OPERATING WITH

AUTOTHERMIC GASIFICATION METHOD

TECHNICAL FIELD

The invention relates to a water tube steam boiler featuring a combustion efficiency maximization system operating with autothermic gasification method, which includes new methods, processes, systems and components in the solid fuel section of the solid and liquid/gas fired smokeless steam boiler, which is developed as an alternative to the boilers of current technology.

As a result of the R&D, optimization and design studies carried out on the solid fuel section of the "Solid and Liquid/Gas Fired, Coal Type Adjustable, Fully Automated Smokeless Hot Water/Steam Boiler", the subject of patent number 2014/09990, a new boiler operating with autothermic gasification method with fully automated combustion efficiency maximization system has been developed. With the maximization of combustion efficiency in the new boiler, the sulfur dioxide emission is also reduced thanks to the dry and wet desulphurization system for pollutant emission carbon monoxide and high sulfur coals, and it is aimed to reduce the pollutant emissions to the lowest level while burning coal and similar solid fuels.

CURRENT BOILER TECHNOLOGIES RELATED TO THE TECHNICAL FIELD OF THE INVENTION:

Regarding the technological field of the invention, currently known boiler technologies used for central heating and industrial steam generation or electricity generation in thermal power plants can be evaluated under different titles in terms of coal-solid fuel burning technology, method and combustion efficiency.

It is a part of the current technology and the closest prior art ("CPA") patent number is TR 2014/09990 Solid and Liquid/Gas Fired, Coal-Type Adjustable, Fully Automated Smokeless Hot Water/Steam Boiler. The subject of the patent application, Solid and Liquid/Gas Fired Smokeless Water Tube Steam Boiler with Combustion Efficiency Maximization System featuring Solid Fuel Section operating with Autothermic Gasification Method, is an invention that was revealed by the development of the R&D and design studies on the solid fuel section of this boiler, which is the closest prior technique.

The subject of the patent, "Solid and Liquid/Gas Fired Smokeless Water Tube Steam Boiler with Combustion Efficiency Maximization System featuring Solid Fuel Section operating with Autothermic Gasification Method", which maximizes the combustion efficiency by minimizing the combustion losses in the burning of coal and similar solid fuels, is shown in Figure-1 as designed containing a water tube with reference numbers of functional section, the main subsystem, secondary subsystem and components (elements). Additionally in Figure-2, Figure-3, Figure-4, Figure-5, Figure-6, Figure-7 and, Figure-8, smokeless combustion process using autothermic gasification method and detailed views regarding subsystems providing combustion efficiency maximization are being shown with reference numbers.

REFERENCE NUMBERS

1. Solid fuel section of the boiler

2. Liquid/gas fuel section of the boiler

3. Water pipe vertical transition gas ducts

4. Steam drum on the water pipe top of vertical transition gas ducts

5. Fly ash collectors - self-cyclone - under vertical transition gas ducts

6. Economizer

7. Flue with wet desulphurization system

8. Superheater placed in the first vertical transition radiation zone

9. Hot steam outlet pipe

10. Steam turbine

11. Generator

12. Gasifier thermomechanical system operating with autothermic gasification method

12.1. Coal supply screw conveyor for gasification

12.2. Double-walled coal supply silo with gasification air circulation 12.3. Double-walled coal preheating duct with gas combustion air circulation

12.4. Autothermic coal gasification channel 12.4.1 Front section of the gasification channel

12.4.2. Water vapor inlet pipe and regulating valve

12.4.3 Front wall forming the middle part of the gasification channel

12.4.4 Rear wall of the gasification duct, which covers the ducts to direct the gas combustion air down

12.4.5. The last section of the gasification channel reaching the combustion chamber

13. Gasification and combustion air inlet - distribution mechanical system

13.1. Forced blower fan and main air inlet duct

13.2. Natural draught or aspiration main air inlet duct

13.3. Gasification air intake upstream directing duct

13.3.1. Channels to direct the gasification air downstream from the double walled silo

13.4. Gas combustion air intake upstream directing duct

13.4.1. Gas combustion air heating ducts

13.4.2. Gas combustion air downstream directing ducts

13.5. Solid combustion air intake downstream directing duct

13.5.1. Intake duct of solid combustion air to the front part of the combustion chamber over the grate

13.5.2. Intake duct of solid combustion air to the combustion chamber under the grate system

14. Electromechanical control and automation system managing the gasification and combustion process

14.1. Gasification and combustion air adjustment system controlled by automation system

14.1.1. Inverter forced aspiration fan 14.1.2 Combustion chamber pressure sensor

14.1.3. Inverter forced blowing fan controlled by combustion chamber pressure sensor

14.1.4. Forced blowing fan main air inlet on-off flap

14.1.5. Natural draught or aspiration main air inlet on-off flap 14.1.6. Gasification air inlet upstream directing flap

14.1.7. Gas combustion air intake upstream directing flap

14.1.8. Solid combustion air intake downstream direction adjustment flap

14.2. Automation System

15. Combustion thermomechanical system that minimizes combustion losses for gas and solid part of coal.

15.1. Front section of autothermic gasification smokeless combustion chamber

15.2. The ceiling of the smokeless combustion chamber that directs the gas combustion air and the gasification product gases down to the end of the combustion chamber

15.3. Travelling-fixed step grate system

15.3.1. Steps under the smokeless combustion chamber starting section, containing grate slices with narrow gaps that prevent dusty coal from falling under the grate without burning

15.3.2. Steps under the middle section of the smokeless combustion chamber, containing grate slices with wider spacing than the front section

15.3.3. Steps under the last section of the smokeless combustion chamber, containing grate sections with narrower spacing than the middle section

15.3.4. Narrower spaced final fixed step grate slices at the end of the grate system

15.4. Coal bed thickness adjustment system at the end of the smokeless combustion chamber front section

15.5 Outlet duct of flame and combustion gases from smokeless combustion chamber 15.6. Solid combustion product ash-slag outlet duct from smokeless combustion chamber

