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Grand Est Region, France

Maximizing Power Generation

Optimization of a biomass cogeneration plant (spreader stoker) through the engineering and commissioning of Advanced Process Control (APC) solutions. The project aimed to improve combustion stability and increase steam production to boost power generation.

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Key Results

APC Project Guaranteed by Enero Solutions

+4,000 MW

Annual Power Generation

+1,3 MWth

Boiler Thermal Output

-90 %

Reduction in Thermal Power Variability

+95 % of Time

Active APC Logic

-70 % Process Variability

Steam Temperature Stabilization

Challenges

Steam Production Instability

Combustion control in a biomass boiler is heavily impacted by variations in the fuel’s Lower Heating Value (LHV), as well as the quantity and distribution of under-grate and secondary air. Without simultaneous control of these parameters, steam flow rate variability can become excessive, restricting the boiler’s ability to achieve and sustain its nominal performance level.

Underexploited Cogeneration Potential

Variations in combustion and steam temperature, combined with fluctuations in steam demand, directly impact power generation. Combustion control that was insufficiently adapted to fuel variations and operating constraints led to sub-optimized electricity production, preventing the facility from sustainably maximizing its cogeneration potential.

Project Overview

Deliver a turnkey energy performance project, featuring the commissioning of Advanced Process Control (APC) logic for combustion and the steam network to coordinate cogeneration.

With the objectives of:

  • Stabilize combustion (Oxygen, steam flow rate)
  • Maximize steam production up to the design limit
  • Maximize power generation based on steam demand
  • Reduce vent and air-cooled condenser losses
  • Reduce manual operator interventions

APC Solutions

The APC solutions achieved a more stable and flexible steam supply to meet process unit demands while maximizing power generation.

Automated constraint management streamlines plant operations and minimizes manual operator interventions.

The verified performance following the commissioning of the APC solutions drove an overall improvement in plant availability and supported compliance with GHG emission targets.

Approach

  • Instrumentation and control loop performance audit
  • Dynamic simulation of boiler and turbine systems
  • Programming of APC logic (Combustion, steam network, drum level, superheated steam temperature)
  • Validation and operator training on simulator
  • Operational and economic performance tracking, remote support

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