The environmental protection policies and legal obligations motivate process industries to implement
new low-emission and high-efficiency technologies. For the purpose of production process optimization
and related control system design it is worthwhile to first build an appropriate process model. Apart from
favorable execution speed, accuracy, and reliability features, the model also needs to be straightforward
and only include the physical and design characteristics of the overall plant and its individual components,
instead of relying on empirical relationships. To this end, this paper presents a nonlinear dynamic
model of the single-drum natural-circulation steam boiler evaporator circuit, based exclusively on the
fundamental physical laws of conservation of mass, energy and momentum, wherein the reliance upon
empirical relationships has been entirely avoided. The presented boiler system modeling approach is
based on the analysis of the physical phenomena within the boiler drum, as well as within downcomer
and furnace tubes, and it also takes into account the boiler system design-specific features such as
cyclone steam separators, thus facilitating the derivation of a fully-physical process model. Due to the
straightforwardness of the derived process model, it should also be useful for the analysis of similar
steam boiler facilities, requiring only adjustments of key operational and design parameters such as operating
pressure, temperature, steam capacity and characteristics of ancillary equipment such as pumps. To
illustrate the model effectiveness, it has been employed in the analysis of the phenomena occurring in
different parts of the particular boiler system for the case of realistic disturbance event, wherein the
model inputs are based on the field data from the boiler on-board data collection system (DCS). It is anticipated
that the proposed physical boiler model should also be easily adapted for the case of boiler systems
utilizing alternative fuels, thus aiding in the optimization of the dedicated control and
supervision systems.
The environmental protection policies and legal obligations motivate process industries to implement
new low-emission and high-efficiency technologies. For the purpose of production process optimization
and related control system design it is worthwhile to first build an appropriate process model. Apart from
favorable execution speed, accuracy, and reliability features, the model also needs to be straightforward
and only include the physical and design characteristics of the overall plant and its individual components,
instead of relying on empirical relationships. To this end, this paper presents a nonlinear dynamic
model of the single-drum natural-circulation steam boiler evaporator circuit, based exclusively on the
fundamental physical laws of conservation of mass, energy and momentum, wherein the reliance upon
empirical relationships has been entirely avoided. The presented boiler system modeling approach is
based on the analysis of the physical phenomena within the boiler drum, as well as within downcomer
and furnace tubes, and it also takes into account the boiler system design-specific features such as
cyclone steam separators, thus facilitating the derivation of a fully-physical process model. Due to the
straightforwardness of the derived process model, it should also be useful for the analysis of similar
steam boiler facilities, requiring only adjustments of key operational and design parameters such as operating
pressure, temperature, steam capacity and characteristics of ancillary equipment such as pumps. To
illustrate the model effectiveness, it has been employed in the analysis of the phenomena occurring in
different parts of the particular boiler system for the case of realistic disturbance event, wherein the
model inputs are based on the field data from the boiler on-board data collection system (DCS). It is anticipated
that the proposed physical boiler model should also be easily adapted for the case of boiler systems
utilizing alternative fuels, thus aiding in the optimization of the dedicated control and
supervision systems.
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