Boiler Design Research Articles

Calculations of Gas and Grate Boilers Combustion Chambers - Verification of Methods Based on Measurement Data of Actual Boilers

In the paper the comparison of the results of analytical methods for determining the temperature at the outlet from the furnace, based on the design and measurement data of the industrial boilers is presented. The comparison is done on WR10 and WR40 grate boilers as well as OG55 gas boiler. The calculations of the furnaces are based on different assumptions. Some of the methods described in the literature on the subject have been developed based on the operating data of large power boilers. In Poland, the most frequently used method is the normative method from 1973. This method is in fairly good agreement with the results obtained during the warranty tests of real units. However, it is not the most up-to-date edition of this methodology. The results of the analysis of the discussed boilers indicate that the normative methods are characterized by the best degree of convergence with the temperature values obtained directly from the measurements of these units.

Review of Thermal Calculation Methods for Boilers—Perspectives on Thermal Optimization for Improving Ecological Parameters

This article presents an overview of thermal calculation methods used in boilers powered by fossil fuels (solid, liquid or gas). The analysis was carried out mainly in terms of combustion chamber calculation methods. Changing standards and legal regulations regarding the use of fossil fuels in Europe and the world make it necessary to adapt calculation methods and boiler design to current requirements, and many of them are related to outdated boiler models or for fuels that are no longer so heavily used in industrial solutions. Current research and development trends implemented in the EU and in the world related to the issues of the European Green Deal, the Fit for 55 directive and other ecological trends in the energy sector make it necessary to verify and remodel the calculation methods used so far in terms of the thermal efficiency of the device, fuel consumption or the use of fuels not previously used in their wide range in a wider application. Hence, the knowledge and updating of the state of knowledge in the field of the thermal calculation of boilers in terms of their environmental performance is necessary and strongly sought after by researchers. It is undoubted that in the next few years, boilers will continue to be the main source of thermal energy, especially in the power industry or industry. A reasonable energy transition should be based on the direction of the thermal optimization of already functioning structures and adaptation of their operating parameters to the planned new ecological fuels in the sense of the intensification of energy converted from primary form to thermal energy, and in the last step, it should reorganize the energy and industrial sectors, leaving only these groups of devices treated as a stable and necessary source of energy. Therefore, it should be recognized that activities aimed at improving the thermal parameters of boilers should directly improve the thermal efficiency of the device, and this will translate into fuel savings and reduce their negative impact on the environment.

Study of Steam Turbine Unit Operation Using Natural Gas Combustion in Pure Oxygen to Ensure Decarbonisation through Gas Path Modernization (using the Example of a TGM-94 (EP-500/140) steam boiler)

The research is aimed at substantiating the technical use of natural gas combustion in an environment with a high oxygen content and, in the long-run objective - in pure oxygen in a steam turbine power unit. To achieve this aim, the following problems were solved: the development of a mathematical model of a steam turbine power unit for operation when burning natural gas in pure oxygen, a numerical study of the power unit operation when replacing air with oxygen from 0 to 100%, and an assessment of the efficiency of the equipment in these modes. The most important result is an increase in the efficiency of the steam turbine power unit when switching to burning natural gas in an environment with a high oxygen content. The significance of the results obtained is to ensure the efficiency of CO2 capture from flue gases without a complete reconstruction of the facility. The object of the study was the Krasnodar Thermal Power Plant. In the study, the previously verified mathematical model of the power unit was modified. The model was created using the Boiler Designer software product. The mathematical model was modified by zeroing air leaks into the boiler gas path, replacing the regenerative air heater with a tubular one, and bypassing the air heater along the flue gases when operating on an oxygen-air mixture. The maximum increase in the boiler unit efficiency is 0.6% and is in the range of air substitution with oxygen from 40 to 60%.

Numerical Study on Flame Geometric Characteristics of Ammonia-Fueled Small Boiler

Amidst global efforts to cut carbon emissions, the carbon-neutral fuel sector is at a crossroads of opportunity and challenge. The pursuit of clean, sustainable energy alternatives is critical. Ammonia, with its zero-carbon and hydrogen-rich profile, is emerging as a promising clean fuel, yet its combustion behavior in industrial boilers demands further study. This paper presents a numerical analysis of the flame geometry characteristics of ammonia combustion at an equivalence ratio of 1. The study delineates the dimensions of the flame, specifically its diameter and length, offering valuable insights that can inform the design of industrial boilers. This research contributes to the broader understanding of ammonia's role in the transition towards more sustainable energy solutions in industrial settings.

