Advanced Furnace Cleaning - Kiet Pham - 27072018

Advanced Furnace Cleaning with
Intelligent Water Cannon

Technology
Clyde Bergemann GmbH, Germany
kiet.pham@de.cbpg.com
SURABAYA, Indonesia
www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 1

Agenda
• Situation & Challenges
• Advanced Furnace Cleaning Solution
• Reference Installations
• Summary

Agenda
• Summary

Situation - Typical challenges
• Varying fuel quality and fuel mix
• Different boiler operation modes

(e. g. load variability, different mill combinations)
• Inhomogeneous fouling at heating surfaces
• Reduced boiler efficiency
• Pile-up in hopper
• High costs for boiler cleaning
• Unplanned outages caused by slagging and fouling

 Results of a global, inflexible and fixed cleaning strategy gives rise to two scenarios as below:
 “Too little cleaning”
• Reduced heat transfer

• Clinker growth
• Increase of boiler off gas temperature
• Reduction of steam production and steam temperature
• Overload of intercoolers
• Reduction of boiler efficiency

 Results of a global, inflexible and fixed cleaning strategy:
 “Too much cleaning”

• Avoidable steam consumption
• Avoidable wear of soot blowing system
• Increase of erosion risk
• Increase of soot blowing costs

Slagging and Fouling
C A Furnace slagging
Slagging
B  Deposits within furnace, in areas directly
exposed to flame radiation such as
B Slagging/Fouling furnace walls and some widely spaced
pendant super-heaters. Take place in the
hottest parts of boiler.
D C Heavy fouling
Fouling
 Deposits in areas NOT directly exposed to
A D Light fouling flame radiation such as the more closely
spaced tubes in convection sections of
boiler.
E E Fouling/Blockage

Agenda
• Summary

Automation
Superheater/ ECO
Re-Heater  SMART CONTROLTM
 Part Retractable
 Remote Control
 Retractable Sootblowers
Sootblowers  Rotating Element
Optimisation
 Oscillating Sootblowers
 Smart Clean
Sootblowers
Air heater/Gas heater PlatformTM
 SMART Helix RSG
 Rake Sootblowers
 Jetblower
 Dual Medium blower
DeNOx
 Rake
Sootblowers
Furnace
 Wall Deslagger
 SMART Cannon

Furnace Cleaning – Conventional and
Advanced
 Cleaning solutions for the furnace:
• Conventional
− Wall blowers
− Water blowers
• Advanced
− Water Cannons
 Cleaning media
• steam/water
 Critical cleaning parameters can be flexibly set depending on deposition type or intensity
 This allows for an efficient and flexible boiler cleaning

Cleaning Devices for Furnace
Conventional Wall Deslagger Water Cannon
vs. Water Cannon
20
Meter
+58,0
Effective area of
Water Cannon
+48,7
+38,0
Uncleaned Area
Conventional
Wall Deslagger

SMART Cannon: Advanced Technology
Volumetric expansion
Functional principle
 Water jet impinging on deposits surface, penetrates through the
Water/Steam
pores, causing a volumetric expansion of the water drops which Water
results in the breaking-up of deposits

 With a state-of-the-art control technology, the water jet creates a
Deposition
meander shaped pattern on the side and opposite wall
 Monitoring the drive unit as well as combining different nozzle
sizes and blowing pressures ensures that even opposite walls at a
distance of 35 meters are effectively cleaned

SMART Cannon – Complete System

Specific SMART Cannon Components
Mounting frame
 is a steel construction with standard fitting provisions for Drive modules
the crimp box and the drive modules is designed to hold the
complete product with the necessary stability brings
compactness to the overall design
Crimp box
Mounting
Crimp box – frames
Boiler side

Intelligent Boiler Cleaning
Use of SMART Clean with Water Cannons:
 The result: Intelligent boiler cleaning
Overview of complete steam generating process

Flexible:
- Demand driven
- Automatic
- Real-time

SMART Clean Controls
When?
DCS
SMART Clean PC Server

Where?
How?
SMARTVisualization
Clean Software
SMART Control
CLEANING MANAGER
PLC or DCS
SMART Furnace
Selective and
SMART Convection
targeted
cleaning actions
TDM Matrix Clean SHFM
Cleaning devices
SMART Clean Sensors

Use of SMART Clean with Water Cannons:
SMART Furnace
 Zone based analysis of the furnace status

based on direct heat flux measurement or surface temperature
distribution.
(e. g. with SMART Flux sensors, SMART InfraScan)
 Deduction of a selective furnace

cleaning strategy
 Optimization of the heat transfer in

furnace area
 Definition of appropriate cleaning actions

Diagnostics with SMART Clean
SMART Flux Sensor – Heat flux measurement
 Direct feedback about slagging status
Q= ∆ ϑλ
s
∆ϑ = T1 – T2 [K]
s = Distance [m]
λ = Heat conductance value [ m*K

W
]
Analysis and Decision with SMART Clean
 Input data Heat flux signal
• Boiler parameter (e. g. load) SMART Flux Sensor
• SMART Flux measurement data
(heat flux signal)
 Signal analysis
Cleaning
• Monitoring of change of Heat flux characteristics (signal
analysis) in combination with other operational parameters. Cleaning action
Change of
characteristics

Diagnostics with SMART Clean
SMART InfraScan – Surface temperature measurement
• Diagnostic module for SMART Furnace
• Large scale analysis of surface temperature distribution on
furnace walls
• Precise detection of slagged areas
• Cleaning strategy is flexibly adapted to slagging status
Surface temperature signal
SMART InfraScan

