Advanced Cogeneration controls design and implementation using a first-principles simulator, 2016 Pulping, Engineering, Environmental, Recycling, Sustainability (PEERS) Conference Proceedings
In a quest for energy efficiency, steam header systems have been modified making cogeneration processes increasingly complex and harder to operate. Advanced Process Controls (APC) is usually the solution for improving steam plant runnability and maximizing overall plant profitability. However, commissioning of an APC package on a steam system is risky and the long-term maintenance of these packages is so cumbersome that most APC are eventually turned off after just a few year of operation. This paper shows how first-principle simulations are now used to reduce commissioning risk and improve the long term operation of an APC package. The paper will also present recent APC project results where simulators were used to test the logic, tune the controllers and train the operation team. In these projects, the “virtual steam plant” approach allowed the new APC logic to be commissioned with no production losses and with the expected long-term profitability improvement.
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