Upload
others
View
1
Download
0
Embed Size (px)
Citation preview
PULP AND PAPER SOLUTION GUIDE
How to save steam and improve run time on a Recovery Boiler
Background
Sootblowers in a recovery boiler consume a significant
amount of valuable high-pressure steam. Although
paramount to keep the recovery boiler running at
its full capacity without plugging the gas passes,
sootblower steam usage can be excessive—and costly.
This cost cannot be passed to consumers, requiring
mill engineers to continuously look for opportunities
to reduce costs for improved profitability.
While it is impossible to completely eliminate
sootblower steam consumption, current technology
advancements have successfully reduced the
sootblower steam usage to a level well below 5%
of the total boiler steam production. Our experience
with the solutions listed in this guide has shown a
sootblower system is able to achieve 2.5% of the
boiler MCR.
Clyde Bergemann’s Solutions
1) High Performance Contoured Fully Expanded
Nozzle (CFE III)
An ideal nozzle is able to fully expand the blowing
medium to the ambient pressure and thereby convert
the pressure completely into velocity. But in practice, it
is impossible to achieve 100% efficiency. A conventional
nozzle generally has low nozzle efficiency (less than 50%),
so the amount of steam consumed by a conventional
nozzle has to be increased in order to compensate for the
lower nozzle efficiency.
Clyde Bergemann’s CFE III nozzle has pushed the
envelope with breakthrough nozzle efficiency greater
than 90%. This higher nozzle efficiency means that CFE
III can generate the same amount of cleaning power
as its conventional nozzle counterpart at a much lower
steam flow rate. Conversely, it also means that CFE III
can generate more cleaning power than a conventional
nozzle at the same steam flow rate.
2) CFEIII-LE (Leading Edge) Nozzles
CFEIII-LE is the proven nozzle technology that is specifcally
designed to extend boiler runtime. Deposit bridging
occurs at the leading edge of the heat exchangers when
the fouling conditions are hard to combat. CFEIII-LE uses
a new deposit removal mechanism called “debonding”
rather than the typical fracture mechanisms and removed
heavy deposit by using a torque angle provided by the
very deposit itself located at the leading edge of the tube
sections.
3) SMART Clean™ Intelligent SootBlowing Control
System (ISB)
SMART Clean™ Intelligent SootBlowing (ISB) is a closed
loop control system that uses feedback from the heat
exchanger, gathered in real-time during normal boiler
operation. This is designated to intelligently manage
the sequence of sootblower operation. This enables
a targeted cleaning strategy that saves steam by
dynamically managing the sootblowing timing and flow.
2
BeforeSystem Upgrade
CFE Nozzle Upgrade
SMART Clean Upgrade
Performance Monitoring & Optimization
4
3.5
3
2.5
1.5
1
0.5
0
40
35
30
25
20
15
10
5
0
$2.0 M/yr
$1.5 M/yr
$1.1 M/yr $1.0 M/yr
34 kph
25 kph
19 kph16 kph
Sootblowing Costs ($ Million/yr) Sootblowing Costs ($ Million/yr)
SMART Clean™ can also identify sootblowers that are
located in non-critical areas, where the deposits can be
easily removed with a one-way sootblowing strategy.
One-way-sootblowing uses the full cleaning power of the
sootblower only during the insertion process. The cleaning
power is reduced to a minimum level, which is just enough
to keep the lance from overheating during the retraction
process, further saving valuable sootblowing steam.
4) Remote Performance Monitoring &
Optimization:
Clyde Bergemann offers Sootblower Performance
Monitoring and Optimization Service for your recovery
boilers. Our team of veteran industry professionals has
optimized dozens of systems nationwide and can help
you:
• Optimize your boiler cleaning system strategy
• Bench mark boiler performance with the rest of the
industry
• Generate automated performance and maintenance
reports for maintenance planning and asset
management
Remote monitoring and optimization are carried
out through secure VPN access, in collaboration
with the plant’s security and information technology
team, to obtain critical boiler and sootblower-related
performance data. The raw data is then converted
into valuable knowledge and used to make informed
decisions. A monthly performance report is submitted,
and bi-weekly conference calls with plant engineers
are enforced to coordinate the action plan and drive
improved results.
Use of complete Clyde Bergemann solutions with data from recovery boiler 5.0 Mlb BLDS/day
TM
3
Clyde Bergemann Power Group Americas Inc. Boiler Efficiency Product Division
4015 Presidential Parkway Atlanta, GA 30340
1 800-241-5996T: 770-557-3600F: 770-557-3651
Internet: www.cbpg.comeMail: [email protected]
5) Steam Saver Sootblowing Technology (RSP-H):
Sootblowers consume a significant amount of
valuable high pressure steam produced by the boiler.
A tremendous cost-saving alternative is to use lower
pressure steam from the outlet of the steam turbine at
150 – 250 psig (10-17) bar.
RSP-H is Clyde Bergemann’s new generation sootblower
designed to produce cleaning force equivalent to that of
a higher-pressure sootblower. This technology enables
CB-
2012
/09.
We
rese
rve
the
right
to
mak
e te
chni
cal c
hang
es w
ithou
t no
tice.
Return On Investment based on 350 days of annual operation and 1.5 MWhr additional green energy generation
the mill to direct all high-pressure boiler steam to a steam
turbine generating additional 1-3 MW power, while the
extraction steam from the turbine is used for sootblowing.
Four U.S. pulp mills have used Clyde Bergemann Steam
Saver sootblowing technology to generate more MW
and improve profitability. While initial investment is not
nominal, the payoffs for this technology, even for retrofits,
are extremely significant- more than enough to make the
investment worthwhile.
$40
$1200K
$800K
$400K
$0
$504K
Annual ROI (US $1000s)
$45 $50 $55 $60 $65
Average Sell Price for Green Energy (US $/MWhr)
$567K$630K
$693K$756K
$819K
High Pressure Steam = $8/kLb
High Pressure Source
POWER
TO MILL
150 - 25- PSIG(10 -17 BAR)
PRV
SOOTBLOWINGSTEAM
600 - 1,500 PSIG(41 - 103 BAR)
TURBINE
BOILER
POWER
TO MILL
150 - 25- PSIG(10 -17 BAR)
SOOTBLOWINGSTEAM
600 - 1,500 PSIG(41 - 103 BAR)
TURBINE
BOILER
Low Pressure Steam = $4/kLb
Low Pressure Source
Steam Saver Sootblowing
150-250 PSIG 150-250 PSIG
RSP-HSootblower
RSP-HSootblower