Patent Description:
The present disclosure relates generally to chemical pulping and particularly to recovery boilers and dissolving tanks used in the pulp and paper industry.

In the chemical pulping industry, mill operators treat lignocellulosic material with either strong acids or strong bases to disassociate the lignin from the cellulosic fibers. Operators may then separate, wash, and further process the cellulosic fibers into pulp or other pulp-based products. Chemical process examples include: the Kraft process (also known as the "sulfate process"), the sulfite process, the soda pulping process, and the sulfite semi-chemical pulping process.

While the processing chemicals for each type of chemical process may vary, mill operators frequently recover and recycle these process chemicals to operate the mill economically. Many chemical pulp mills use pyrolytic chemical recovery systems to recycle at least a portion of the cooking chemicals.

In a typical chemical recovery process, operators heat and inject concentrated spent cooking chemicals, known generically as "black liquor," into a chemical recovery boiler. The recovery boiler evaporates the remaining water from the black liquor and solid compounds in the black liquor undergo partial pyrolysis. The remaining inorganic compounds fall to the bottom of the recovery boiler and then exit as molten liquid smelt.

This smelt exits through one or more smelt spouts at the bottom of the recovery boiler. As the smelt contacts green liquor in a dissolving tank, the smelt explodes and emits a series of audible sounds. This is generally known as "banging" by those in the industry. The smelt flowing from the spout is typically between <NUM> degrees Celsius ("°C") to <NUM>, while the average temperature of the green liquor is about <NUM> to <NUM>.

To manage smelt dissolution, avoid excessive noise, and mitigate the possibility of catastrophic explosions, conventional dissolving tanks generally use disruptors to disrupt the smelt as the smelt falls from the spout into the dissolving tank. Disruptors can be one or more shatter jets, or other devices configured to disrupt the flow of smelt from the smelt spout prior to the smelt reaching the liquid level of the dissolving tank. A shatter jet blasts the falling smelt with steam or other shattering fluid at high pressure to create smelt droplets. These droplets collectively have a greater surface area than an undisrupted smelt flow. The individual droplets also have a smaller volume than an overall undisrupted smelt flow. The increased surface area and smaller volume of reactants permit banging explosions that are generally less intense than the explosions would be if the smelt contacted the green liquor as a continuous, uninterrupted, undisrupted flow.

In many mills, operators commonly move in and among the processing equipment to monitor process conditions and output. The flow of smelt from a spout is variable. Molten smelt may periodically accumulate behind temporary dams of inorganic material in the recovery boiler, and turbulent process conditions can occasionally send a jet of super-heated gas from the spout opening. Even with appropriate protection, it is generally advisable for personnel to stand as far away from the spout openings as possible to avoid being proximate to the smelt spouts in an upset condition. An explosion in the dissolving tank or recovery boiler poses a serious safety risk to personnel in the immediate vicinity, and the resulting fire poses a serious risk to personnel in the rest of the mill. Such explosions also cause an unregulated amount of pollutants to enter the air and groundwater and predicate significant production loss. Explosions of this scale can inactivate a mill for weeks or months.

To accommodate variations in smelt flow, current shatter jets encourage operators to stand physically close to shatter jets to adjust the rate of steam flow and/or the position of the shatter jets manually. Depending upon the particular boiler, proximity of equipment relative to the shatter jets may reduce the operator's ease of access to steam flow adjustment valves. Such reduced access may encourage operators to stand too close to the spout opening, or position themselves in such a way that they will increase the risk of injury.

Furthermore, manual adjustment of the shatter jet can be time consuming and can quickly become out of step with the changing flow characteristics of the smelt. A typical recovery boiler may have about three to six smelt spouts on at least one side of the recovery boiler. By way of example, one person adjusting all of the shatter jets on a typical <NUM> million pounds of dry solids per day ("lbds/day") recovery boiler may take an average of <NUM> minutes. During that time, the process conditions inside the recovery boiler may be in a near constant state of flux. That is, by the time the operator finishes adjusting the shatter jets in response to a process condition measurement taken at the top of the hour, the recovery boiler may have experienced myriad changes in process conditions, thereby minimizing the effects of the operator's manual adjustments.

Previous innovations in this field have focused on reducing the risk of substantial smelt explosions. For example, <CIT>, entitled, "Cooled Smelt Restrictor at Cooled Smelt Spout for Disrupting Smelt Flow from the Boiler," describes a single use emergency apparatus for rapidly closing the spout opening in the event of a smelt deluge.

<CIT>, entitled, "Acoustic Emission System and Method for Predicting Explosions in a Dissolving Tank," describes a system configured to measure and evaluate banging in order to predict smelt explosions. While these systems have been generally effective at reducing explosions, both systems are reactive and generally trigger a failsafe just moments before an explosion might otherwise occur. Therefore, a failure of one of these systems at a critical moment could result in the same explosions that plagued conventional recovery boilers and dissolving tanks.

<CIT> describes an ultrasonic smelt dissolving and shattering system configured to reduce the time needed to dissolve smelt in a dissolving tank.

The problem of exposing recovery boiler operators to safety risks as a result of operators manually adjusting disruptors in response to changing smelt flow characteristics and the problem of dissociated smelt flow characteristics and disruptor operating condition (e.g. disruptor position and disrupting fluid output) is solved by a disruptor adjustment system comprising the features of claim <NUM>, by a recovery boiler dissolving tank disruptor adjustment system as recited in claim <NUM>, comprising the disruptor adjustment system; and by a method for monitoring and adjusting a disruptor operating condition for a disruptor disposed over a dissolving tank as recited in claim <NUM>. Optional features are set forth in the respective dependent claims.

The disruptor adjustment system would be designed to allow an electrical or pneumatic actuator to adjust the position (insertion depth and angle) of the disruptor based on process data from a recovery boiler. The process data may include, but is not limited to, smelt flow leaving the smelt spout, dissolving tank operational data, and smelt spout cooling water temperatures.

The disruptor could also be controlled remotely based on information from a camera.

The exemplary systems described herein may further increase personnel safety by eliminating the need for operating personnel to adjust manually the flow of fluid through the disruptors and/or the position of the disruptors during normal, upset, or transient conditions.

The foregoing will be apparent from the following more particular description of exemplary embodiments of the disclosure, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, with emphasis instead being placed upon illustrating the disclosed embodiments.

The following detailed description of the preferred embodiments is presented only for illustrative and descriptive purposes and is not intended to be exhaustive or to limit the scope and spirit of the invention. The embodiments were selected and described to best explain the principles of the invention and its practical application. One of ordinary skill in the art will recognize that many variations can be made to the invention disclosed in this specification without departing from the scope and spirit of the invention.

Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of various features and components according to the present disclosure, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate embodiments of the present disclosure, and such exemplifications are not to be construed as limiting the scope of the present disclosure in any manner.

References in the specification to "one embodiment," "an embodiment," "an exemplary embodiment", etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic.

Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiment selected for illustration in the drawings, and are not intended to define or limit the scope of the disclosure.

Numerical values should be understood to include numerical values which are the same when reduced to the same number of significant figures and numerical values which differ from the stated value by less than the experimental error of conventional measurement technique of the type described in the present application to determine the value.

All ranges disclosed herein are inclusive of the recited endpoint and are independently combinable (for example, the range "from <NUM> millimeters to <NUM> millimeters" is inclusive of the endpoints, <NUM> millimeters and <NUM> millimeters, and all intermediate values).

As used herein, approximating language may be applied to modify any quantitative representation that may vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as "about" and "substantially," may not be limited to the precise values specified. The modifier "about" should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression "from about <NUM> to about <NUM>" also discloses the range "from <NUM> to <NUM>.

It should be noted that many of the terms used herein are relative terms. For example, the terms "upper" and "lower" are relative to each other in location, i.e. an upper component is located at a higher elevation than a lower component in a given orientation, but these terms can change if the device is flipped. The terms "inlet' and "outlet" are relative to a fluid flowing through them with respect to a given structure, e.g. a fluid flows through the inlet into the structure and flows through the outlet out of the structure. The terms "upstream" and "downstream" are relative to the direction in which a fluid flows through various components, i.e. the flow of fluids through an upstream component prior to flowing through the downstream component.

The terms "horizontal" and "vertical" are used to indicate direction relative to an absolute reference, i.e. ground level. However, these terms should not be construed to require structure to be absolutely parallel or absolutely perpendicular to each other. For example, a first vertical structure and a second vertical structure are not necessarily parallel to each other. The terms "top" and "floor" or "base" are used to refer to locations/surfaces where the top is always higher than the floor/base relative to an absolute reference, i.e. the surface of the Earth. The terms "upwards" and "downwards" are also relative to an absolute reference; an upwards flow is always against the gravity of the Earth.

The term "directly," wherein used to refer to two system components, such as valves or pumps, or other control devices, or sensors (e.g. temperature or pressure), may be located in the path between the two named components.

While the processing chemicals for each type of chemical process may vary, mill operators frequently recover and recycle these process chemicals to operate the mill economically. For example, in the Kraft process, mill operators digest lignocellulosic material (commonly wood chips) in large pressurized vessels with "white liquor" comprising sodium hydroxide (NaOH) and sodium sulfide (Na<NUM>S). During the digestion step, the white liquor reacts with lignin and other compounds in the lignocellulosic material and takes on a dark color. Unsurprisingly, this reacted liquor is known as "black liquor. " Whereas the white liquor comprises the reactants sodium hydroxide (NaOH) and sodium sulfide (Na<NUM>S), the black liquor contains the chemical products sodium carbonate (Na<NUM>CO<NUM>) and sodium sulfate (Na<NUM>SO<NUM>). While sodium hydroxide (NaOH) and sodium sulfide (Na<NUM>S) are generally inexpensive, it is generally cost prohibitive to purchase new solutions of sodium hydroxide (NaOH) and sodium sulfide (Na<NUM>S) to maintain production. For this reason, many chemical pulp mills use pyrolytic chemical recovery systems to recycle at least a portion of the produced sodium carbonate (Na<NUM>CO<NUM>) and sodium sulfate (Na<NUM>SO<NUM>). Converting these products back into the commercially useful chemical reactants, sodium hydroxide (NaOH) and sodium sulfide (Na<NUM>S), allows mills to run economically.

New black liquor from a chemical digester is generally dilute and non-combustible. Therefore, to prepare black liquor for pyrolysis, operators generally funnel the black liquor through flash tanks or other evaporation steps to concentrate the solid particles in the black liquor. Operators then heat and inject the concentrated black liquor into a chemical recovery boiler. The recovery boiler evaporates the remaining water from the black liquor droplets and the solid compounds in the black liquor undergo partial pyrolysis. The remaining inorganic compounds fall to the bottom of the furnace and accumulate in a char bed. Some of the carbon and carbon monoxide in the char bed acts as a catalyst to convert most of the sodium sulfate (Na<NUM>SO<NUM>) into sodium sulfide (Na<NUM>S). The sodium sulfide (Na<NUM>S) then exits the recovery boiler with the sodium carbonate (Na<NUM>CO<NUM>) as liquid smelt.

This smelt flows through one or more smelt spouts at the bottom of the recovery boiler. Coolant, usually water, may cool the smelt spouts. Operators typically collect the green liquor and transport the green liquor to a causticizing plant to react the sodium carbonate (Na<NUM>CO<NUM>) with lime (CaO) to convert the sodium carbonate (Na<NUM>CO<NUM>) into sodium hydroxide (NaOH) and thereby reproduce the white liquor.

As the smelt contacts the green liquor in a dissolving tank, the smelt explodes and emits a series of audible sounds. This is generally known as "banging" by those in the industry. The smelt flowing from the spout is typically between <NUM> to <NUM>, while the average temperature of the green liquor is about <NUM> to <NUM>. Without being bound by theory, it is believed that the large temperature difference may increase the reactivity of the smelt and green liquor and thereby cause or contribute to banging. If left unregulated, a sudden influx of smelt may cause an explosion in the dissolving tank and recovery boiler, which poses grave safety risks to nearby operating personnel.

To manage smelt dissolution and to avoid excessive noise and the possibility of catastrophic explosions, conventional dissolving tanks generally disrupt the smelt as the smelt falls from the spout. Disruptors may be one or more shatter jets. A shatter jet blasts the falling smelt with steam or other shattering fluid at high pressure to create smelt droplets. These droplets collectively have a greater surface area than an undisrupted smelt flow. The individual droplets also have a smaller volume than an overall undisrupted smelt flow. The increased surface area and smaller amounts of reactants allows for banging explosions that are generally less intense than the explosions would be if the smelt contacted the green liquor as a continuous, uninterrupted, undisrupted flow. Typically, the end of the spout is elevated above the liquid level of green liquor and the shatter jets disrupt falling smelt as the smelt falls from the spout end. The shatter jet nozzles cannot be adjusted remotely. When a smelt upset occurs, operators generally cannot safely adjust the discharge rate of disrupting fluid into the dissolving tank.