16. Combustion efficiency maximization system with full automation working with autothermic gasification method

16.1. Combustion gas analyzer system

16.2. Temperature sensor measuring the temperature of the slag at the end of the combustion chamber

16.3. Inverter fire supply system that determines the speed of the combustion process with autothermic gasification

17. Dry and wet desulphurization system for high sulfur coals, 17.1. S02 analyzer that continuously measures and records the sulfur dioxide in combustion gases

17.2. Inverter lime supply screw conveyor for dry desulphurisation

17.3. Inverter supply pump for wet desulphurisation flue system

DETAILED DESCRIPTION OF THE INVENTION

As seen in Figure-1, water tube steam boiler is comprised of five main functional parts namely the solid fuel section of the boiler (1), the liquid/gas fuel part of the boiler (2), the vertical transition gas channels with water pipes (3), the steam drum on the water pipe ceiling of the vertical transition gas channels (4) and fly ash collectors - self-cyclone - under the vertical transition gas ducts (5); combustion product gases coming out of the solid fuel section (1) or the liquid/gas fuel section (2) of the boiler pass through the water tube vertical transition gas ducts (3) and then through the economizer (6), which increases the heat transfer efficiency, to the atmosphere through the flue (7) featuring a wet desulphurization system. In the water tube steam boiler, which can produce dual power (electricity + process steam) with cogeneration system or only electricity with thermal power plant system, the saturated steam emerging from the steam drum (4) above the water tube top of the vertical transition gas ducts is converted to superheated steam in the superheater (8) located in the radiation zone of the first vertical transition duct of the boiler, and directed to the steam turbine (10) with the superheated steam outlet pipe (9), the mechanical energy in the steam turbine is then transformed into electrical energy through the generator (11). The exhaust steam (rotten steam) at the exit of the steam turbine (10) can also meet the process steam and/or heating need of the plant as part of the cogeneration system. The boiler subject of this invention can be used only for electricity generation in thermal power plants, and it can also be used only in the production of process steam in textile and food sectors.

Regarding the Solid and Liquid/Gas Fired Smokeless Water Tube Steam Boiler with Combustion Efficiency Maximization System Featuring Solid Fuel Section Operating With Autothermic Gasification Method subject of this invention, the solid fuel section (1) comprises of two sub-thermomechanical systems namely the gasifier thermomechanical system (12) operating by the autothermic gasification method by automatically adjusting according to basic characteristics such as the lower heat value of the solid fuel or coal used, humidity and volatile-fixed carbon ratio and ash-slag ratio and the combustion thermomechanical system (15) minimizing combustion losses for coal produced gases of the gasifier system and the gas and solid parts of coal by processing the solid fuel part via smokeless combusting in the same combustion chamber after gasification, and two subsystems, namely the gasification and combustion air intake - distribution mechanical system (IB) that distributes the gasification and combustion air of the system according to the needs of the system and electromechanical control and automation system (14) that manages the gasification and combustion process that are integrated into these two sub thermomechanical systems, totalling up to four basic functional subsystems.

The solid fuel part (1) of the boiler consists of these four basic functional subsystems whereas the new boiler has an electromechanical control and automation system (14) managing the combustion process with gasification and combustion process that controls the grate movement and a combustion efficiency maximization system that continuously and steadily captures the maximum combustion efficiency thanks to the fully automated combustion efficiency maximization system (16) working with the autothermic gasification method with software (algorithm) that adjusts proportionally to the optimum oxygen value selected according to the minimum carbon monoxide (target zero carbon monoxide) value measured in the combustion gases or the selected optimum slag temperature value.

In the new boiler, minimum level of pollutants emission and maximum heat transfer efficiency are also provided in the flue having wet desulphurization system (7) together with maximum combustion efficiency thanks to the fully automated dry and wet desulphurization system for coals with high sulfur content (17) and the solid fuel combustion waste discharging system that minimizes all losses in ash and slag removal.

The subject of the patent, namely "Solid and Liquid/Gas Fired Smokeless Water Tube Steam Boiler with Combustion Efficiency Maximization System Featuring Solid Fuel Section Operating with Autothermic Gasification Method" which maximizes the combustion efficiency by minimizing the combustion losses with the gas and solid part of coal, performs the smokeless combustion process with the autothermic gasification method and combustion efficiency maximization with full automation with the working method consisting of the following steps:

- For gasification of the gasifier sub-thermomechanical system (12), operating per autothermic gasification method, the coal is fed through the coal supply screw conveyor (12.1) to the double-walled coal supply silo (12.2) featuring gasification air circulation, including a coal level detection sensor,

- In the double-walled coal supply silo (12.2) featuring gasification air circulation, the coal, which starts to dry with the effect of the gasification air heated by the heat generated by the system itself, flows downwards and goes down to the double-walled coal preheating channel (12.3) with gas combustion air circulation,

- In the double-walled coal preheating duct (12.3) with gas combustion air circulation, this passes through an autothermically controlled preheating process with the effect of the heat generated in the combustion chamber, while the heat generated by the system itself and the water vapor released during the drying of the coal flows down to the combustion chamber,

- coal enters in the autothermic coal gasification duct (12.4), with hot gasification air, water vapor and, when necessary, additional water vapor for the gasification of the coals with low moisture content coming through the water vapor intake pipe and regulating valve (12.4.2) at the front part of the coal gasification duct (12.4.1).

