A Multivariate Analysis of Fouling

in Kraft Recovery Boilers

Peter Versteeg
Honghi Tran
2007 Annual Research Review Meeting on
“INCREASING ENERGY AND CHEMICAL RECOVERY EFFICIENCY IN THE KRAFT PROCESS”
and “ALTERNATIVE FUELS FOR LIME KILNS”
November 6 - 8, 2007
University of Toronto
Recovery Boiler A

• CE unit overhauled
in 1990 by B&W
• 3.5 million lbs dry
solids/day
• 550,000 lb/hr steam
at 900 psig and
830°F

2
Flue Gas

3
Principal Component Analysis
Black Liquor
Temperature

Black
Liquor
Solids

Black Liquor
4
Flow Rate
Principal Component Analysis
Black Liquor
Temperature

PC #1

Black
Liquor
Solids

Black Liquor
5
Flow Rate
Principal Component Analysis
Black Liquor
Temperature

PC #1

Black
Liquor
Solids
PC #2
Black Liquor
6
Flow Rate
 Variables Collected
Black Liquor Steam
• Firing Load • Flow Rate
• Solids • Temperature
• Pressure • Pressure
• Composition • Enthalpy
Air Boiler Bank
• Flow Rates • Drafts
• Temperatures • Temperatures
Feedwater Economizer
• Flow Rate • Drafts
• Temperature • Temperatures
Sootblowing Steam Flow
SO2 Concentration
ID Fan Speed
TRS Concentration
Excess O2 7
 2002 – 2005 Daily Average Data
(Shutdowns Removed)
I II

IV III

N = 1263 points
8
 Colored By BL Flow Rate

I II

IV III

325 - 350 USGPM

275 - 325 USGPM 9
200 - 275 USGPM
Colored By Final Steam Flowrate

I II

IV III

325 - 475 klb/hr

475 - 575 klb/hr 10
575 - 625 klb/hr
 Colored By Boiler Bank Outlet
Flue Gas Temperature

I II

IV III

600 - 690 °F
690 - 750 °F 11
750 - 780 °F
 RB A Daily Average Data – All Data
(Shutdowns Removed)
I II High

Energy
Transfer

IV III Low

Low RB Firing Operation Type High RB Firing

12
 Daily Average Data – High Fouling
vs. Low Fouling Periods
I II High

Energy
Transfer

IV III Low

Low RB Firing Operation Type High RB Firing

High Fouling Period ~ 5 months, 3 cleanings
13
Low Fouling Period ~7 months, 1 cleanings
Contributions
SD’s from SD’s from
Dataset Average Dataset Average

Low Fouling High Fouling 14

Period Period
 Partial Least Squares
Regression
Inputs Outputs
BL BL BL Boiler Boiler Economizer
Flow Solids Temp Bank Bank Outlet Temp
Rate Inlet Outlet
Temp Temp
Day 1 Day 1

Day 2 Day 2

Day 3 Day 3

15
 Inputs Outputs
BL Temperature
Y Actual
PC #1

BL Solids
Y Predicted
PC #2
BL Flow
Rate

16
 Key Variables
Inputs Outputs
Black Liquor Steam
• Firing Load • Flow Rate
• Solids • Temperature
• Pressure • Pressure
• Composition • Enthalpy
Air Boiler Bank
• Flow Rates • Drafts
• Temperatures • Temperatures
Economizer
TRS Concentration
• Drafts
SO2 Concentration • Temperatures
Feedwater
Sootblowing Steam Flow • Flow Rate
• Temperature
17
Excess O2 ID Fan Speed
Actual Final Steam Flow Rate Final Steam Flow Rate

y = 0.99*x+0.93
R2 = 0.90

Predicted Final Steam Flow Rate 18

RB A Black Liquor Properties
Final Steam Steam Boiler Bank
Flow Rate Enthalpy Outlet Temp ID Fan
(Q2 = 0.90) (Q2 = 0.91) (Q2 = 0.66) (Q2 = 0.79)
BL Flow
+++++ +++++ +++++ +++++
Rate
BL Solids ++++ +++ --
BL Temp
BL
-- -- ---
Pressure
BL Cl

19
 RB A Daily Average Data – BL Solids
(Shutdowns Removed)
I II High

Energy
Transfer

IV III Low

Low RB Firing Operation Type High RB Firing

72.5 – 76.8 %
70.3 - 72.5 %
20
52.8 - 70.3 %
#2 RB Air Properties (Flow, Temp)
Final Steam Steam Boiler Bank
Flow Rate Enthalpy Outlet Temp ID Fan
(Q2 = 0.90) (Q2 = 0.91) (Q2 = 0.66) (Q2 = 0.79)
AF Total ++++ ++++ +++ ++++
AF Prim. -- -- --
AF Sec. +++ ++ ++
AF Tert. +++++ +++++ ++++ +++++
AT Prim. - --
AT Sec. ++++
AT Tert. +

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#2 RB Sootblowing Steam Flow
Final Steam Steam Boiler Bank
Flow Rate Enthalpy Outlet Temp ID Fan
(Q2 = 0.90) (Q2 = 0.91) (Q2 = 0.66) (Q2 = 0.79)
North +++ ++++
South

22
 #2 RB Additional Variables
Final Steam Steam Boiler Bank
Flow Rate Enthalpy Outlet Temp ID Fan
(Q2 = 0.90) (Q2 = 0.91) (Q2 = 0.66) (Q2 = 0.79)
Excess O2 ----- ----- ---- ---
TRS + + ++ +++
SO2 -- -- +++
Green
Liquor + + ++ +++
Flow
White
Liquor -- -- ++++ ++
Sulfidity
Saltcake Cl -- --

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Additional Results and Conclusions

• Results are boiler dependant

• PCA
– Identify the variability due to fouling
– Process Monitoring and Comparing
Periods
• PLS
– Determining specific variables that are
likely causes of fouling

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 Implementation
• Prosensus
– Builds On-line PCA and PLS models in
many industries
– Software and Equipment

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RB A (58 Day Run)

High

Energy
Transfer

Low

26
RB B (65 Day Run)

High

Energy
Transfer

Low

27
RB C (52 Day Run)

High

Energy
Transfer

Low

28
 Acknowledgements

• Val Deleo
• John Andrew

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