Occasionally, smelt may cool prematurely in the recovery boiler or spout and decrease or eliminate the smelt flow rate. In this antediluvian state, liquid smelt tends to accumulate behind the obstruction. If the obstruction dislodges, the sudden smelt influx may overwhelm the shatter jet's ability to disrupt the smelt into sufficiently small droplets and an agitator's ability to mix the influx into the green liquor effectively. Moreover, if the deluge is particularly substantial, the smelt may flow over the sides of the spout and bypass the shatter jets entirely. In other scenarios, a shatter jet or agitator may fail. In these situations, the increased volume of smelt contacting the green liquor drastically increases the banging's explosive intensity and explosion risk.

In many mills, operators commonly move in and amongst the processing equipment to monitor process conditions and output. An explosion in the dissolving tank or recovery boiler poses a serious safety risk to personnel in the immediate vicinity, and the resulting fire poses a serious risk to personnel in the rest of the mill. Such explosions also cause an unregulated amount of pollutants to enter the air and groundwater and predicate significant production loss. Explosions of this scale can inactivate a mill for weeks to months.

<FIG> depicts a recovery boiler <NUM> having a smelt spout <NUM> adjacent to a dissolving tank <NUM>. The smelt spout <NUM> directs a volume of smelt <NUM> into the dissolving tank <NUM>. A typical recovery boiler <NUM> may have between three and six smelt spouts <NUM> disposed around the bottom of at least one side of the recover boiler <NUM> for example. Some recovery boilers <NUM> have smelt spouts <NUM> on oppositely disposed sides. As seen in the cutaway, the dissolving tank <NUM> contains a dissolving liquid <NUM>. The dissolving liquid <NUM> is commonly green liquor. The liquid level <NUM> of the dissolving liquid <NUM> is generally below the top <NUM> of the dissolving tank <NUM>. A primary agitator <NUM> driven by a motor M agitates the dissolving liquid <NUM> and helps equalize the dissolving liquid's temperature. The motor M may be a variable speed drive motor. Although the primary agitator <NUM> depicted in <FIG> is a propeller <NUM> connected to a driveshaft <NUM>, it will be understood by those having ordinary skill in the art that an "agitator" is a device configured to move dissolving liquid <NUM> through the dissolving tank <NUM>. Other agitators may include for example, fluid jets <NUM>, devices that undulate the dissolving liquid <NUM>, and other rotating bodies.

Primary agitators <NUM> typically comprise a propeller <NUM> or other mechanical implement extending into the dissolving liquid <NUM>. Secondary agitators (see <NUM>) may be fluid jets <NUM> that inject air or other fluid into the dissolving liquid <NUM> to agitate the dissolving liquid <NUM>. While it is possible to use secondary agitators (see <NUM>) simultaneously with primary agitators <NUM>, operators more commonly activate secondary agitators (see <NUM>) when primary agitators <NUM> fail or underperform. As the volume of smelt <NUM> falls from the spout <NUM>, a disruptor <NUM>, for example, a "shatter jet," directs a pressurized disrupting fluid <NUM> (commonly in the form of steam) toward the falling smelt <NUM>. The disrupting fluid <NUM> interrupts the continuous smelt stream <NUM> and thereby creates smelt droplets <NUM>. While shatter jets are common types of disruptors <NUM>, it will be understood that other devices that break up or dropletize the smelt stream <NUM> falling form the spout <NUM> is a "disruptor" <NUM>.

After the smelt droplets <NUM> contact the dissolving liquid <NUM>, the smelt droplets <NUM> emit an audible bang and eventually dissolve into the dissolving liquid <NUM>. In an upset condition, the amount of undissolved smelt in the dissolving tank <NUM> increases. When the amount of undissolved smelt increases in the dissolving tank <NUM> due to an increased flow rate, the incoming smelt stream <NUM> can overwhelm a disruptor's ability to shatter the smelt stream <NUM> into sufficiently small smelt droplets <NUM>. Without being bound by theory, it is believed that the vast differences in temperatures between the volume of smelt <NUM> and the dissolving liquid <NUM> causes the smelt droplets <NUM> to explode soon after contacting the dissolving liquid <NUM>.

An operator <NUM> is included in <FIG> to show the approximate scale of a person relative to the recovery boiler <NUM> and dissolving tank <NUM>. Process conditions frequently change in a recovery boiler <NUM>. For example, boiler load and falling salt cake from the top of the recovery boiler can change the rate of smelt flow and the position of the smelt flow relative to the disruptor. To ensure that the disruptor <NUM> is still dropletizing the smelt flow effectively, operators traditionally manually adjusted the position of the disruptor including the angle of the disruptor and the extent to which the disruptor <NUM> extends into the hood <NUM> of the dissolving tank <NUM>. In addition, operators <NUM> could manually adjust the rate at which disruptor fluid <NUM> emanated from the disruptor <NUM>.

Manual disruptor adjustment poses a significant safety risk. For example, the temperature inside the recovery boiler <NUM> typically ranges from about <NUM> to about <NUM> when fully operational. Windboxes <NUM> feed a near constant flow of air into the recovery boiler <NUM> to maintain combustion. To facilitate efficient pyrolysis, operators tend to try to create a cyclone of airflow into the recovery boiler <NUM>. As seen in <FIG> and <FIG>, the spout opening <NUM> extends directly into the inside of the recovery boiler <NUM>. The turbulent conditions of the recovery boiler <NUM> occasionally emit superheated gases from the spout openings <NUM>.

As <FIG> illustrates, the spout opening <NUM> is frequently aligned with the inspection door <NUM> in the dissolving tank hood <NUM>. To protect a proximate operator <NUM>, the inspection door <NUM> may be closed during recovery boiler operation. When an operator is not present, the inspection door <NUM> can be open. Some mills aim cameras through the open inspection door <NUM> to monitor the smelt flow <NUM>. However, if the operator <NUM> intends to make manual adjustments, the operator typically opens to inspection door <NUM> between adjustments to evaluate how effectively the disrupting fluid <NUM> is hitting the smelt falling from the smelt spout <NUM>. While this inspection door is open, the operator <NUM> risks being exposed to unpredictable jets of superheated gas emanating from the spout opening <NUM>. Furthermore, these gas jets may eject drops of molten <NUM> to <NUM> smelt <NUM> onto the operator <NUM>. The operator <NUM> is therefore at significant risk of bodily injury when adjusting the disruptor manually. Additionally, the placement of other equipment proximate to the disruptor <NUM> may limit the operator's range of motion while adjusting the operating conditions <NUM> of the disruptor <NUM> and may motivate the operators to position his or her body in a precarious position at the risk of falling or incurring other injuries.