- As the coal entering the gasification duct descends between the front wall (12.4.3) forming the middle part of the gasification duct and the rear wall (12.4.4) of the gasification duct that covers the gas combustion air downstream ducts, approaching the last part (12.4.5) of the gasification duct reaching the combustion chamber, it passes through a controlled autothermic gasification process, which gradually increases with the heat generated in the combustion chamber,

- The air entering from the forced blowing fan main air intake duct (13.1) or from the natural suction or aspiration main air intake duct (13.2) of the gasification and combustion air intake - distribution mechanical system (13) is heated after being directed upstream for gasification by gasification air intake upstream directing duct (13.3), circulating the double- wall coal supply silo (12.2) featuring gasification air circulation, then directed downstream towards the coal via directing ducts (13.3.1.), passing through gas combustion air intake upstream directing duct (13.4), gas combustion air heating ducts that circulate and heat the gas combustion air around the coal preheating duct (13.4.1), gas combustion air downstream directing ducts (13.4.2) directing the gas combustion air down the rear wall of the gasification duct, solid combustion air intake downstream directing duct (13.5), intake duct of the solid combustion air to combustion chamber front part over the grate (13.5.1), and intake duct of solid combustion air to combustion chamber under the grate system (13.5.2).

- The gasification air, gas combustion air and solid combustion air, whose inlet and distribution are mechanically enabled, are provided by the gasification and combustion air adjustment system (14.1) controlled by the automation system of the electromechanical control and automation system (14) that manages the gasification and combustion process, and adjusting the required flow rates according to the coal type,

-Providing a forward controlled flow of coal on the grate system under the combustion chamber, which enters the combustion chamber by completing the gasification process with the movement of travelling grates that adjust the speed of the gasification and combustion process managed by the automation system (14.2).

- With autothermic gasification of the combustion thermomechanical system (15), which minimizes combustion losses with the gas and solid part of the coal, the air enters the front part of the smokeless combustion chamber (15.1), completing the gasification process and starting to burn at appropriate ignition temperatures,

- The autothermic gasification gases, together with the gas and solid combustion air set at the required flow rate, flow forward from the combustion chamber's gas combustion air under the ceiling (15.2) that directs the gasification product gases down to the end of the combustion chamber, while igniting at the high temperature provided by the heat generated in the combustion chamber and completing the smokeless combustion process, after that, flame and combustion product gases exit from the outlet duct (15.5),

- With the flow of the coal combustion bed, air enters the smokeless combustion process with the gas and solid combustion air adjusted at the required flow rate according to the coal type - In the last part of the combustion chamber, the solid part of the coal entering the smokeless combustion process, at the end of the grate system, the smokeless combustion process is completed by passing through the last fixed step grate slices (15.3.4) with narrower gaps and the ash - slag is directed down from the smokeless combustion chamber solid combustion product ash - slag outlet duct (15.6) while measuring its temperature,

- While the gas and solid part of the coal pass through the smokeless combustion process in the same combustion chamber, measuring the parameter that determines the combustion efficiency in the fully automated combustion efficiency maximization system (16) operating with the autothermic gasification method, which is the oxygen ratio in combustion gases, the slag or oxygen/slag temperature on the last fixed step grate continuously measured and recording the carbon monoxide in the combustion gases for temperature value selection,

- the smokeless combustion process is completed with gas and solid part of the coal with the maximum continuous combustion efficiency achieved by adjusting the motion of the inverter fire supply system (16.3), which determines the speed of the combustion process with autothermic gasification of the maximization system operating full automatic with autothermic gasification method (16), according to the optimum oxygen or optimum slag temperature value selected according to the parameter that determines the measured combustion efficiency which is the measured and recorded minimum carbon monoxide value (target zero carbon monoxide).

The process is completed with the working method consisting of the process steps listed above and both the gasification product gases and the post -gasification solid part of the coal passed through the autothermic gasification process are burned with the smokeless combustion process carried out in the same combustion chamber, and carbon monoxide, which is the polluting emission, is minimized with maximum combustion efficiency.

While the Solid and Liquid/Gas Fired Smokeless Water Tube Steam Boiler with Combustion Efficiency Maximization System featuring Solid Fuel Section operating with Autothermic Gasification Method which is the subject of this patent, performs the smokeless combustion process with the autothermic gasification method, it also has the feature that maximizes the combustion efficiency with full automation by minimizing all burning losses of the gas and solid part of the coal. In addition, if the emission of sulfur dioxide is high, it is ensured that the pollutant emission, which is the sulfur dioxide emission, is minimized through the fully automated dry and wet desulphurization system for coals with high sulfur content. On the other hand, thanks to the solid fuel combustion waste evacuation system, which minimizes all losses that may occur during ash and slag removal, thermal losses arising from the discharge of solid fuel combustion wastes are also minimized.

As stated above, the Solid and Liquid/Gas Fired Smokeless Water Tube Steam Boiler with Combustion Efficiency Maximization System featuring Solid Fuel Section operating with Autothermic Gasification Method which is the subject of this patent consists of five basic subsystems that complement each other, including two thermomechanical systems, namely gasifier thermomechanical system (12) with autothermic gasification method shown in Figure-2 and combustion thermomechanical system (15) shown in Figure-5 that minimizes the burning losses for the gas and solid part of the coal while in the gasifier system gases produced from coal and the solid fuel part after gasification are processed with smokeless combustion in the same combustion chamber, and those that integrate with these two systems, namely gasification and combustion air inlet - distribution mechanical system (13) shown in Figure-3, electromechanical control and automation system (14) shown in Figure-4 that regulates gasification and combustion processes and the combustion efficiency maximization system (16) shown in Figure-7 that proportionally controls the grate movement to maximize combustion efficiency according to the parameter, which is determined by measuring the parameter showing the combustion efficiency.

Gasifier thermomechanical system with autothermic gasification method (12) consists of four functional parts for gasification which are coal supply screw conveyor (12.1), double- walled coal supply silo with gasification air circulation (12.2), double-walled coal preheating duct with gas combustion air circulation (12.2) and autothermic coal gasification starting from the end of the preheating duct and reaching the front part of the combustion chamber (12.4).

