# US 2014/0196639 A1 · System and method for controlling one or more process parameters associated with a combustion process

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- Number: US 2014/0196639 A1
- Document ID: US20140196639A1
- Status: Published application
- Kind: A1
- Application number: 13/837,221
- Filed: 2013-03-15
- Published: 2014-07-17
- Earliest claimed: 2013-01-14
- Assignees: Babcock & Wilcox Power Generation Group, Inc.
- Applicants: Babcock & Wilcox Power Generation Group, Inc.
- Inventors: Daniel B. Johnson; Shannon R. Brown
- Web page: https://patentgrep.com/patent/US20140196639A1

## CPC

- F23J 15/02: of purifiers, e.g. for removing noxious material (traps for solid residues F23J3/04)
- B01D 53/346: {Controlling the process}
- B01D 53/504: {characterised by a specific device}
- B03C 3/013: Conditioning by chemical additives, e.g. with SO3
- B03C 3/017: Combinations of electrostatic separation with other processes, not otherwise provided for
- B03C 3/68: Control systems therefor {(electricity supply or control systems for cleaning the electrodes B03C3/746, B03C3/763)}
- B01D 53/8631: {Processes characterised by a specific device}
- B01D 2251/2062: Ammonia
- B01D 2251/404: of calcium
- B01D 2258/0283: Flue gases
- B03C 2201/24: for measuring or calculating of parameters, e.g. efficiency
- F23J 2215/20: Sulfur; Compounds thereof
- F23J 2219/40: Sorption with wet devices, e.g. scrubbers
- G01N 1/22: in the gaseous state {(specially adapted for biological material G01N33/497; measuring breath flow A61B5/087)}
- G01N 31/005: {investigating the presence of an element by oxidation (G01N31/12 takes precedence)}
- G01N 31/12: using combustion (G01N25/20 takes precedence)
- G01N 33/1846: {Total carbon analysis}
- F23J: REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES (combustion apparatus for consuming smoke or fumes, e.g. exhaust gases, F23G7/06)
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- B03C: MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS (separating isotopes B01D59/00; combinations of magnetic or electrostatic separation with separation of solids by other means B03B, B07B)
- G01N: INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES (measuring or testing apparatus or processes other than immunoassay, involving enzymes or microorganisms C12M, C12Q)

## Abstract

The present invention relates generally to the generation of steam via the use of a combustion process to produce heat and, in one embodiment, to a device, system and/or method that enables one to control one or more process parameters of a combustion process so as to yield at least one desirable change in at least one downstream parameter. In one embodiment, the present invention is directed to a system and/or method for controlling at least one process parameter of a combustion process so as to yield at least one desirable change in at least one downstream process parameter associated with one or more of a wet flue gas desulfurization (WFGD) unit, a particulate collection device and/or control of additives thereto and/or a nitrogen oxide control device and/or control of additives thereto and/or additives to the system.

## Claims

### Claim 1

A method for optimizing a wet flue gas desulfurization unit, the method comprising the steps of:
(I) measuring, analyzing and/or controlling at least one parameter selected from:
(a) the type and/or amount of fuel to be combusted in the combustion process;
(b) the oxidation air flow rate to the combustion process;
(c) the ammonia slip across the selective catalytic reduction unit;
(d) the nitrogen oxide output from a selective catalytic reduction unit;
(e) the particulate control and/or capture device;
(f) the mercury speciation in the flue gas and/or absorber tank;
(g) the selenium speciation in the flue gas and/or absorber tank;
(h) the chemistry in the flue gas and/or absorber tank of the WFGD;
(i) the oxidation reduction potential of the absorber tank of the WFGD;
(j) the amount of the suspended solids in the absorber tank of the wet flue gas desulfurization unit;
(k) the analysis of the limestone and/or lime utilized in the wet flue gas desulfurization unit;
(l) the amount of various reagents supplied to the wet flue gas desulfurization unit tower;
(m) the SO2 concentration at the flue gas inlet of the wet flue gas desulfurization unit;
(n) the inlet opacity of the wet flue gas desulfurization unit;
(o) the PI data from the wet flue gas desulfurization unit;
(p) the amount of dissolved solids in the wet flue gas desulfurization unit; and/or
(q) the relative saturation of the gypsum crystals in the wet flue gas desulfurization unit;
(II) generating data from the at least one parameter of Step (I);
(III) using the data generated in Step (II) to adjust at least one operational parameter selected from:
(A) the operational wet flue gas desulfurization unit tower level;
(B) the reagent feed flow to the wet flue gas desulfurization unit;
(C) the oxidation air flow to the wet flue gas desulfurization unit;
(D) the rate of absorber bleed from the wet flue gas desulfurization unit;
(E) the liquid to gas ratio in the wet flue gas desulfurization unit tower;
(F) the number of operating absorber recycle pumps in the wet flue gas desulfurization unit;
(G) the dewatering operation parameters;
(H) the ammonia feed rate to the selective catalytic reduction unit;
(I) the gypsum purity;
(J) the gypsum-related scale formation in the wet flue gas desulfurization unit absorber tower;
(K) the parasitic power loss by the wet flue gas desulfurization unit equipment;
(L) the oxidation-reduction potential in the absorber recirculation tank;
(M) the wet flue gas desulfurization unit effluent stream waste water treatment parameters;
(N) the SO2 removal efficiency by the wet flue gas desulfurization unit;
(O) the relative saturation of the gypsum crystals in the slurry; and/or
(P) the total dissolved solids in the wet flue gas desulfurization unit.