Furthermore, a typical recovery boiler <NUM> may have wall width of about <NUM> feet to about <NUM> feet for example and have about three to about six smelt spouts. <NUM> The process conditions within a recovery boiler <NUM> change constantly, yet it can take the average operator about <NUM> minutes on average to adjust all disruptors <NUM> manually, thereby increasing the operator's exposure to safety risks while also failing to maintain the operating conditions <NUM> (<FIG>) of the disruptor <NUM> in response to the dynamic changes in smelt flow and in the smelt's physical and chemical properties.

To mitigate this problem, an exemplary embodiment of a recovery boiler dissolving tank disruptor adjustment system <NUM> is provided. <FIG> depicts such an exemplary embodiment comprising: a dissolving tank <NUM>, a smelt spout <NUM> adjacent to the dissolving tank <NUM>, wherein the smelt spout <NUM> is configured to convey a volume of smelt <NUM> into the dissolving tank <NUM>. A disruptor <NUM> is configured to disrupt the volume of smelt <NUM> flowing from the smelt spout <NUM> into the dissolving tank <NUM>. A sensor <NUM> is configured to record process data <NUM> from a recovery boiler <NUM>, and a control system <NUM> is configured to receive a sensor output signal <NUM> from the sensor <NUM>, wherein the sensor output signal <NUM> indicates the process data <NUM> at a measured time T, wherein the control system <NUM> is further configured to compare the sensor output signal <NUM> to a programmed operation range for a process condition, and to send a disruptor input signal <NUM> to the disruptor <NUM> to adjust a disruptor operating condition <NUM> if the process data <NUM> is outside of the programmed operation range.

In certain exemplary embodiments, the sensor <NUM> contains a signal generator <NUM> (<FIG>) configured to generate the sensor output signal <NUM>. In other exemplary embodiments, the signal generator <NUM> is separate from the sensor <NUM>.

In certain exemplary embodiments, an actuator <NUM> is operatively engaged to the disruptor <NUM>, wherein the actuator <NUM> is configured to adjust a position of the disruptor <NUM> in response to a disruptor input signal <NUM>.

For the purposes of this disclosure, the position of the disruptor <NUM> is a disruptor operating condition <NUM>. The position of the disruptor <NUM> can comprise an insertion depth. In other exemplary embodiments, the position of the disruptor <NUM> can comprises an angle of the disruptor <NUM>. In still other exemplary embodiments, the position of the disruptor <NUM> comprises both the insertion depth of the disruptor in the hood <NUM> of the dissolving tank <NUM> and the angle of the disruptor <NUM>. For the purposes of this disclosure, a "disruptor operating condition" <NUM> can be a rate of disrupting fluid flow.

In certain exemplary embodiments, the process data <NUM> is selected from the group consisting of: a rate of smelt flow, dissolving tank operational data, and a smelt spout cooling water temperature.

In certain exemplary embodiments, the system may further comprise a camera configured to capture an image of the smelt <NUM> in the smelt spout <NUM>.

Another exemplary embodiment is a disruptor adjustment system <NUM> comprising: a disruptor assembly <NUM> configured to disrupt a volume of smelt <NUM> flowing from a smelt spout <NUM> into the dissolving tank <NUM>, wherein the disruptor assembly <NUM> comprises an actuator <NUM> operatively engaged to a disruptor <NUM>, a sensor <NUM> configured to record process data <NUM> from the recovery boiler <NUM>; and a control system <NUM> configured to receive a sensor output signal <NUM> from the sensor <NUM>, wherein the sensor output signal <NUM> indicates the process data <NUM> at a measured time T, wherein the control system <NUM> is further configured to compare the sensor output signal <NUM> to a programmed operation range, and to send a disruptor input signal <NUM> to the disruptor assembly <NUM> to adjust a disruptor operating condition <NUM> if the process data <NUM> of the sensor output signal <NUM> is outside of the programmed operation range.

In certain exemplary embodiments, the actuator <NUM> is configured to adjust a position of the disruptor <NUM> in response to a disruptor input signal <NUM>.

In yet another exemplary embodiment of an exemplary system, the control system <NUM> is further configured to receive a disruptor output signal <NUM> indicating the disruptor output, wherein the control system <NUM> is further configured to send an agitator input signal <NUM> to an agitator <NUM> to adjust the rate of agitation when the disruptor output signal <NUM> indicates that the disruptor output is at a maximum and when the sensor output signal <NUM> indicates that the process data <NUM> is outside of the programmed operation range.

An exemplary system can further comprise multiple sensors <NUM> disposed in, on, or around the recovery boiler <NUM>, wherein the multiple sensors <NUM> are configured to measure multiple process data types.

Process data <NUM> may come from the following sources for example: temperature of the smelt spout cooling water, temperature of the dissolving tank vent stack, dissolving tank operational data (such as dissolving tank noise, and smelt flow position from the smelt spout), digital data that quantifies smelt flow and/or velocity of the smelt exiting the smelt spout <NUM>, digital data quantifying smelt inventory in the recovery boiler <NUM> (such as volume, location, etc.), and chemical characteristics of the smelt <NUM>. Combinations of any of these types of process data <NUM> is considered to be within the scope of this disclosure. Other process data from a chemical recovery mill that can be correlated to smelt flow are considered to be within the scope of this disclosure.

In an exemplary embodiment, the process data <NUM> is the temperature for the smelt spout cooling water that exits the smelt spout <NUM>. This is known as the outlet temperature of the smelt spout cooling water. A high outlet temperature of the cooling water could indicate a heavy smelt flow. An exemplary control system <NUM> as described herein is configured to adjust one or more disruptor operating conditions to mitigate the deviations in the smelt flow. A low outlet temperature of the cooling water could indicate a low smelt flow for example.

In other exemplary embodiments, the process data <NUM> is the temperature measured from the dissolving tank vent stack. A high vent stack temperature could indicate a heavy smelt flow. A low vent stack temperature could indicate a low smelt flow. In exemplary embodiments where the process data <NUM> is dissolving tank operational data, increased noise, or "banging" could indicate poor disruptor position and/or heavy smelt flow. In embodiments wherein digital data quantifies smelt flow and/or the velocity of smelt <NUM> exiting the smelt spout <NUM>, a high velocity indicates a high smelt flow, whereas a lower velocity indicates a lower smelt flow. In embodiment wherein the digital data quantifies the smelt inventory in the recovery boiler <NUM> (e.g. the volume, location of the smelt bed, etc.) a high volume could indicate that a heavy smelt flow is forthcoming.

