Time has given us some perspective – and compelling data – about integrating combustion optimization software with boiler optimization spectroscopy sensors. So I wanted to close our blog series on the CombustionOpt and Zolo integration project with some thoughts on what we’ve learned, where the system is at now, and what Deely’s vision is for this technology going forward.

Lessons learned and bumps in the road
With any new technology there’s a learning curve, and this project was no exception. We overcame several obstacles to get to the point we’re at now.

Shortly after the Zolo system was installed and energized, we had a rash of unexplained window failures (windows in front of the lasers). After investigating, we concluded that the culprit was overheating. The problem was resolved by installing longer sight tubes which moved the windows further from the furnace. But we experienced more failures after the tubes were replaced. This time we found that the culprit was BB’s from the shotgun used to assist with de-slagging. We resolved the problem by installing plugs in the sight tubes whenever the boiler is de-slagged.

We experienced other disruptions such as communication loss between CombustionOpt, the Zolo system, and the DCS, as well as low load operation. The systems are automatically disabled below a certain load. We also had unit outages, during which time we weren’t able to collect any data or perform modeling.

Success hinges on team effort and strong champions
Throughout these challenges, CPSE, NeuCo, and Zolo worked together as one team. The project has been a success, mostly due to the collaboration and communication from all those involved, as well as support from the plant and management. In any project, it is essential to have a strong champion who truly believes in and is willing to go to bat for the product or technology. I’ve said it before and I’ll say it again, if there’s not a strong champion, don’t waste your money buying the product because the project will likely fail.
 
Compelling results
We documented the benefits of the CombustionOpt and Zolo integration by performing an “off vs. on” test. With the system disabled, NOx climbed and we ran with high NOx for two days. At the end of the second day the system was enabled and shortly after NOx decreased by 19 percent. In addition to lowering NOx, we’ve also been able to maintain CO under limit. Fuel efficiency benefits have translated to substantial CO2 benefits. Having believed in this project from the beginning, it’s been great to show everyone what the system can accomplish.  

Expanding application of the technologies
We’re still finding ways to apply the integrated technologies. For example, we’re currently decoupling the Fuel Air dampers per elevation, which will allow all dampers individual movement and each to have its own demand signal. Based on what we have seen and as the internal support and interest for this project grows, we’ve decided to move forward and purchase another integrated system for the sister unit (JT Deely 2) which we hope to have up and running by mid-summer 2009.