### Claim 2

A method for optimizing a wet flue gas desulfurization unit, the method comprising the steps of:
(i) measuring, analyzing and/or controlling at least one parameter in real time selected from:
(a) the type and/or amount of fuel to be combusted in the combustion process;
(b) the oxidation air flow rate to the combustion process;
(c) the ammonia slip across the selective catalytic reduction unit;
(d) the nitrogen oxide output from a selective catalytic reduction unit;
(e) the particulate control and/or capture device;
(f) the mercury speciation in the flue gas and/or absorber tank;
(g) the selenium speciation in the flue gas and/or absorber tank;
(h) the chemistry in the flue gas and/or absorber tank of the WFGD;
(i) the oxidation reduction potential of the absorber tank of the WFGD;
(j) the amount of the suspended solids in the absorber tank of the wet flue gas desulfurization unit;
(k) the analysis of the limestone and/or lime utilized in the wet flue gas desulfurization unit;
(l) the amount of various reagents supplied to the wet flue gas desulfurization unit tower;
(m) the SO2 concentration at the flue gas inlet of the wet flue gas desulfurization unit;
(n) the inlet opacity of the wet flue gas desulfurization unit;
(o) the PI data from the wet flue gas desulfurization unit;
(p) the amount of dissolved solids in the wet flue gas desulfurization unit; and/or
(q) the relative saturation of the gypsum crystals in the wet flue gas desulfurization unit;
(ii) generating real-time data from the at least one parameter of Step (I);
(iii) using the real-time data generated in Step (ii) to adjust at least one operational parameter selected from:
(A) the operational wet flue gas desulfurization unit tower level;
(B) the reagent feed flow to the wet flue gas desulfurization unit;
(C) the oxidation air flow to the wet flue gas desulfurization unit;
(D) the rate of absorber bleed from the wet flue gas desulfurization unit;
(E) the liquid to gas ratio in the wet flue gas desulfurization unit tower;
(F) the number of operating absorber recycle pumps in the wet flue gas desulfurization unit;
(G) the dewatering operation parameters;
(H) the ammonia feed rate to the selective catalytic reduction unit;
(I) the gypsum purity;
(J) the gypsum-related scale formation in the wet flue gas desulfurization unit absorber tower;
(K) the parasitic power loss by the wet flue gas desulfurization unit equipment;
(L) the oxidation-reduction potential in the absorber recirculation tank;
(M) the wet flue gas desulfurization unit effluent stream waste water treatment parameters;
(N) the SO2 removal efficiency by the wet flue gas desulfurization unit;
(O) the relative saturation of the gypsum crystals in the slurry; and/or
(P) the total dissolved solids in the wet flue gas desulfurization unit.

### Claim 3

A method for optimizing a wet flue gas desulfurization unit, the method comprising the steps of:
controlling, measuring and/or analyzing at least one process parameter of a combustion process and/or at least one combustion process air quality control system in order to yield at least one data set;
using the at least one data set to effect a desirable change in at least one downstream process parameter associated with one or more of a wet flue gas desulfurization unit, a particulate collection device and/or a nitrogen oxide control device.

### Claim 4

A method for optimizing a wet flue gas desulfurization unit, the method comprising the steps of:
controlling, measuring and/or analyzing at least two process parameters of a combustion process and/or at least one combustion process air quality control system in order to yield at least one data set;
using the at least two data sets to effect a desirable change in at least one downstream process parameter associated with one or more of a wet flue gas desulfurization unit, a particulate collection device and/or a nitrogen oxide control device.