Digital data can come from a visual analysis system. In one such exemplary embodiment, a camera can be aimed through an open inspection door <NUM> to record the flow of smelt <NUM> from the spout <NUM>. Referring to <FIG>, the camera or other image capture device can record pictures or video and transmit the pictures or video to a control system comprising a platform. The platform can comprise a user interface, a module for performing numerical analysis, and a data storage module. The user interface can be a mobile device for example (such as a smart phone, tablet, or laptop for example) or a monitor (such as in a control center for example). The digital data (i.e. a type of process data <NUM>) is relayed to the control system. The control system further comprises a tool for analyzing the picture of video to quantify the process data. For example, the analysis tool can quantify the percentage of sulfate, unburned material, and sulfite in a given sample. The control system can then store the analysis results in a data module, use a numerical analysis module to further analyze the results and calculate historical trends, and display the results (i.e. numeric data) on the user interface for remote operator review. In certain exemplary embodiments, the operator can then remotely adjust a disruptor operating condition <NUM> in response to results displayed on the user interface. In other exemplary embodiments, the control system can suggest changes to the remote operator. In such embodiments, the remote operator initiates the sending of the disruptor input signal <NUM> to adjust an operating condition <NUM> of the disruptor <NUM> in response to certain process data <NUM>. In yet other exemplary embodiments, the control system can send a disruptor input signal <NUM> to the disruptor assembly <NUM> to adjust a disruptor operating condition <NUM> without remote operator review.

In embodiments in which the process data <NUM> is one or more chemical characteristics of smelt (sulfidity, etc.) a low sulfidity increases the viscosity and the melting temperature of smelt, thereby often leading to a lower angle of smelt flow. By contrast, a high sulfidity deceases smelt viscosity to a point. An exemplary system <NUM> as described herein is configured to adjust one or more disruptor operating conditions to mitigate the deviations in smelt flow.

In certain exemplary embodiments, multiple disruptors <NUM> are disposed above the dissolving tank <NUM>. In certain exemplary embodiments, an operator may adjust the disruptor <NUM> remotely based upon visual inputs from a sensor <NUM>, and in such embodiments, the sensor is likely to be a camera or other image capture device.

Another exemplary disruptor adjustment system <NUM> comprises: a disruptor assembly <NUM> configured to disrupt a volume of smelt <NUM> flowing from a smelt spout <NUM> into the dissolving tank <NUM>, wherein the disruptor assembly <NUM> comprises an actuator <NUM> operatively engaged to a disruptor <NUM>, a sensor <NUM> configured to record process data <NUM> from the recovery boiler <NUM>, and a control system <NUM> configured to receive a sensor output signal <NUM> from the sensor <NUM>, wherein the sensor output signal <NUM> indicates the process data <NUM> at a measured time T, wherein the control system <NUM> is further configured to compare the sensor output signal <NUM> to a programmed operation range for the process data <NUM>, and to send a disruptor input signal <NUM> to disruptor assembly <NUM> to change a first disruptor operating condition <NUM> to a second disruptor operating condition <NUM> if the sensor output signal <NUM> is outside of the programmed operation range.

Sensors <NUM> may be disposed in or around the dissolving tank <NUM> or in or around the recovery boiler <NUM> to monitor process conditions. The signal generators <NUM> typically associated with the sensors <NUM> generate a sensor output signal <NUM> and transmit the sensor output signal <NUM> to the control system <NUM>. The control system <NUM> in turn is configured to adjust a disruptor operating condition <NUM> based on the value of the sensor output signal <NUM>. Other "process conditions" may include, for example, temperature of the recovery boiler, temperature of the dissolving liquid <NUM>, acoustic emissions from the banging, and the density of the dissolving liquid <NUM>.

In certain exemplary embodiments, the control system <NUM> may be selected from the group consisting of a computer, a programmable logic controller ("PLC"), a field programmable gate array ("FPGA"), an application-specific integrated circuit ("ASIC"), or other processor.

In the depicted exemplary embodiment, the control system <NUM> is in signal communication with the disruptor assembly <NUM>, the sensors <NUM>, and optionally, the primary agitator <NUM>. Signal communication may be achieved through wires or wirelessly. It is further contemplated that "signal communication" may comprise the use of one or more intermediate signal processors (e.g. amplifiers, analog to digital converters, relays, filters, etc.) configured to modify and/or transmit the signals between the control system <NUM> and the disruptor assembly <NUM>, the sensors <NUM>, and optionally, the primary agitator <NUM>. Combinations of any of the disclosed embodiments are within the scope of this disclosure.

As an example of an exemplary method, the control system <NUM> may receive a disruptor output signal <NUM> from a disruptor <NUM> and a sensor output signal <NUM> from a sensor <NUM>. The disruptor output signal <NUM> may indicate that the disruptors <NUM> are emitting disrupting fluid <NUM> at a maximum flow rate. The sensor output signal <NUM> may indicate that the density of the dissolving liquid <NUM> is above the desirable range. The control system <NUM> may analyze the signals <NUM>, <NUM> and send an agitator input signal <NUM> to the agitator (see <NUM>, <NUM>) to increase the rate of agitation. A nominal range for the density of the dissolving liquid <NUM> is typically between <NUM>,<NUM> kilograms per meter cubed ("kg/m<NUM>") and <NUM>,<NUM>/m<NUM>. If the sensor <NUM> is a temperature sensor, the desirable or "nominal" temperature range for the dissolving liquid <NUM> if the dissolving liquid <NUM> is green liquor is about <NUM> to <NUM>.

<FIG> and <FIG> depict one embodiment of a control system <NUM> for adjusting a disruptor operating condition <NUM> to mitigate the effects of smelt flow variations.

The control system <NUM> is in communication with the disruptor adjustment systems <NUM> that have been described above with reference to <FIG>. For example, the control system <NUM> may include at least one signal generator <NUM> in communication with disruptor adjustment systems <NUM> that adjusts a disruptor operating condition <NUM> in responses to changes in smelt flow characteristics. In one embodiment, the at least one signal generator <NUM> is in communication with the disruptor assembly <NUM>.

In some embodiments, the control system <NUM> may include a receiver <NUM> for receiving measured smelt flow deviations between the smelt flow and the emission end <NUM> of the disruptor <NUM>.

In some embodiments, the control system <NUM> may further include a corrective disruptor operating condition analyzer <NUM> that employs a hardware processor <NUM> for performing a set of instructions for comparing the smelt flow deviations to the baseline smelt flow position values in providing a corrective disruptor operating condition dimension. As employed herein, the term "hardware processor subsystem" or "hardware processor" can refer to a processor, memory, software or combinations thereof that cooperate to perform one or more specific tasks. In useful embodiments, the hardware processor subsystem can include one or more data processing elements (e.g., logic circuits, processing circuits, instruction execution devices, etc.). The one or more data processing elements can be included in a central processing unit, a graphics processing unit, and/or a separate processor- or computing element-based controller (e.g., logic gates, etc.). The hardware processor subsystem can include one or more on-board memories (e.g., caches, dedicated memory arrays, read only memory, etc.). In some embodiments, the hardware processor subsystem can include one or more memories that can be on or off board or that can be dedicated for use by the hardware processor subsystem (e.g., ROM, RAM, basic input/output system (BIOS), etc.).