In the double-walled coal supply silo (12.2) with gasification air circulation, which has a coal level detection sensor to keep the coal at a constant level, the coal fed by the coal supply screw conveyor (12.1) for gasification begins to dry. The double-walled coal preheating duct (12.3) with gas combustion air circulation enables the coal prepared for gasification by drying in the double-walled coal supply silo to pass through preheating together with the gasification air and water vapor.

In the autothermic coal gasification duct (12.4), while entering the front section of the coal gasification duct (12.4.1) that starts at the end of the coal preheating duct, the gasification efficiency can also be increased for such coal or solid fuels by spraying steam at the appropriate flow rate through the water vapor intake pipe and regulating valve (12.4.2) for gasification of the coals with low moisture content.

While the coal entering the gasification process flows down between the front wall (12.4.3) forming the middle part of the autothermic coal gasification duct and the rear wall (12.4.4) covering the ducts that direct the gas combustion air down, it passes to the last part of the autothermic coal gasification duct (12.4.5) reaching the combustion chamber with an accelerated autothermic gasification process together with the heat it receives from the combustion chamber. Since the last section (12.4.5) of the autothermic gasification duct that reaches the combustion chamber is also a transition section that forms the starting part of the combustion chamber, the autothermic gasification process, which is accelerated by the effect of the heat generated by the combustion process, tries to complete the gas production by passing through the last stage while the combustion process in this section is started.

The gasification and combustion air intake - distribution mechanical system (13) shown in Figure-3 consists of five functional parts or elements which are main air intake duct with forced blowing fan (13.1), main air inlet duct with natural draft or aspiration (13.2), gasification air intake upstream directing duct (13.3), gas combustion air intake upstream directing duct (13.4) and solid combustion air intake downstream directing duct (13.5).

The gasification and combustion air intake - distribution mechanical system (13) offers two options of main air intake, the main air intake duct with forced blowing fan and the main air intake duct with natural draft or aspiration. The gasification and combustion main air entering from the main air intake duct through one of these two options is divided into three branches through the gasification air intake upstream directing duct (13.3), gas combustion air intake upstream directing duct (13.4) and solid combustion air intake downstream directing duct (13.5), and the flow rates can be adjusted automatically or manually on the screen of the automation system (14.2), according to optimum air requirement per coal or solid fuel types.

The gasification air intake upstream directing duct (13.3) contains the gasification air upstream directing ducts (13.3.1) for gasification around the double-walled coal supply silo (12.2) with gasification air circulation and then diverting the gasification air to the coal from the double-walled silo.

Electromechanical control and automation system (14) that manages the gasification and combustion process consists of two parts: the gasification and combustion air adjustment system (14.1) controlled by the automation system and the automation system (14.2) that adjusts the system according to the combustion efficiency and flue gas emissions.

Electromechanical control and automation system (14) that manages the gasification and combustion process shown in Figure-4, adjusts the working capacity (gasification and combustion capacity) of the boiler proportionally according to the target steam pressure or temperature required by the plant, and at the same time, it has an algorithm and software that enables maximization of combustion efficiency by automatically adjusting the ratio of solid and gas fired combustion air. Automation system (14.2), which automatically adjusts and controls the main parameters (coal flow rate, gasification and combustion air flow rate etc) affecting the combustion efficiency of the gas and solid part of the coal in a manner to maximize the combustion efficiency according to the parameter measured in the combustion gases, performs this function by controlling the following electromechanical systems.

Gasification and combustion air adjustment system controlled by automation system (14.1) consists of a total of eight elements: forced aspiration fan with inverter (14.1.1) providing the optimum amount of air needed, combustion chamber pressure sensor (14.1.2) and forced blowing with inverter controlled by combustion chamber pressure sensor fan (14.1.3), main air inlet on - off flap with forced blowing fan (14.1.4), main air intake on-off flap with natural draft or aspiration (14.1.5), gasification air intake upstream adjustment flap (14.1. 6), gas combustion air intake upstream adjustment flap (14.1.7) and solid combustion air intake downstream adjustment flap (14.1.8).

The motion of the grate, which ensures the flow of the coal combustion bed with the motion of travelling grates that adjust the speed of the gasification and combustion process controlled by the automation system (14.2), determines both the flow rate of the coal and the gasification and burning capacity of the boiler. The automation system (14.2) controls the coal flow rate, gasification and combustion air flow with the gasification process according to the target steam pressure or temperature required by the plant, and adjusts the fuel-air ratio to maximize combustion efficiency according to the parameter measured in the combustion gases together with the gasification and combustion air adjustment system, which includes the elements listed above.

Combustion thermomechanical system (15) that minimizes combustion losses for gas and solid part of coal consists of six functional parts which of three main parts that fulfill basic functions namely the front part of the smokeless combustion chamber (15.1) which forms the front part of the combustion chamber consisting of front, middle and end parts to fulfill different functions at the middle part, the sloped ceiling (15.2) which forms the bottom of the liquid/gas fuel part (2) of the boiler at the top and directs the gas combustion air of the smokeless combustion chamber and gasification product gases down to the end of the combustion chamber, the travelling-fixed step grate system (15.3) on the lower side, containing grate slices with different gaps, minimizing unburned solid fuel losses under the smokeless combustion chamber; whereas the other parts are the coal combustion bed thickness adjustment system (15.4) at the end of the front part of smokeless combustion chamber, the flame and combustion gases exit duct (15.5) from the smokeless combustion chamber and the solid combustion product ash-slag exit duct (15.6) from the smokeless combustion chamber. The combustion thermomechanical system (15), which consists of these six functional parts and minimizes the combustion losses for the gas and solid part of the coal, provides the gases produced by the autothermic gasification method and the solid part of the gasification residue of the coal to be burned with the smokeless combustion process at the same time, it also has features that minimize all combustion losses.