Improved sprayed water boiler design for steam production

The lengthy time required for conventional boilers to attain a steady state, their sizable size, the substantial pressure drop, and their high cost are all disadvantages. The objective of this study was to develop a novel design for a boiler to achieve better performance based on a sprayed water boiler (SWB) through injectors with a specific spray rate in a near-atomized form over tubes containing hot gases. As the water temperature in the SWB is equal to the temperature of the water sprayed by the injectors, the temperature difference between the hot gases and the water is higher than in the conventional boiler. A parametric study was conducted to investigate the main parameters affecting the boiler performance, such as the steam quantity and quality, the time required to reach the steady state condition, the size of the boiler, and the drop pressure on the hot-gas side. The results showed that the size of the SWB was significantly smaller than that of a conventional boiler. When generating steam of the same quantity and quality, the size of the SWB is one-third of the conventional size. This reduces the manufacturing costs of the boiler and the pressure drop of the hot gases inside the boiler. It was also found that the thermal efficiency of the SWB was higher, and the start-up time to reach a steady state of operation was less than 1% of the time required for the conventional boiler. To close the gaps in the theoretical design, an experimental test should be performed.

Efficient Combustion of the Fixed Coal Layer in an Advanced Combustion Chamber Design for Low-Power Boilers

In the long term, coal will remain a competitive resource in the thermal power sector, primarily due to its abundant global reserves and low costs. Despite numerous factors, including significant environmental concerns, the global share of coal power generation has remained at 40% over the past four decades. Efficient and clean coal combustion is a high priority wherever coal is used as a fuel. An improved low-power boiler design has been proposed to enhance efficiency during fixed-bed coal combustion. This design reduces harmful emissions into the atmosphere by optimizing parameters and operating modes. In this study, mathematical modeling of gas velocity and temperature distribution during fixed-bed coal combustion was conducted for a conventional grate system and an improved grate-free system. Experimental methods were employed to develop descriptive airflow models in the fixed coal layer, considering nozzle diameter and air supply pressure in the furnace chamber without a grate system. Comparative evaluations of fixed-bed coal combustion rates were performed using an experimental laboratory setup with both grate and grate-free stove systems.

Оценка эффективности завихрения воздуха при распылении водоугольных суспензий пневматической форсункой

Due to modern requirements for environmental protection, introduction of environmentally friendly power engineering technologies involves search and development of new energy sources. One of the ways to meet these requirements and maintain the same level of energy production by thermal power plants is to use multicomponent fuels. The most promising and affordable heavy fuel oil from the point of view of energy, ecology and economy are coal-water slurries (CWS). In this regard, the study of the properties and characteristics of such fuels is relevant. The coal-water slurries have been prepared in a rotary hydrodynamic cavitation generator. A pneumatic atomizer with external mixing is used to spray the coal-water slurries. Interferometric Particle Imaging method is used to determine the average size of fuel droplets after atomization. The authors have conducted experimental studies of the characteristics of atomization of coal-water slurries based on lignite and pyrogenetic liquid with a pneumatic atomizer with a tangential supply of a spraying agent. A three-stage method to prepare lignite-based slurries with pyrogenetic liquid has been tested. It has been established that when using this technique, the fluidity of coal-water fuel is maintained even with the introduction of 20 % by weight of pyrogenetic liquid into the composition of coal-water slurries when replacing both water and coal in equal proportions. The kinematic viscosity of coal-water suspensions increases when pyrogenetic liquid is added, despite a decrease in the concentration of the solid component. The change of suspension density is insignificant. The results of the study of atomization process have shown that the tangential air supply to the atomizer leads to an increase of the jet spraying angle by 6° compared with direct supply. At the same time, the average droplet size in the jet of a two-component CWS with direct air supply is 8 % smaller. The results of the study have made it possible to obtain completely new knowledge that can significantly advance domestic and world science and technology in the field of power engineering, namely the technology of coal-water fuels atomization. Experimental studies have determined the main patterns of influence of the CWS properties and the method of spraying agent supply on the formation of a gas-drop jet. Such patterns will provide conditions for the effective atomization of quite viscous CWS in the combustion chambers of energy boilers. The results obtained will enable designers and constructors to develop highly efficient designs of steam and hot water boilers and gasifiers fueled by CWS.