More specifically, in an exemplary embodiment, the control system <NUM> receives data measured on the smelt flow position relative to the disruptor position from a sensor <NUM>, which can measure the smelt flow position during operation. The control system <NUM> then employs the corrective disruptor operating condition analyzer <NUM> to compare the data measured on the smelt flow position from the sensor <NUM> to the baseline smelt flow position <NUM> that was previously determined in step <NUM> of the method depicted in <FIG>. The baseline smelt flow position values may be stored in the memory <NUM> of the control system <NUM>, which can be provided in a module for baseline smelt flow position <NUM>. In some embodiments, the corrective disruptor operating condition analyzer <NUM> determines if the difference between the baseline smelt flow position <NUM> and the measured smelt flow is a deviation that is significant enough to be a smelt flow deviation from which the disruptor adjustment system <NUM> may benefit from a correction in a disruptor operating condition <NUM> actuated by the actuator <NUM> or by adjusting the rate of disrupting fluid dissemination. To determine if correction is suitable, the corrective disruptor operating condition analyzer <NUM> may employ a number of rules that are actuated by the hardware processor <NUM> in calculating a solution to smelt flow position deviations.

Each of the components for the control system <NUM> that are depicted in <FIG> may be interconnected via a system bus <NUM>.

Any of the systems or machines (e.g., devices) shown in <FIG> may be, include, or otherwise be implemented in a special-purpose (e.g., specialized or otherwise non-generic) computer that has been modified (e.g., configured or programmed by software, such as one or more software modules of an application, operating system, firmware, middleware, or other program) to perform one or more of the functions described herein for that system or machine. For example, a special-purpose computer system able to implement any one or more of the methodologies described herein is discussed above, and such a special-purpose computer may, accordingly, be a means for performing any one or more of the methodologies discussed herein. Within the technical field of such special-purpose computers, a special-purpose computer that has been modified by the structures discussed herein to perform the functions discussed herein is technically improved compared to other special-purpose computers that lack the structures discussed herein or are otherwise unable to perform the functions discussed herein. Accordingly, a special-purpose machine configured according to the systems and methods discussed herein provides an improvement to the technology of similar special-purpose machines.

The control system <NUM> may be integrated into the processing system <NUM> depicted in <FIG>. The processing system <NUM> includes at least one processor (CPU) <NUM> operatively coupled to other components via a system bus <NUM>. A cache <NUM>, a Read Only Memory (ROM) <NUM>, a Random Access Memory (RAM) <NUM>, an input/output (I/O) adapter <NUM>, a sound adapter <NUM>, a network adapter <NUM>, a user interface adapter <NUM>, and a display adapter <NUM>, are operatively coupled to the system bus <NUM>. The bus <NUM> interconnects a plurality of components as will be described herein.

The processing system <NUM> depicted in <FIG>, may further include a first storage device <NUM> and a second storage device <NUM> are operatively coupled to system bus <NUM> by the I/O adapter <NUM>. The storage devices <NUM> and <NUM> can be any of a disk storage device (e.g., a magnetic or optical disk storage device), a solid state magnetic device, and so forth. The storage devices <NUM> and <NUM> can be the same type of storage device or different types of storage devices.

A speaker <NUM> is operatively coupled to system bus <NUM> by the sound adapter <NUM>. A transceiver <NUM> is operatively coupled to system bus <NUM> by network adapter <NUM>. A display device <NUM> is operatively coupled to system bus <NUM> by display adapter <NUM>.

A first user input device <NUM>, a second user input device <NUM>, and a third user input device <NUM> are operatively coupled to system bus <NUM> by user interface adapter <NUM>. The user input devices <NUM>, <NUM>, and <NUM> can be any of a keyboard, a mouse, a keypad, an image capture device, a motion sensing device, a microphone, a device incorporating the functionality of at least two of the preceding devices, and so forth. Of course, other types of input devices can also be used, while maintaining the spirit of the present invention. The user input devices <NUM>, <NUM>, and <NUM> can be the same type of user input device or different types of user input devices. The user input devices <NUM>, <NUM>, and <NUM> are used to input and output information to and from the processing system <NUM>.

Of course, the processing system <NUM> may also include other elements (not shown), as readily contemplated by one of skill in the art, as well as omit certain elements. For example, various other input devices and/or output devices can be included in processing system <NUM>, depending upon the particular implementation of the same, as readily understood by one of ordinary skill in the art. For example, various types of wireless and/or wired input and/or output devices can be used. Moreover, additional processors, controllers, memories, and so forth, in various configurations can also be utilized as readily appreciated by one of ordinary skill in the art. These and other variations of the processing system <NUM> are readily contemplated by one of ordinary skill in the art given the teachings of the present invention provided herein.

<FIG> is a flowchart depicting possible signal paths of the sensor output signal <NUM>, which is measured by the sensor <NUM> in measuring process data <NUM>, such as the position of the smelt flow relative to the disruptor <NUM>. In operation, the sensor <NUM> measures the distance D of the smelt flow <NUM> to the disruptor <NUM> to generate a sensor output signal <NUM>. The sensor <NUM> then transmits the sensor output signal <NUM> to the control system <NUM> that is configured to analyze the sensor output signal <NUM>. The control system <NUM> may take a variety of forms physically, and may include by way of example, an integrated power and signal device, or separate power and signal processing devices connected together. The control system <NUM> may be digital or analog, and controlled by programmable logic controller ("PLC") logic or relay logic. In an exemplary embodiment, the control system <NUM> includes a corrective disruptor operating condition analyzer <NUM> that compares the value of the sensor output signal <NUM> to a baseline smelt flow position <NUM>. The baseline smelt flow position <NUM> may include the values stored within the module for baseline smelt flow position <NUM> that can be stored in the memory <NUM> of the control system <NUM>. The control system <NUM> can then send disruptor input signal <NUM> to the disruptor assembly <NUM> if the sensor output signal <NUM> differs (e.g. is not an element in) from the baseline smelt flow position <NUM>. In one embodiment, if the sensor output signal <NUM> exceeds the baseline smelt flow position <NUM>, the disruptor input signal <NUM> directs actuator <NUM> to change the angle of the disruptor <NUM> relative to the smelt flow <NUM>. In another exemplary embodiment, if the sensor output signal <NUM> exceeds the baseline smelt flow position <NUM>, the disruptor input signal <NUM> directs actuator <NUM> to change insertion depth of the disruptor <NUM> in the hood <NUM> relative to the smelt flow <NUM>. In an exemplary embodiment, the disruptor <NUM> provides a redundant disruptor output signal <NUM> to the control system <NUM> to confirm the disruptor operating condition <NUM> of the disruptor <NUM>.