In the front part (15.1) of the smokeless combustion chamber with autothermic gasification of the combustion thermomechanical system (15) that minimizes combustion losses for the gas and solid part of the coal, while the coal tries to complete the gasification process on the one hand, on the other hand, the gases produced start to burn at high ignition temperatures in the upper part of the combustion chamber. The ceiling (15.2) of the smokeless combustion chamber which also forms the bottom of the liquid/gas fuel part (2) of the boiler, directs gasification product gases with gas combustion air downstream, allowing ignited gases pass through the hottest zone of the combustion chamber to completely burn at high temperature. Thus, the gasification product gases completing their combustion pass from the smokeless combustion chamber through the flame and combustion gases exit duct (15.5) to the part of the boiler that provides heat transfer by radiation, conduction and convection.

The coal combustion bed thickness adjustment system (15.4) at the end of the front part of the smokeless combustion chamber allows the passage of the solid combustion air entering under the grate in optimum amount in accordance with the combustion bed resistance on the grate by adjusting the combustion bed thickness of the coal entering the combustion chamber at the thickness selected per grain size of the coal or solid fuel used.

Travelling-fixed step grate system (15.3) shown in Figure-6 containing grate slices having different gaps that minimizes unburned solid fuel losses under the smokeless combustion chamber, consists of four functional parts or elements: steps under the front part of the smokeless combustion chamber containing grate slices with narrow gaps (15.3.1) preventing dusty coal from falling under the grate without burning, steps at the middle part of the smokeless combustion chamber, containing grate slices with wider gaps compared to the front part (15.3.2), steps under the end part of the smokeless combustion chamber, containing grate slices with narrower gaps compared to the middle part (15.3.3), and narrower-spaced final fixed step grate slices (15.3.4) at the end part of the grate system. Thanks to this travelling-fixed step grate system, which includes grate slices with different gaps, the unburned fuel particles belonging to the coal's solid part in combustion process are prevented from falling under the grate from the first step to the last step's grate of the combustion chamber, thus minimizing the ash losses under the grate. In addition, thanks to the steps, which are located at the end of the middle part of the smokeless combustion chamber and contain grate slices with slag crusher teeth, the slag softens in coals having low slag melting temperature and adheres to grates and restricts the air passage, solving the combustion capacity problem arising from such coals to some extent.

The combustion efficiency maximization system (16), shown in Figure-7, with full automation operating with autothermic gasification method, consists of three functional elements: the combustion gas analyzer system (16.1) which includes an oxygen sensor that continuously measures the oxygen content and a carbon monoxide sensor that continuously measures carbon monoxide in the combustion product gases, the temperature sensor (16.2) measuring the temperature of the slag at the end of the combustion chamber, and the inverter fire supply system (16.3) that determines the speed of the combustion process with autothermic gasification.

While the gases produced by autothermic gasification and the solid part of the coal after gasification pass through the smokeless combustion process in the same combustion chamber, the fully automated combustion efficiency maximization system working with autothermic gasification method (16) simultaneously and continuously measures and records the oxygen rate, the amount of carbon monoxide and the slag temperature leaving the combustion chamber via combustion gas analyzer system (16.1), which includes an oxygen sensor that continuously measures the oxygen content and a carbon monoxide sensor that continuously measures carbon monoxide in the combustion product gases, that is, measuring the content of combustion gases and temperature sensor (16.2) measuring the temperature of the slag at the end of the combustion chamber.

The oxygen ratio, which is the indicator of excess air (access air) losses, which is the most important loss for combustion product gases, and the amount of carbon monoxide, which is an incomplete combustion product, must be reduced to the lowest possible level in terms of maximizing the combustion efficiency of gasification gases.

On the other hand, during the completion of the smokeless combustion process of the solid part of the coal entering the smokeless combustion process on the travelling-fixed step grate system (15.3) that minimizes unburned solid fuel losses after autothermic gasification by passing through the last fixed step grate slices with narrower gaps (15.3.4) at the last part of the combustion chamber and while the combustion residual ash-slag is dragged over the last fixed step grates by measuring the temperature and descended from the ash-slag exit duct (15.6), the slag as well as the unburned solid fuel particles should not fall down.

The inverter fire supply system (16.3) of the travelling-fixed step grate system (15.3) that determines the speed of the combustion process by autothermic gasification by moving the travelling grate steps, also minimizes the excess air (access air) losses on the travelling-fixed step grate system (15.3) including grate slices with different gaps towards the end of the combustion chamber, which were formed due to slag formation, according to the oxygen ratio, which is an indicator of excess air losses.

The combustion efficiency maximization system (16) consisting of combustion gas analyzer system (16.1), the temperature sensor (16.2) measuring the temperature of the slag at the end of the combustion chamber, and inverter fire supply system (16.3) determining the speed of the combustion process with autothermic gasification, maximizes the combustion efficiency by minimizing both the burning losses of the autothermic gasification product gases and the burning of solid fuel after gasification and the excess air (access air) losses caused by the slag formation on the grate steps.

The combustion efficiency maximization system primarily measures the oxygen ratio, the amount of carbon monoxide in the combustion product gases and the ash-slag temperature at the last fixed step grate continuously, and continuously controls the motion of the inverter fire supply system (16.3), which determines the speed of the combustion process with autothermic gasification through the automation system (14.2), according to the oxygen or slag temperature value that maximizes the combustion efficiency. The automation system (14.2) has an algorithm and software that aims to achieve the maximum value of the combustion efficiency by minimizing or completely zeroing the carbon monoxide emission, which is the missing combustion product in the combustion gases, and minimizing the unburned solid fuel wastes in the slag.