Design and modifications of boiler mounting device in Asmara brewery factory

Energy and environment are closely related and important issues in the present all over world. Present industrial and others organization thought the unique of energy utilization and diverse source reviles such as coal, oil, gas, nuclear, hydropower, solar, wind and biofuel. The Non-renewable energy sources are being limited in this world and energy conservation is one of growing need nowadays. The major issues in the world’s energy consumption are getting used in boilers. Thus, this energy used has to be wisely consumed with great efficiency in industries. Boilers are considered as an important and an expensive property in many industries. In addition to initial cost, boilers have high operational and maintenance cost in order to secure production in safe and acceptable working conditions. In this study concerned with an energy saving, economic and environmental analysis of the fire tube boiler in ASMARA BREWERY. In this project, we concentrated on the improvement of boiler efficiency by recovering a portion of heat content of the flue gas. This is possible due to the most dominant device which is the economizer. The preexisting boiler was designed without an economizer. The present modification involved about the design of economizer in the boiler to reduce fuel consumption and thermal shock. Furthermore, in this type of boiler attain higher efficiency and little enhancement in the efficiency of the boiler will save an outsized amount of fuel and also help to reduce CO2 emission.

Numerical simulations and an experimental study for optimal design of a 1500 [formula omitted] water-tube condensing boiler

The present study is focused on investigating the condensation process and numerical simulation for optimal design of a 1500 kW water-tube condensing boiler. The specific geometry of the heat exchanger of this boiler involves compact arrangement of spiral coils to enhance heat transfer efficiency and achieve high capacity. Experimental validation is conducted on a 580 kW condensing boiler. Numerical simulations of the flow for gas and water sides of the boiler are performed in parallel using the ANSYS-FLUENT software with the k-omega (SST) turbulence model. Twelve models with different combustion chamber dimensions, coil numbers and revolutions are considered. Important design criteria include flue gas temperature, combustion chamber pressure and water pressure drop in the coils. The results indicate that increasing effective heating surface area and reducing coils gap decrease flue gas temperature to the dew point. Increasing coil revolutions has a greater impact on flue gas temperature and boiler weight compared to increasing coil numbers. With the same number of coils, by adding an extra revolution the weight is increased approximately 17 % and the effective heating surface area about 21 %. On the other hand, for the same number of revolutions, each additional spiral coil increases both of the weight and the effective heating surface area approximately 4 %. Moreover, with an increase in the number of the coils and a decrease in the number of revolutions, the pressure within the combustion chamber is decreased. By reducing the gap size, the flue gas temperature is reduced approximately 2 °C and the combustion chamber pressure is increased about 18 %. Base on the design criteria, the model six with 27 spiral coils and 7–8 revolutions, is identified as the optimal design. This progress and capability allows the design and manufacture of high-capacity boilers for residential sector as well as for industrial applications.

Analytical study on improving the efficiency and environmental friendliness of solid organic fuels

The purpose of this study was to analyse methods of increasing the efficiency and environmental friendliness of the use of solid organic fuels (SOF) in electricity generation. This study employed a comprehensive approach to the analysis and optimisation of technological processes, operational systems, and environmental aspects of the use of SOF. The study found that the use of modern technologies, such as gasification and pyrolysis, considerably increases the efficiency of converting SOF into electricity. Optimisation of boiler and turbine designs and automation of fuel supply systems helps to reduce energy losses and improve overall system efficiency. It was found that the use of new materials for boilers increases their resistance to corrosion and erosion, which extends the service life of the equipment. The study also showed that the introduction of gas cleaning and secondary combustion systems significantly reduces emissions of harmful substances, which improves environmental performance. An analysis of ash utilisation opportunities showed that its use as a fertiliser or construction material is a promising area. The study proved that an integrated approach to the use of SOF can substantially increase their efficiency and environmental friendliness. The findings of the study suggest that the use of innovative methods of combustion process control allows achieving more stable and efficient power generation. It was proved that the introduction of automated monitoring and control systems reduces operating costs and increases the reliability of equipment. The study also found that the use of advanced analytical tools to predict equipment wear and tear allows for prompt preventive maintenance, which further increases the efficiency and duration of uninterrupted operation of energy systems

Experimental and simulation study on coal-fired power generation coupling with fluidized bed biomass gasification