The computer program product can provide a method for maintaining a desirable position between an emission end <NUM> of a disruptor <NUM> and a smelt flow <NUM>. For example, the present disclosure provides a computer program product comprising a non-transitory computer readable storage medium having computer readable program code embodied therein. The computer readable program code can provide the steps of measuring a baseline smelt flow position <NUM> between at least one emission end <NUM> of a disruptor <NUM> and the smelt flow <NUM>. An actuator <NUM> may be engaged to the at least disruptor <NUM>.

Computer readable program instructions for carrying out operations of the present invention may be assembler instructions, instruction-set-architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state-setting data, or either source code or object code written in any combination of one or more programming languages, including an object oriented programming language such as SMALLTALK, C++ or the like, and conventional procedural programming languages, such as the "C" programming language or similar programming languages.

<FIG> is a flow diagram showing a method for adjusting a disruptor operating condition <NUM> to mitigate the effects of variations in the smelt flow position <NUM>, in accordance with one embodiment of the present disclosure. <FIG> illustrate an exemplary disruptor adjustment system <NUM> that can be used in combination with the method described with reference to <FIG>. <FIG> and <FIG> illustrates some embodiments of a control system <NUM> for use with the structures and methods depicted in <FIG>.

In some alternative implementations, the functions noted in the blocks may occur out of the order noted in the figures.

Referring to block <NUM> of <FIG>, in one embodiment, the method for maintaining a desirable disruption of the smelt flow <NUM> may begin with measuring a baseline smelt flow position between at least one disruptor emission end <NUM> and the smelt flow <NUM> pouring from the smelt spout <NUM> at desirable conditions. The boiler depicted here is a recovery boiler <NUM>. However, the methods, systems and structures of the present disclosure are not limited to only this example. The methods, structures and systems described herein are applicable to any boilers that smelt spouts <NUM>.

As used herein, the "smelt flow position" is a dimension between the smelt flow <NUM> and an emission end <NUM> of at least one disruptor <NUM>. The smelt flow position is depicted in <FIG>, in which the dimension for the smelt flow position is identified by D. The smelt flow position in the systems described herein may be continually measured, and compared to the "baseline smelt flow position". In some embodiments, the difference between the baseline smelt flow position and the measured smelt flow position provides the differential by which the disruptor <NUM> may be adjusted to provide for an optimized distance and angle between the emission end <NUM> of the disruptor <NUM> and the smelt flow <NUM>. The baseline smelt flow position may take into account a mode of operation for the recovery boiler <NUM>. For example, the baseline smelt flow position may be different for startup of the recovery boiler <NUM>, when the recovery boiler <NUM> is processing reduced throughput of black liquor, when the recovery boiler is processing black liquor of different chemical compositions, when the recovery boiler is operating at capacity, and a combination of those factors. The baseline smelt flow position may also take into account different operational considerations of the disruptor <NUM>, such as the throughput capacity of the disruptor <NUM>.

Referring to <FIG>, the baseline smelt flow position <NUM> may be stored in the memory <NUM> of a control system <NUM> for maintaining a desirable distance D and orientation between an emission end <NUM> of the disruptor <NUM> and the smelt flow <NUM>. The control system <NUM> may also be referred to as the controller that receives a sensor output signal <NUM> from a sensor <NUM> measuring the position of the smelt flow <NUM> relative to the emission end <NUM> of the disruptor <NUM>. The control system <NUM> can further adjust a disruptor operating condition <NUM> to compensate for the deviations in the smelt flow position. In one embodiment, the control system <NUM> may include at least one module of memory <NUM> for storing baseline smelt flow position values for a dimension between at least one disruptor <NUM> and the smelt flow <NUM>.

The baseline smelt flow position values may be entered into the control system <NUM> by an operator that interfaces with the control system <NUM> over a user interface adapter <NUM>, as depicted in <FIG>. In this example, an operator of the recovery boiler <NUM> may enter values for the baseline smelt flow position from at least one input device <NUM>, <NUM>, <NUM>. The at least one input device <NUM>, <NUM>, <NUM> may be any computing device, such as a desktop computer, mobile computer, laptop computer, tablet, smart phone and/or computer specific to the turbine.

The input devices <NUM>, <NUM>, <NUM> may be in connection with the user interface adapter <NUM> via a wireless connection, or the input devices <NUM>, <NUM>, <NUM> may be hard wired into electrical communication with the user interface adapter <NUM>.

The baseline smelt flow position may be a value that is manually measured from the recovery boiler <NUM> during start up, or while the recovery boiler <NUM> is offline, and may also take into account measurements while the recovery boiler <NUM> is in operation.

In some other embodiments, the control system <NUM> may employ machine learning to adjust the baseline smelt flow position taking into account at least one of historical measurements for the smelt flow position, real time measurements of the smelt flow position and operator suggested values for the smelt flow position. Machine learning algorithms build a mathematical model based on sample data, known as "training data", in order to make predictions or decisions without being explicitly programmed to perform the task. In this case, the historical measurements may be employed with operation conditions to provide training data algorithms, which can in turn be employed to use real time data to update the baseline smelt flow position.

Referring to <FIG>, the method may continue at block <NUM> using a disruptor adjustment system comprising a disruptor assembly, the disruptor assembly may include an actuator engaged to a disruptor, wherein the disruptor assembly is actuated by a motive force from the actuator to change a disruptor operating condition <NUM>, wherein a disruptor operating condition <NUM> may be selected from the group consisting of: the disruptor angle of insertion, the disruptor depth of insertion, and the rate of disrupting fluid exiting the emission end <NUM> of the disruptor <NUM>.

The method may further include measuring smelt flow deviations between the smelt flow and the emission end <NUM> of the disruptor block <NUM>. The method may continue with block <NUM> in further calculating a difference between the smelt flow position deviations and the baseline smelt flow position. In some embodiments, the calculation of the difference between the smelt flow position deviations and the baseline smelt flow position is provided by a control system <NUM>, which can include a corrective disruptor operating condition analyzer <NUM>. Referring to block <NUM> of <FIG>, in some embodiments, the method includes changing a disruptor operating condition <NUM> to compensate for the difference between the smelt flow position deviations and the baseline smelt flow position.