The automation system (14.2) follows two alternative paths, depending on the characteristics of the solid fuel or coal used and the ash-slag structure to achieve this goal:

Firstly, in order to achieve the lowest oxygen ratio that provides the lowest measured carbon monoxide value, adjusting the motion speed of the inverter fire supply system (16.3) that determines the combustion process with authothermic gasification proportionally and decreasing the speed as this target oxygen value approaches, and stopping completely upon this oxygen value is reached to prevent the oxygen value from decreasing more than necessary, that is to prevent the missing combustion product carbon monoxide from increasing again. Then proportionally adjusting the speed of the grate system that starts moving as soon as the oxygen value rises again upon the stopping of the inverter fire supply system (16.3) determining the speed of the combustion process with autothermic gasification, until target oxygen value is reached. As long as this lowest oxygen value, which provides the measured minimum or zero carbon monoxide value, is maintained in a stable way, both the thermal losses caused by the excess air (access air) and the combustion losses due to incomplete combustion are minimized and the maximum value of the efficiency is maintained in a stable way.

The second way is, in order to achieve the lowest slag temperature that provides the lowest measured carbon monoxide value, to adjust the speed of the inverter fire supply system (16.3) determining the speed of the combustion process with autothermic gasification, according to the slag temperature value proportionally, reducing the speed proportionally as it approaches the optimum slag temperature value, and preventing the unburned solid fuel wastes from falling down with the slag when it reaches this temperature value. Because, as soon as the unburned solid fuel wastes leave the combustion chamber and fall down, the carbon monoxide value of the missing combustion product starts to rise again with the solid fuel combustion losses. As long as the optimum slag temperature value is maintained consistently, both the solid fuel combustion losses and the carbon monoxide value of the missing combustion product are kept at the lowest level or the maximum value of the combustion efficiency is also consistently maintained.

Thus, the combustion efficiency maximization system (16) in the coal combustion section of the boiler subject of this patent works on the basis of the optimum oxygen value based on the minimum carbon monoxide (target zero carbon monoxide) measured in combustion product gases or the solid combustion waste ash-slag temperature value and maintains the maximum combustion efficiency it has consistently achieved.

The steam boiler, which is the subject of the patent, also reduces the pollutant sulfur dioxide emission in the flue gases to the level below the limit values thanks to the fully automated dry and wet desulphurization system (17) for high sulfur coals.

Dry and wet desulphurisation system for high-sulfur coals (17) consists of three functional parts or elements which are, S02 analyzer (17.1) that continuously measures and records the sulfur dioxide in the combustion gases, the lime supply screw conveyor with inverter (17.2) for dry desulphurisation and the inverter supply pump (17.3) for the wet desulphurization flue system.

The S02 analyzer (17.1), which continuously measures and records the sulphur dioxide in the combustion product gases, continuously measures and records the S02 emission depending on the sulfur content of the fired coal or solid fuel and provides data input to the automation system (14.2). According to this measured data, either dry desulphurization system with powder lime supply or wet desulphurization system with high PH value water supply will be preferred to reduce S02 emission. When necessary, both systems can be used together.

For dry desulphurization, the lime supply screw conveyor with inverter (17.2) transfers the dust lime taken from the lime silo to the coal supply spiral, and ensures that the dust lime at the flow rate adjusted by the inverter according to the sulfur content in the coal, enters the coal supply silo of the boiler from the coal supply spiral with an optimum mixture. Thus, according to the measured S02 value, sulfur dioxide emission reacts with powder lime (calcium hydroxide) as its flow is controlled automatically by the inverter by means of the automation system (14.2) that controls the dry desulphurization system with full automation and calcium sulfate (gypsum) is formed, and as a result of this high efficiency dry desulphurisation, the sulfur dioxide emission in the combustion gases is reduced below the desired limit values.

For the wet desulphurisation flue system, the inverter supply pump (17.3) sprays water with appropriate PH value at flow rate adjusted by the inverter according to the measured S02 value through nozzles to the combustion product gases passing through wet desulphurisation flue. Thanks to the automation system (14.2) with software that controls the wet desulphurization system with full automation according to the measured S02 value, sulfur dioxide, which reacts with water, the flow rate of which is automatically adjusted with the inverter, turns into sulfuric acid and falls into the sedimentation pool of the flue. Thus, sulfur dioxide emission leaves the flue by minimizing the combustion gases with a high efficiency wet desulphurization provided with full automation.

Thanks to the solid fuel combustion waste discharging system in the subject steam boiler already existing in current technology, by means of air tightness, it minimizes all losses that may occur by preventing all excess air (access air) losses that may decrease the combustion and heating efficiency due to the excess air that may enter the combustion chamber or the boiler system during the removal and discharge of solid combustion product ash and slag from the combustion chamber.

As explained in detail above, the invention is a steam boiler system with combustion efficiency maximization system featuring a solid fuel part operating with autothermic gasification method, comprised of a gasifier thermomechanical system (12) operating with autothermic gasification method by automatically adjusting according to the characteristics of the solid fuel used, combustion thermomechanical system (15) that minimizes the combustion losses for the gas and solid part of the coal by realizing the solid fuel part after gasification with the smokeless combustion process in the same combustion chamber, gasification and combustion air intake - distribution mechanical system (13) that distributes the gasification and combustion air according to the needs of the system, electromechanical control and automation system (14) that adjusts the working system of the boiler and enables maximization of combustion efficiency by using parameters that determine the combustion efficiency in the combustion product gases, and manages the combustion process with gasification and combustion efficiency maximization system (16) with full automation working with autothermic gasification method that maximizes the combustion efficiency by minimizing the combustion losses of both the autothermic gasification product gases and the post-gasification solid fuel combustion losses.