Positive-pressure fluidized bed technology utilizes the pressure generated by biomass gasification to facilitate further combustion within the furnace. This technique addresses the safety risks associated with external pressure in fluidizing medium and high-temperature situations and reduces equipment investment and operating expenses. However, research on the effects of the positive-pressure process in fluidized beds on gasification coupled with coal-fired power generation systems is scarce. To fill this research gap, extensive experimentation and Aspen Plus simulation were conducted to investigate the impact of equivalence ratio (ER), gasification pressure, and gasification temperature on the gasification performance. A 660 MW coal-fired boiler model was established to reveal the coupling effect on flue gas temperature and thermal efficiency by gasification from a positive-pressure fluidized bed on the boiler, and its accuracy was proved by comparing the actual boiler design parameters. The power generation cost of the positive-pressure gasification coupled coal-fired power generation system is calculated with the established model. The results indicate that an increase in gasification pressure from 4000Pa to 8000Pa resulted in no significant change in the operating indicators of the boiler, with the tail gas temperature near 132 °C and a boiler thermal efficiency of 92.68 %. Gas yield, carbon conversion rate, and gasification efficiency were positively correlated with gasification temperature and ER. However, the heat value of combustible gas increased with the gasification temperature and decreased with an increase in ER. With the rise of the biomass gas blending ratio, the power generation cost of the unit gradually decreases. Respectively, the positive -pressure would lower the power generation costs of a 660 MW coal-fired boiler by 5.76 × 105$/year. This study demonstrates that positive-pressure fluidized bed gasification may retain high gas yields and efficiency, significantly lowering equipment investment and operating expenses, as a very efficient energy-saving and carbon-reduction technique.

Multi-objective optimization design of high-pressure plate-fin ammonia boiler based on MO-SHERPA algorithm

With the rapid development of electrification, the high-pressure plate-fin ammonia boiler has been widely used as an effective thermal management solution, which has stimulated the demand for its structure design and optimization. The aim of this study was to establish a multi-objective optimization design method for high-pressure plate-fin ammonia boiler based on the hybrid and adaptive search strategy of MO-SHERPA and CFD simulation. Based on this method, a set of pareto-optimal solutions were obtained, and then the optimal configuration with lightest weight and high heat transfer performance was determined by calculating the deviation for weighted sum of comprehensive performance factor, entropy generation rate and structure weight. The effects of fin structural parameters of ammonia boiler were further examined on its performance. The results showed that increasing the spacing and height of offset strip fin and reducing its thickness could effectively improve the heat transfer performance. This study provides a theoretical method and some guidelines for the structural design of ammonia boiler with high operating pressure.

Enhancing Resistance to Corrosion, Erosion and Oxidation of Boiler Steels by Surface Modification Techniques

In coal based thermal power plant, the boiler components (superheater, combustion chamber, superheater tubes, boiler walls, reheater etc.) are subjected to harsh environment characterized by high temperatures, aggressive combustion products, and abrasive particles. Corrosion, erosion, and oxidation relentlessly reduce their lifespan and efficiency, posing significant economic and safety concerns. This review explores the potential of surface modification techniques to act as a valiant shield against these destructive forces, extending the life, enhancing the performance, and ensuring the safe operation of boiler components. In this articles various surface modifications techniques including their merits and demerits are discussed with emphasis on thermal spray techniques. From established methods like thermal spraying and laser cladding to innovative approaches like nanocoatings and electrochemical treatments, each technique is meticulously examined for its effectiveness in boosting corrosion resistance, mitigating erosion wear, and minimizing oxidation at crucial boiler locations. This review culminates in a compelling vision of the future, where sophisticated surface modification techniques become an integral part of boiler design and maintenance strategies. By harnessing the power of these technologies, we can usher in an era of more efficient, reliable, and sustainable boiler operation, safeguarding investments and protecting the environment.

Concept Design of the WRB-6 Water-Tube Boiler with a Stepped Grate and a Furnace for Burning Straw Bales in a Cigar System

The article presents the conceptual design of the solid fuel from the forest and sawmill production waste and agricultural waste biomass-fired water boiler. The project was supported by thermal and flow calculations. The designed WRB-6 boiler is a 3-pass unit with a fully screened furnace chamber and is equipment of a local biomass heating plant. It is fired with biomass, transported over no more than 30 km. The furnace has a double function – dual fuel. Both fuels can be burned simultaneously or alternately, depending on seasonal availability. In the front part there is a channel for feeding and burning large bales of cereal straw. The lower closure of the chamber is a mechanically inclined grate for the combustion of wood biomass in the granulation of chips. As part of the work, calculations of the amount of biomass fuels possible to be obtained on the local market with economy of delivery were also performed. As a result of the calculations, the temperatures of water and flue gas at the outlet, boiler efficiency, slagging and impurity indices for biomass were also presented.

