers
- Visko Teepak, Lommel – 1 steam header (start-up due in June 2020)
Please contact Emerson Process Management for more information.