Operation method of the steam boiler system with combustion efficiency maximization system featuring solid fuel part operating with autothermic gasification methods, subject of this invention, comprises of the following steps;

• supply coal or other solid fuel to the gasifier sub-thermomechanical system (12) operating with the autothermic gasification method by maintaining a constant level,

• solid fuel, which starts to dry with the effect of the gasification air heated by the heat generated by the boiler itself, flows downwards and goes down to the double- walled coal preheating duct (12.3) with gas combustion air circulation,

• drying of the solid fuel with the heat produced by the boiler in the double-walled coal preheating duct (12.3) with gas combustion air circulation and the solid fuel coming down to the combustion chamber with the water vapor released during this time,

• while going down to the combustion chamber, the solid fuel goes through an autothermically controlled preheating process with the effect of the heat generated in the combustion chamber,

• after the preheating process, the solid fuel entering the autothermic coal gasification channel (12.4) and going through an increasing gasification process as it approaches the combustion chamber, descends towards the last part of the gasification channel (12.4.5) reaching the combustion chamber,

• solid fuel goes through a controlled autothermic gasification process, which gradually increases with the heat generated in the combustion chamber while descending to the last part (12.4.5) of the gasification channel reaching the combustion chamber, • the ensuring of the intake and distribution of gasification air, gas combustion air and solid combustion air in accordance with the functions of gasification and combustion air inlet - distribution mechanical system (IB),

• adjustment of the gasification air, gas combustion air and solid combustion air, which are supplied and distributed, at the required flow rates according to the solid fuel feature, with the electromechanical control and automation system (14) that manages the gasification and combustion process,

• with autothermic gasification of the combustion thermomechanical system (15), which minimizes combustion losses with the gas and solid part of the solid fuel, the air enters the front part of the smokeless combustion chamber (15.1), completing the gasification process and starting to burn at appropriate ignition temperatures,

• providing forward flow of solid fuel entering the combustion chamber by completing the autothermic gasification process on the grate system under the combustion chamber,

• the autothermic gasification product gases flow forward under the ceiling (15.2), which directs the gas combustion air of the combustion chamber and the gasification product gases down to the end of the combustion chamber,

• autothermic gasification gases complete the smokeless combustion process by igniting at the high temperature provided by the heat generated in the combustion chamber while flowing forward with the combustion air set at the required flow rate, and the flame and combustion product gases from the smokeless combustion chamber exit through the outlet duct (15.5) and pass to the vertical transition gas ducts section,

• after gasification, the solid part of the coal enters the smokeless combustion process with solid ignition / combustion air on the travelling-fixed step grate system (15.3), which minimizes unburned solid fuel losses under the smokeless combustion chamber and contains grate slices with different gaps,

• the solid part of the solid fuel entering the smokeless combustion process after gasification completes the smokeless combustion process by passing the narrower last fixed step grate slices (15.3.4) at the end of the grate system, and the combustion residue is dragged out of the combustion chamber, • measuring the parameter that determines the combustion efficiency in the fully automated combustion efficiency maximization system (16) operating with the autothermic gasification method, while the gas and solid part of the solid fuel pass through the smokeless combustion process in the same combustion chamber,

• The motion of the inverter fire supply system (16.3), which determines the speed of the combustion process with autothermic gasification through the automation system of the combustion efficiency maximization system (16) working with the autothermic gasification method, adjusts the motion according to the parameter that determines the measured combustion efficiency with the gas and solid part of the solid fuel with continuous maximum combustion efficiency and thereby completes the smokeless combustion process,

Gasifier thermomechanical system (12) operating with the autothermic gasification method described above; includes the double wall coal supply silo (12.2) with gasification air circulation, which enables the coal inside to be heated with the gasification air heated by the heat produced by the boiler itself in the surrounding double wall and to obtain water vapor from the moisture inside the coal by drying the coal, the double wall coal preheating duct (12.3) with gas combustion air circulation which is used to heat the gas combustion air by circulating it in the surrounding double skin and to ensure that the coal passes through preheating together with the water vapor and gasification air produced from its moisture by drying the coal inside, the autothermic coal gasification duct (12.4) starting from the end of the double wall coal preheating duct (12.3) with gas combustion air circulation and reaching the front part of the combustion chamber, where the gasification process is started and completed, and also in the autothermic coal gasification duct (12.4), the subsections namely, the front section (12.4.1) of the coal gasification duct, which starts at the end of the coal preheating duct and where autothermic gasification of coal begins, water vapor intake pipe and regulating valve (12.4.2) that sprays steam at appropriate flow when necessary for gasification of low moisture coals, front wall (12.4.3) which forms the middle part of the autothermic coal gasification channel, used to allow coal passage in the gasification process, rear wall (12.4.4) that includes the gas combustion air ducting ducts used to allow the passage of coal in the reduction process and last section (12.4.5) of the autothermic coal gasification duct reaching the combustion chamber, which is a transition section where the gasification process is completed with an accelerated autothermic gasification process with the heat it receives from the combustion chamber.

Coal enters the system, with hot gasification air, water vapor and, when necessary, additional water vapor for the gasification of the coals with low moisture content coming through the water vapor intake pipe and regulating valve (12.4.2) at the front part of the coal gasification duct (12.4.1).

Gasification and combustion air intake - distribution mechanical system (IB) comprises of main air intake duct with forced blowing fan (13.1) through which the main air to be distributed in the system is supplied, main air intake duct with natural suction or aspiration (13.2) used to provide the main air intake to the system when the forced blowing fan (13.1) is out of order, gasification air intake upstream directing duct (13.3) which directs the main air intake upstream for coal gasification, gas combustion air intake upstream directing duct

(13.4), solid combustion air intake downstream directing duct (13.5) which directs the main air intake down to burn the solid part of the coal after gasification and at the same time the gasification and combustion air intake - distribution mechanical system (13) divides the gasification and combustion main air entering from the main air intake duct into three branches via gasification air intake upstream directing duct (13.3), gas combustion air intake upstream directing duct (13.4) and solid combustion air intake downstream directing duct

(13.5). Gasification air upstream directing duct (13.3) includes ducts (13.3.1) that direct the heated gasification air that was directed upstream for gasification and circulated around the double-wall coal supply silo with gasification air circulation (12.2) down from the double wall silo towards the coal, gasification combustion air intake upstream directing duct (13.4) includes gas combustion air heating ducts (13.4.1) that enable the gas combustion air directed upstream for gasification, to be heated around the double-wall coal preheating duct with gas combustion air circulation (12.3), whereas gas combustion air intake upstream directing duct (13.4) includes gas combustion air downstream directing ducts (13.4.2) that direct the gas combustion air required for the combustion of the gases obtained by gasifying coal to the combustion chamber.

