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Grand Est Region, France

Biomass Fluidized Bed Cogeneration Optimization

The project aimed to improve combustion stability, maximize steam production, and boost power generation through the engineering and commissioning of Advanced Process Control (APC) solutions.

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Key Results

APC Project Guaranteed by Enero Solutions

+4,000 MW

Annual Power Generation

+5 °C

Average Steam Temperature

-60 %

CO Emissions Reduction

+98 % of Time

APC Logic Active

-55 % Process Variability

Fluidized Bed Temperature Stabilization

-76 % Process Variability

Boiler Drum Level Stabilization

Challenges

Fluidized Bed Stability

Fluidized sand bed combustion technology offers high speed and strong responsiveness, enabling steam production to adapt efficiently to process demands. However, achieving this performance requires precise control of fluidization and bed temperature.

Energy and Operational Variability

The boiler recovers various grades of wood as well as off-gases from black pellet production, leading to significant variations in the fuel’s Lower Heating Value (LHV) that impact combustion. Compounding these fluctuations are variable export steam demands, which directly affect power generation.

Underutilized Cogeneration Potential

The combination of these factors constrained cogeneration performance, resulted in sub-optimal power generation, and risked non-compliance with GHG targets.

Project Overview

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

With the objectives of:

  • Stabilize fluidized bed combustion (Oxygen, bed temperature, steam flow),
  • Maximize electrical output within process constraints,
  • Reduce CO emissions,
  • Minimize production losses,
  • Reduce manual operator intervention.

APC Solutions

Combustion, steam network, boiler drum level, and superheated steam temperature solutions.

The APC solutions delivered a more stable and flexible steam supply to meet plant demand while maximizing power generation.

Automatic constraint management streamlines plant operations, significantly minimizing manual intervention.

Validated performance following APC commissioning enhanced overall plant availability while ensuring compliance with GHG emission targets.

Approach

  • Instrumentation and control performance audit,
  • Dynamic boiler and turbine simulation,
  • APC logic programming,
  • Operator simulator validation and training,
  • Operational and economic performance tracking,
  • Remote support.

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