An exemplary method for monitoring and adjusting a disruptor operating condition <NUM> for a disruptor <NUM> disposed over a dissolving tank <NUM> comprises: receiving a sensor output signal <NUM> from an sensor <NUM>, the sensor output signal <NUM> indicating a process condition at a measured time T; receiving a disruptor output signal <NUM> from a disruptor assembly <NUM> disposed over a dissolving tank <NUM> indicating a current disruptor operating condition <NUM>, comparing the sensor output signal <NUM> with a baseline smelt flow position for the process condition; comparing the disruptor output signal <NUM> with a baseline disruptor operating condition for the disruptor <NUM>; and sending a disruptor input signal <NUM> to the disruptor <NUM> to adjust the disruptor operating condition <NUM> when the sensor output signal <NUM> is outside the desirable operation range for the process condition.

An exemplary recovery boiler dissolving tank disruptor adjustment system comprises: a dissolving tank, a spout adjacent to the dissolving tank, wherein the spout is configured to convey a volume of smelt into the dissolving tank, a disruptor configured to disrupt the volume of smelt flowing from the spout into the dissolving tank, a sensor configured to record process data from a recovery boiler, and a control system configured to receive a sensor output signal from the sensor, wherein the sensor output signal indicates the process data at a measured time, wherein the control system is further configured to compare the sensor output signal to a programmed operation range for the process condition, and to send a disruptor input signal to the disruptor to adjust a disruptor operating condition if the process data is outside of the programmed operation range.

An exemplary system may further comprise an actuator operatively engaged to the disruptor, wherein the actuator is configured to adjust a position of the disruptor in response to a disruptor input signal.

In certain exemplary embodiments, the position of the disruptor is a disruptor operating condition.

In certain exemplary embodiments, the position of the disruptor comprises an insertion depth.

In certain exemplary embodiments, the position of the disruptor comprises an angle of the disruptor.

In certain exemplary embodiments, the disruptor operating condition further comprises a rate of steam flow.

In certain exemplary embodiments, the process data is selected from the group consisting of: a rate of smelt flow, dissolving tank operational data, and a smelt spout cooling water temperature.

An exemplary system may further comprise a camera configured to capture an image of the smelt in the smelt spout.

An exemplary disruptor adjustment system comprises: a disruptor assembly configured to disrupt a volume of smelt flowing from a smelt spout into the dissolving tank, wherein the disruptor assembly comprises an actuator operatively engaged to a disruptor, a sensor configured to record process data from the recovery boiler, and a control system configured to receive a sensor output signal from the sensor, wherein the sensor output signal indicates the process data at a measured time, wherein the control system is further configured to compare the sensor output signal to a programmed operation range, and to send a disruptor input signal to the disruptor assembly to adjust a disruptor operating condition if the process data of the sensor output signal is outside of the programmed operation range.

In certain exemplary embodiments, the actuator is configured to adjust a position of the disruptor in response to a disruptor input signal.

An exemplary system may further comprise a camera configured to capture an image of the smelt leaving the smelt spout.

In certain exemplary embodiments, the control system is further configured to receive a disruptor output signal indicating the disruptor output, wherein the control system is further configured to send an agitator input signal to an agitator to adjust the rate of agitation when the disruptor output signal indicates that the disruptor output is at a maximum and when the sensor output signal indicates that the process data is outside of the programmed desirable range.

In certain exemplary embodiments, the control system is further configured to receive a transducer output signal indicating the transducer output, wherein the control system is further configured to send a disruptor input signal to the disruptor to adjust the rate of disruption when the transducer output signal indicates that the transducer output is at a maximum and when the sensor output signal indicates that the process condition is outside of the programmed desirable range.

An exemplary system may further comprise multiple sensors disposed in, on, or around the recovery boiler, wherein the multiple sensors are configured to measure multiple process data types.

An exemplary system may further comprise multiple disruptors disposed above the dissolving tank.

An exemplary disruptor adjustment system comprises: a disruptor assembly configured to disrupt a volume of smelt flowing from a smelt spout into the dissolving tank, wherein the disruptor assembly comprises an actuator operatively engaged to a disruptor; a sensor configured to record process data from the recovery boiler; and a control system configured to receive a sensor output signal from the sensor, wherein the sensor output signal indicates the process data at a measured time, wherein the control system is further configured to compare the sensor output signal to a programmed operation range for the process data, and to send a disruptor input signal to disruptor assembly to change a first disruptor operating condition to a second disruptor operating condition if the sensor output signal is outside of the programmed operation range.

An exemplary method for monitoring and adjusting a disruptor operating condition for a disruptor disposed over a dissolving tank comprises: receiving a sensor output signal from an sensor, the sensor output signal indicating a process condition at a measured time; receiving a disruptor output signal from a disruptor assembly disposed over a dissolving tank indicating a current disruptor operating condition; comparing the sensor output signal with a baseline smelt flow position for the process condition; comparing the disruptor output signal with a baseline disruptor operating condition for the disruptor; and sending a disruptor input signal to the disruptor to adjust the disruptor operating condition when the sensor output signal is outside the desirable operation range for the process condition.

An exemplary method may further comprise receiving an agitator output signal from an agitator indicating a rate of agitation, and sending an agitator input signal to the agitator to adjust the rate of agitation when the disruptor output signal is outside of the programmed desirable operation range for the disruptor.

Claim 1:
A disruptor adjustment system comprising:
a disruptor assembly (<NUM>) comprising a disruptor (<NUM>) and an actuator (<NUM>), the disruptor (<NUM>) being configured to emit disrupting fluid (<NUM>) to disrupt a volume of smelt (<NUM>) flowing from a smelt spout (<NUM>) into a dissolving tank (<NUM>), and the actuator (<NUM>) being operatively engaged to the disruptor (<NUM>) and configured to adjust a position of the disruptor (<NUM>);
a sensor (<NUM>) configured to record process data from a recovery boiler (<NUM>); and
a control system (<NUM>) configured to receive a sensor output signal (<NUM>) from the sensor (<NUM>), wherein the sensor output signal (<NUM>) indicates the process data (<NUM>) at a measured time (T), wherein the control system (<NUM>) is further configured to compare the sensor output signal (<NUM>) to a programmed operation range for the process data (<NUM>), and to send a disruptor input signal (<NUM>) to the disruptor assembly (<NUM>) to adjust a disruptor operating condition (<NUM>) if the process data (<NUM>) of the sensor output signal (<NUM>) is outside of the programmed operation range.