How Should Technology Follower Companies of Developing Countries Innovate Through Design Capability?

Design capability and design management have been recognized as critical tools for innovation. Reviewing the significant themes in design capability and innovation, the Design Capability Model for Innovation has been put forward in 2022. This article explores the design capability of a technology follower company through the innovation process of a condensing boiler design by referring to this model. The company and the design process have been undertaken as a revelatory single case study stating causal explanations based on the theories. Design capability development of technology follower companies depends on their technological development path and business strategies that they follow in Global Value Chains (GVCs). Focusing on technology follower companies, this article provides a unique insight into the crucial role of design capability and design management in achieving design-driven innovation and also expands the perspective of business practices and academic research.

Experimental Study on Gas-Solid Two-Phase Flow Characteristics of a Vertical Cyclone Combustor System.

According to the design and operational parameters of the cyclone liquid slag-discharging boiler, an experimental platform for the cyclone burner was designed and constructed in a cold state based on the principle of similarity. The experimental study investigated the effects of parameters, such as swirl-vane angles, coal concentration, operating parameters, and particle size, on the flow distribution and vertical riser resistance characteristics of the vertical cyclone burner. The results showed that there were differences in flow distribution among the cyclone burners, and the most uniform flow distribution was achieved when the swirl-vane angle of the primary air was 30°. The concentration of pulverized coal significantly influenced the pressure drop in the vertical ascending section, which increased with higher concentrations of pulverized coal. When the concentration of pulverized coal remains constant, the pipeline pressure drop is minimized at a primary air velocity of 7.5 m/s. As the secondary wind speed increased, the pressure drop consistently rose; when the secondary wind speed is 22 m/s, the pressure drop of the pipeline is the maximum; however, excessively high secondary wind speeds were found to be detrimental to the formation of an optimal aerodynamic field in the burner. Furthermore, when the pulverized coal concentration was held constant, materials with larger particle sizes exhibited the highest pressure drop. When the particle size increases from 50 to 150 μm, the pressure drop of the vertical riser segment also increases. Finally, based on the Barth additional pressure drop theory, the pressure drop formula of the vertical riser is fitted by a dimensional analysis method, and the correlation formula of the pressure drop test of gas-solid two-phase flow in the vertical riser is obtained.

Optimizing biomass combustion in a 130 t/h grate boiler: Assessing gas-phase reaction models and primary air distribution strategies

Grate-firing technology is widely used for biomass combustion for heat and power production due to its good fuel flexibility. However, grate boilers often suffer from high unburnout, low efficiency, and high emissions, and require optimization to improve their performance. The distribution of primary air along the grate length significantly affects combustion and pollutant formation behaviors in the furnace; however, this effect is often under-investigated and poorly quantified. In this study, combustion of corn stover in a 130 t/h grate boiler is investigated experimentally and numerically. To establish a reliable baseline computational fluid dynamics (CFD) model and provide valuable reference for modeling and optimizing this industrial grate boiler, this study first investigates the applicability of the commonly used gas-phase reaction models. The finite rate/eddy dissipation model is found to outperform other gas-phase reaction models such as eddy dissipation model and eddy dissipation concept, which well predicts the temperature and shape of the flame in both the kinetics-controlled primary combustion zone and the diffusion-controlled burnout zone and shows the best agreement with the measured and site observations. Then, the study simulates and quantifies the effects of different primary air distribution modes (uniform, staged and refined-staged) on combustion performance of the boiler. Compared with the uniform primary air distribution, both the staged and refined-staged primary air distribution show an obvious increase in the char burnout ratio, from 76.5 % to 87.8 % and 95.5 %, respectively. Furthermore, the CO concentration at the furnace outlet is remarkably reduced, from 3178 ppm to 2766 ppm and 1917 ppm, respectively. This demonstrates that reasonable air supply in the latter two primary air distribution cases facilitates complete combustion in both the fuel-bed and freeboard. Moreover, in the latter two cases, the temperature distribution in the freeboard becomes more uniform, and the local oxygen-rich regions are eliminated. These are beneficial in suppressing the NO formation, as the emission of which decreases from 172 mg/m3 (at 11 % O2) to 161 mg/m3 and 156 mg/m3, respectively. This work provides important theoretical guidance for the accurate modeling and optimization of grate-firing boilers as well as the design of new grate boilers.