Intelligence with SMART Clean
Optimised cleaning:
 Online adaption of the cleaning patterns to determined slagging hotspots
• Target-oriented and demand-driven cleaning
• Reduction of cleaning media
• No exposure on clean surfaces in the furnace

Analysis Result with SMART Clean
 Input data
• Boiler parameter (e. g. load) Slagging status
• SMART Flux measurement data
(heat flux signal)
• SMART InfraScan measurement data (surface temperature signal)
 Signal analysis
• Monitoring of surface temperature and change of heat flux pattern
 Analysis result
• Slagging intensity for each zone
• Selection of cleaning figures

Agenda
• Summary

Advanced Furnace Cleaning Solution – First
Reference Installation in Malaysia
“Tanjung Bin Power Plant”
 3 sub critical units – 700 MW each
 1 Ultra super critical unit of 1000 MW
 Main Fuel – Bituminous and Sub-Bituminous Coal

Situation
 Varying Fuel Mix and deteriorating quality of Coal
 Excessive increase of furnace exit gas temperature and decrease
of boiler efficiency
 Heavy formation of deposits

Tanjung Bin Plant – Solution
 In August 2015, after several Technical discussions, Tanjung Bin was

convinced and decided to order the “Advanced Furnace Cleaning
Solution -Water Canon” for one Unit.
 Water Cannon provides a much greater furnace coverage and enables

effective cleaning of furnace deposits.
 The cleaning effect is unparalleled to any other cleaning device available

in the market.
 Provides flexibility to use different fuels for combustion.

Tanjung Bin Plant – Solution / Result
 After being satisfied with the performance, just couple of months later,
they decided to order “Water Cannons” for the Unit 10 and Unit 30.
 Reduction in FEGT by at least 50 Deg C.
 Increased heat absorption in furnace.
 Reduction costs for off load Boiler cleaning.
 Major reduction in maintenance costs of sootblowers.
 Extended Boiler availability

References
Mae Moh, Thailand
 “On-load” boiler cleaning of furnace area
• 48 x SMART Cannon
• Controls
Technical data - Plant
Fuel type Hard coal
Boiler type Tower type
Performance 300 MW
Technical data - Clyde Bergemann equipment

Cleaning media water
Cleaning equipment SMART Cannon

References
Yunghung, South Korea
 “On-load” boiler cleaning of furnace area
• 48 x SMART Cannon
• Controls
Technical data - Plant
Fuel type Hard coal
Boiler type Tower type
Performance 800 MW
Technical data - Clyde Bergemann equipment

Cleaning media water
Cleaning equipment SMART Cannon

References Europe / USA
 Over 3000 x SMART CANNONs worldwide
 95 % of hard coal / lignite fire boilers have been equipped with intelligent
SMART FURNACE system
 Asia countries are behind European countries in respect of advanced
cleaning technology
 All new boilers in Europe will be designed considering advanced cleaning
technology based on Water Cannon and SMART Furnace

Agenda
• Summary

Summary
Use of Advanced furnace cleaning technology enables
 Prevention of uncontrollable deposits and reduction of boiler shut
downs
 Improved heat absorption in the evaporator
 Reduced furnace exit gas temperature
 More flexibility in the use of different fuel qualities and compositions
 Reduced steam consumption
 Lower influence on process due to targeted and reduced furnace
cleaning
 Continuous monitoring and analysis of the thermal stress on the
evaporator wall heating surfaces
 Increase of boiler efficiency

Kiet PHAM
Clyde Bergemann GmbH
Phone +49 281 815-319
Mobile +49 171 8914 958
E-Mail: kiet.pham @de.cbpg.com

www.cbpg.com

Advanced Furnace Cleaning - Kiet Pham - 27072018

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Advanced Furnace Cleaning - Kiet Pham - 27072018

Uploaded by

Copyright:

Available Formats

Advanced Furnace Cleaning with

Intelligent Water Cannon

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 1

• Advanced Furnace Cleaning Solution

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 2

• Advanced Furnace Cleaning Solution

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 3

• Different boiler operation modes

• Inhomogeneous fouling at heating surfaces

• Reduced boiler efficiency

• High costs for boiler cleaning

• Unplanned outages caused by slagging and fouling

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 4

 “Too little cleaning”

• Reduced heat transfer

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 5

 “Too much cleaning”

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 6

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 7

• Advanced Furnace Cleaning Solution

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 8

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 9

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 10

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 11

results in the breaking-up of deposits

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 12

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 13

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 14

Overview of complete steam generating process

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 15

SMART Clean PC Server

SMART Clean Sensors

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 16

 Zone based analysis of the furnace status

 Deduction of a selective furnace

 Optimization of the heat transfer in

 Definition of appropriate cleaning actions

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 17

 Direct feedback about slagging status

λ = Heat conductance value [ m*K

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 19

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 20

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 21

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 22

• Advanced Furnace Cleaning Solution

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 23

 3 sub critical units – 700 MW each

 1 Ultra super critical unit of 1000 MW

 Main Fuel – Bituminous and Sub-Bituminous Coal

 Heavy formation of deposits

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 24

 In August 2015, after several Technical discussions, Tanjung Bin was

 Water Cannon provides a much greater furnace coverage and enables

 The cleaning effect is unparalleled to any other cleaning device available

 Provides flexibility to use different fuels for combustion.

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 25

 Increased heat absorption in furnace.

 Reduction costs for off load Boiler cleaning.

 Major reduction in maintenance costs of sootblowers.

 Extended Boiler availability

www.prbcoals.com | 2018 ASIAN SBC Users’ Group Conference 26

Technical data - Clyde Bergemann equipment