Electromechanical control and automation system (14) that manages gasification and combustion processes mentioned above includes the gasification and combustion air adjustment system (14.1) controlled by the automation system used to adjust the gasification and combustion air required by the system so as to maximize the combustion efficiency and automatically adjusts the gasification and combustion capacity of the boiler, and the automation system (14.2) that automatically adjusts and controls the entire working system and efficiency of the boiler. Gasification and combustion air adjustment system (14.1) controlled by automation system uses main components, namely, the gasification air intake upstream direction adjustment flap (14.1.6) used to adjust the flow rate of the gasification air, the gas combustion air intake upstream adjustment flap (14.1.7) to adjust the flow rate of the gas combustion air, the solid combustion air intake downstream direction adjustment flap (14.1.8) to adjust the flow rate of the solid combustion air.

Combustion thermomechanical system for gas and solid part of coal minimizing combustion losses (15) mentioned above, includes the autothermic gasification and smokeless combustion chamber front part (15.1) where solid fuel completes the gasification process and starts to burn at ignition temperatures, the ceiling (15.2) that directs the gas combustion air of the smokeless combustion chamber and the gasification product gases down to the end of the combustion chamber, travelling-fixed step grate system containing grate slices that minimize unburned solid fuel losses under the smokeless combustion chamber (15.3). In travelling-fixed step grate system (15.3); there are slag crusher teeth used to break the slag formed in the combustion chamber. Again the travelling-fixed step grating system (15.3); contains grate slices with different gaps in order to minimize unburned solid fuel losses under the smokeless combustion chamber.

The grates in the travelling-fixed step grate system (15.3) contain steps (15.3.1) under the smokeless combustion chamber front section, which contain grate slices with narrow gaps that prevent dusty coal from falling under the grate without burning, steps (15.3.2) under the middle section of the smokeless combustion chamber to accelerate the combustion process, containing grate slices with wider gaps than the starting section, steps (15.3.3) with narrower spaced grid sections compared to the middle part in order to reduce the excess air losses in the slag formed at the end of the combustion, under the last part of the smokeless combustion chamber and the last fixed step grid slices with narrower gaps (15.3.4) at the end of the grid system, which is produced longer to allow burning of unburnt solid fuel in the combustion waste slag.

Fully automated combustion efficiency maximization system operating with autothermic gasification method (16) described above, includes the combustion gas analyzer system (16.1) that is used to measure the content of combustion product gases, the temperature sensor (16.2) measuring the temperature of the slag at the end of the combustion chamber used to prevent the solid fuel from being separated with the slag before it completes its combustion in the combustion chamber after gasification and the inverter fire supply system (16.3) that determines the speed of the combustion process with autothermic gasification by moving the grid system under the combustion chamber. Combustion gas analyzer system (16.1) measures the oxygen within combustion gases in order to adjust the motion of the inverter fire supply system (16.3) that regulates the speed of the combustion process with autothermic gasification through the fully automated combustion efficiency maximization system operating with autothermic gasification method (16) and also measures the carbon monoxide within combustion gases in order to adjust the motion of the inverter fire supply system (16.3) that regulates the speed of the combustion process with autothermic gasification through the fully automated combustion efficiency maximization system operating with autothermic gasification method (16). Temperature sensor measuring the temperature of the slag at the end of the combustion chamber (16.2); can be used to regulate the movement of the inverter fire supply system (16.3) that determines the speed of the combustion process with autothermic gasification through fully automated combustion efficiency maximization system operating with autothermic gasification method (16). Fully automated combustion efficiency maximization system (16) working with autothermic gasification method adjusts the motion of the inverter fire supply system (16.3), which determines the speed of the combustion process with autothermic gasification to ensure maximum combustion, using the optimum oxygen selected according to the minimum carbon monoxide value and the selected optimum slag temperature value through the automation system (14.2). Alternatively, it adjusts the motion of the inverter fire supply system (16.3), which determines the speed of the combustion process with autothermic gasification, using the optimum oxygen value selected according to the minimum carbon monoxide value through the automation system (14.2) in order to ensure maximum combustion efficiency. Again alternatively, fully automated combustion efficiency maximization system (16) working with autothermic gasification method adjusts the motion of the inverter fire supply system (16.3), which determines the speed of the combustion process with autothermic gasification to ensure maximum combustion, using the oxygen value and the selected optimum slag temperature value through the automation system (14.2). Again alternatively, fully automated combustion efficiency maximization system (16) working with autothermic gasification method adjusts the motion of the inverter fire supply system (16.3), which determines the speed of the combustion process with autothermic gasification to ensure maximum combustion, using optimum slag temperature value through the automation system (14.2).

Electromechanical control and automation system (14) that manages the gasification and combustion process described above; also manages the dry and wet desulphurisation system (17) for high-sulphur coals in order to reduce the emission of sulphur dioxide in combustion product gases. Electromechanical control and automation system managing gasification and combustion processes (14) operates the lime supply of the inverter lime supply screw conveyor (17.2) for dry desulphurisation or the inverter supply pump (17.3) for the wet desulphurisation flue system, according to the sulfur dioxide emission data received from the S02 analyzer (17.1) that continuously measures and records sulfur dioxide in combustion product gases.

As a result, the subject of the invention, "Smokeless Combustion Solid and Liquid/Gas Fired Water Tube Steam Boiler with Combustion Efficiency Maximization System Working with Solid Fuel Part Autothermic Gasification" system, offers a new technology in terms of both energy efficiency and air pollution by minimizing the carbon monoxide and sulfur dioxide, which are polluting emissions, together with the maximization in the combustion efficiency provided by full automation/autothermic gasification.