### Claim 5

A method for optimizing a wet flue gas desulfurization unit, the method comprising the steps of:
measuring, analyzing and/or controlling at least one parameter selected from:
(i) desulfurization tower load;
(ii) oxidation air flow rate;
(iii) one or more boiler parameters;
(iv) one or more selective catalytic reduction unit parameters; and/or
(v) one or more electrostatic precipitator parameters;
generating data from the at least one parameter of the previous Step; and
using the data generated in the previous Step to adjust at least one operational parameter selected from:
(a) one or more gypsum production properties and/or parameters;
(b) the oxidation-reduction potential in the absorber recirculation tank;
(c) the pH of the absorber recirculation tank solution;
(d) the concentration, type and/or speciation of one or more compounds and/or ions in the absorber recirculation tank solution; and/or
(e) the concentration, type and/or speciation of one or more oxidizer compounds and/or ions in the absorber recirculation tank solution and/or the wet flue gas desulfurization unit.

### Claim 6 (depends on 5)

The method of claim 5, wherein the method includes a step of adding at least one of SO3 or trona to an electrostatic precipitator and controlling the amount of such one or more compounds to the electrostatic precipitator so as to reduce the amount of sparking that occurs in an electrostatic precipitator while injecting one or more of SO3 or trona versus the amount of sparking that occurs without such injection.

### Claim 7 (depends on 5)

The method of claim 5, wherein the method includes a step of controlling the amount of sparking that occurs in an electrostatic precipitator so as to reduce the concentration and/or type of one or more oxidizers that are formed as a result of the sparking.

### Claim 8 (depends on 5)

The method of claim 5, wherein the method includes a step of controlling the amount of sparking that occurs in an electrostatic precipitator so as to reduce the concentration and/or type of one or more oxidizers that are formed in the electrostatic precipitator.

### Claim 9 (depends on 8)

The method of claim 8, wherein the one or more oxidizers that are controlled are selected from persulfate, permanganate, manganate, ozone, hypochlorite, chlorate, nitric acid, iodine, bromine, chlorine, fluorine, or combinations of any two or more thereof.

### Claim 10 (depends on 5)

The method of claim 5, wherein the method permits control of both the oxidation-reduction potential and the pH in the solution of an absorber recirculation tank.

### Claim 11 (depends on 10)

The method of claim 10, wherein the oxidation-reduction potential in the solution of an absorber recirculation tank is less than about 500 mV and the pH is less than about 7.

### Claim 12 (depends on 10)

The method of claim 10, wherein the oxidation-reduction potential in the solution of an absorber recirculation tank is less than about 450 mV and the pH is less than about 6.5.

### Claim 13 (depends on 10)

The method of claim 10, wherein the oxidation-reduction potential in the solution of an absorber recirculation tank is less than about 400 mV and the pH is less than about 6.

### Claim 14 (depends on 10)

The method of claim 10, wherein the oxidation-reduction potential in the solution of an absorber recirculation tank is less than about 350 mV and the pH is less than about 6.

### Claim 15 (depends on 10)

The method of claim 10, wherein the oxidation-reduction potential in the solution of an absorber recirculation tank is less than about 300 mV and the pH is less than about 6.

### Claim 16 (depends on 5)

The method of claim 5, wherein the method permits control of the oxidation-reduction potential in the solution of an absorber recirculation tank so that the oxidation-reduction potential is less than about 500 mV.

### Claim 17 (depends on 5)

The method of claim 5, wherein the method permits control of the oxidation-reduction potential in the solution of an absorber recirculation tank so that the oxidation-reduction potential is less than about 450 mV.

### Claim 18 (depends on 5)

The method of claim 5, wherein the method permits control of the oxidation-reduction potential in the solution of an absorber recirculation tank so that the oxidation-reduction potential is less than about 400 mV.

### Claim 19 (depends on 5)

The method of claim 5, wherein the method permits control of the oxidation-reduction potential in the solution of an absorber recirculation tank so that the oxidation-reduction potential is less than about 350 mV.

### Claim 20 (depends on 5)

The method of claim 5, wherein the method permits control of the oxidation-reduction potential in the solution of an absorber recirculation tank so that the oxidation-reduction potential is less than about 300 mV.

### Claim 21 (depends on 5)

The method of claim 5, wherein the method permits control of at least the selenium speciation in the absorber recirculation tank solution while simultaneously permitting control of mercury reemission from the wet flue gas desulfurization unit.

### Claim 22 (depends on 5)

The method of claim 5, wherein the method permits control of at least the selenium speciation in the absorber recirculation tank solution.

### Claim 23 (depends on 5)

The method of claim 5, wherein the method permits control of one or more of the selenium speciation, the manganese speciation, the cobalt speciation, the mercury speciation, or any two or more thereof in the absorber recirculation tank solution.