TITLE: DESIGN OF AN AUTOMATED CONTROL SYSTEM OF BOILER OPERATION

INTRODUCTION:
Over the years the demand for high quality, greater efficiency and automated machines has
increased in the industrial sector. Boilers require continuous monitoring and inspection at
frequent intervals. There are possibilities of errors at measuring and various stages involved
with human workers. Thus the importance of implementing automation into them. The boiler
operation is the most important part of any corrugated boards manufacturing plant and its
automation is the precise effort of this project.
Boiler is defined as a closed vessel in which steam is produced from water by the combustion of
fuel. Generally, in boilers steam is produced by the interaction of hot flue gases with water
pipes which is coming out from the fuel mainly coal or coke. In fuel (coal or coke), chemical
energy stored is converted into heat energy and this heat energy is absorbed by the water
which is then converted into a steam. The boiler pressure is at a higher pressure than the
system of the corrugator thus steam flows from the boiler to the corrugator. The paper or
combined board is at a lower temperature than the steam, therefore heat will flow from the
steam into the paper or board. As heat flows out of the steam it condenses back into water or
condensate. The hot condensate is returned to the boiler where it is regenerated back into
steam. Steam (heat) is added to paper and combined board at three positions on the
corrugator:
At the pre conditioner, pressure roll and corrugating rolls
Pre heaters
Double facer
In the corrugated process, three basic components are brought together to produce combined
board: paper, adhesive and heat. The primary source of heat is the boiler and this implies that
its control and operation is the most important part in a corrugated process.
BACKGROUND:
Hunyani corrugated products is the market leader in the manufacturing and supply of
corrugated cartons for use both locally in Zimbabwe and their regional export market which
includes Zambia, Malawi, Mozambique and South Africa. Its market is diverse. The direct
agricultural segment makes up a large portion of the market base and includes the leaf tobacco
and finished cigarette cartons, floriculture and horticulture packaging and boxes for the poultry
and fish segments among others. The product quality, the ability to design and produce
purpose packaging into all sectors of the economy is what gives Hunyani corrugated products
the edge in the market. This can be achieved by ensuring that equipment is technologically up
to date and suitable and that staff are qualified in their fields of expertise.
In the corrugated process, three basic components are brought together to produce combined
board: paper, adhesive and heat. The primary source of heat is the boiler and this implies that
its control and operation is the most important part in a corrugated process. In the corrugated
process, steam (heat) is used to prepare the liner for bonding to the medium by adding
sufficient energy to begin gelatinizing of the adhesive, and the final drying of the adhesive in
the double facer. There are four types of corrugated boards: single face corrugated, single wall
corrugated, double wall corrugated and triple wall corrugated. Pressure is regulated in the hot
plates according to the type of board run and the type of starch used. The pressure
requirements are as follows:
Single face- 6-8bar
Single wall- 7-8bar
Double wall- 10-12bar
Triple wall- 13-14bar
It must be understood that every steam boiler system requires a proper boiler water treatment
of boiler feed water, adequate regulated blow downs, correct maintenance, periodic safety
checks, Total dissolved substances (TDS) control and regulating system of condensate
contamination. All of these are necessary for long life and efficient boiler service. To be
adequate for use in boilers, water must be free of dissolved minerals, gases such as oxygen and
carbon dioxide, metals such as iron and manganese and be of proper PH. If water is not
maintained at the required quality, the result can be corrosion of pipes, scale build up in pipes
or combination of both. The presence of gases and scale inhibit heat transfer and reduces the
efficiency of the steam system.
While it is theoretically possible to operate a boiler with manual control, the operator must
maintain certain constant parameters of boiler feed water, adequate regular blowdowns, TDS
(total dissolved substances) levels, condensate contamination levels. There are possibilities of
errors at measuring and various stages involved with human workers and this can result in an
inefficient boiler steam system.

PROBLEM STATEMENT:
The manual operation of a boiler uses a lot of energy, uses a lot of workforce and there are
possibilities of errors at measuring and various stages involved with human workers and usually
results in production of low quality steam.
AIM:
To design an automatic control system of boiler operation which can produce a maximum
steam of 15bars.
OBJECTIVES:
To design an automated water quality monitoring and control system of boiler feed
water.
To design an automatic TDS control system.
To design an automatic boiler blow down system.
To design a detection and regulating system for condensate contamination.
JUSTIFICATION:
An efficient and reliable boiler is an essential requirement in the paper industry and the
downtime caused by a failed boiler can have a major effect on production, plant and people.
Improved efficiency have many advantages such as fuel saving, useful life span of boiler,
manpower savings and production of adequate and quality steam. An automatic control system
of boiler operation enables an efficient and reliable steam production and reduces labor costs.
SCOPE:
The design is confined to Hunyani corrugated products. This study will concentrate on coal fired
boilers and on the control and monitoring of boiler operations to achieve an efficient, reliable,
cost effective and safe boiler. This system should be able to produce a maximum of 15bars.