Influence of the Main Working Parameters and Geometrical Parameters on the Supercritical CO2 Flow Instability in a Heated Tube

Supercritical CO2 (sCO2) flow instability is an issue that must be considered in the reasonable design of sCO2 boiler. Because it can cause equipment vibration and heat transfer deterioration. In this article, a numerical model for the sCO2 flow instability in the single tube was developed. Different from the traditional model, the effects of metal heat storage and axial heat conduction in the tube wall were considered. The influence of main parameters on trans-pseudo-critical number (N TPC) and oscillation period (t 0) was studied, with the tube length (L) from 3 to 11 m and the inner diameter (D in) from 10 to 22 mm. N TPC increases with increasing the inlet pressure (P in), mass flux (G), inclination angle (α), and the inlet local resistance coefficient (K in). N TPC decreases with D in and outlet local resistance coefficient (K out). The effects of the sub-pseudo-critical number (N SUBPC), wall thickness (WT) and L on N TPC are nonlinear. With increasing N SUBPC, WT, L, D in, and K out, t 0 increase. As G, α, and K in increase, t 0 becomes smaller. When N SUBPC is lower than 0.9146, t 0 rises with P in increasing. It is opposite with N SUBPC higher than 0.9146.

Experimental study on the sintering characteristics of biomass ash

The alkaline metal content in biomass is high, which leads to a low initial sintering temperature. Therefore, during the process of direct biomass combustion for power generation, there are serious problems such as ash deposition and slagging on the heating surface, which has become a technical bottleneck for the safe, stable and long-term operation of boilers. In industry, the melting characteristics of ash are commonly used to guide boiler design and operation. However, traditional measurement of ash melting temperature has a large subjective error, and the releasing of alkaline metals during the measurement process results bit higher value, which affects the accuracy of the measured characteristic temperature. Comparingly, the initial sintering temperature is lower than the deformation temperature of the ash. This article provides a device for measuring the sintering temperature of biomass ash by using the pressure drop method. A novel two ash chamber system was invented, in which the alkali element released from the first ash chamber was captured by the downstream second ash chamber to compensate the escaping of alkali element. The initial sintering temperature of the second ash chamber has more accuracy with lower value than that measured by the traditional single sample chamber. XRD was used to analyze the mineral composition and causes of sintering of the ash samples before and after sintering. The results show that the sintering mechanisms of different types of biomass are different. In addition, combined with SEM analysis of rice husk, fruit core, rapeseed straw, and corn straw, the results show that the initial sintering temperature of the ash samples measured by the double chamber measurement method is more accurate than that measured by the single chamber measurement method, further validating the reliability of the two ash column system.

Reduction of emissions and improvement of dynamic responses of a supercritical clean coal generation unit via neural network inverse control strategy

Coal power plants have been a major source of undesirable emissions. Despite the technological advancements in renewable energies, coal units are still in-service in many developed and developing countries due to their reliability, adequacy, and flexibility for power delivery. There are some promising technologies for cleaner operation during power production from coal, including supercritical boiler (SC) design and carbon capture and storage (CCS), however, the challenging in innovating effective methods is still open to expand the boundary of knowledge in this speciality. This paper introduces a novel and simple method for reducing CO2 emissions and improving the dynamic responses of a 600 MW SC coal power plant by Artificial Neural Network (ANN) technique. A wide-range data-driven feedforward ANN model has been identified and verified for the various operations recorded as closed-loop data-sets, which covers all situations of startup, once-through mode, and even emergency shutdown of the unit. The closed-loop SC plant model has been augmented with an inverse multivariable coordinate NN controller, developed by analogous learning algorithm to improve the plant automation. With precisely selected setpoints, as operational rules, of temperature, pressure, and earliest possible power demand signals, the automated SC plant has been capable to operate with lower coal consumption - and thus lower emissions – than the existing operation strategy during startup, normal operation, and emergency shutdown modes. The improvement in dynamic responses have been quantified through simulations with comparison with existing performance, which have resulted in an overall average reduction of 2.143 Kg/s in coal consumption.