Sonic Soot Blower System

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Sonic Soot Blower System

  1. 1. Presentation to India PAPERTECH 2010SOUND BLASTSOUND BLASTSOUND BLASTSOUND BLASTSONIC SOOT BLOWERSONIC SOOT BLOWERFACILITATING ENERGY MANAGEMENT THROUGH SONIC SOOTBLOWING IN HIGH PRESSURE BOILERS RELATED TO PULPBLOWING IN HIGH PRESSURE BOILERS RELATED TO PULPAND PAPER PLANTSSOUND BLAST SONIC POWER COMPANY LIMITED PAPERTECH 2010 v01
  2. 2. Congratulations to Organisers ofPAPERTECH 2010for a most successful event and wishd l d dIndian Pulp and Paper Industryparticipants today and all stake holderscontinuous success and prosperity
  3. 3. With 600 paper mills in operation, a 7.8% projected annualgrowth, and an estimated nationwide paper demand of 10.5million tonnes in year 2010, the Pulp and Paper Industry playsan important role in the Indian economy and the next stepforward is to become world class.However, this industry is also the 5th largest energy consumerand the need is acute to better conserve and manage energywith minimum ecological impact.Sonic soot blowing is a low investment, cost effective way ofcleaning the boiler tubes and restore equilibrium conditions toimprove heat absorption and facilitate energy management.p p gy g
  4. 4. Most Paper Plants meet its heat and power needs by in‐housep p ythermal power boilers and waste heat recovery boilers; yetineffective removal of ash deposits from boiler tubes have inmany occasions lead to boiler in‐efficiency, capacity reductions,many occasions lead to boiler in efficiency, capacity reductions,tube overheating failures, and unscheduled shut downs.Sticky ash in Kraft recovery boilers aside, most ash deposits inthese boilers are friable, less sticky and less tenacious, and areremovable by sonic soot blowing or a combination thereof withremovable by sonic soot blowing or a combination thereof withexisting soot blowing systems in boilers.So, what is sonic soot blowing and what sets it apart from othersoot blowing systems? Is it feasible to target zero unscheduledoutages through sonic soot blowing?outages through sonic soot blowing?
  5. 5. What is sonic soot blowing Sonic soot blowing is cleaning of fouled surfaces by compressed air operated sonic soot blowers.Sound waves sent inside boilerSound waves sent inside boiler propagate in all directions and impart energy to ash particulates which fluidize and jump up fromSonic soot blower Tube bundlewhich fluidize and jump up from fouled surfaces to be carried away by the flue gas stream. Flue gas streamCleaning is effective even deep into tube bundles leaving no dead corners unclean.
  6. 6. Sonic soot blowing cleans with time settingSonic soot blowing operates continuously on‐line in successive short cycles where Cleaning with timeOncleaning effect is controlled by cycle time setting (“on” time is in seconds, and “off” time is in minutes).Cleaning with timeA helpful analogy to explain is to imagine cleaning your table once a year, or once a Offmonth, or everyday.  Of course, cleaning the table daily requires much less effort to keep it spotless!TimeNow, apply this to your boiler and clean it say every 20 minutes, or 90 times a day i d f j 3 i d ilinstead of just 3 times daily.
  7. 7. Clean tubes absorb more heat and reduce overheatingCleaning 90 times daily with sonic soot blowingClean tubes improve heat absorption Design conditions of cleanlinessH b b d and reduce overheating failures 0 8 16 24 hHeat absorbed from flue gasCleaning 3 times daily0  8  16  24 hrMore heat loss in flue gas and tubes are prone to overheating 0  8  16  24 hr
  8. 8. What is cleaning in successive short cyclesInitially, ashparticulatesland on tubeSince “off” time in thecleaning cycle is short,only a small quantityWhen cleaning cyclestarts, sound wavescome in and clean upsurfaces andstay there.of ash particulatescan land and willremain quite loose asthere is not enougheasily. The cyclerepeats every fewminutes successivelyto keep the tubethere is not enoughtime for it to compact.to keep the tubesurfaces always clean.
  9. 9. Pre‐ requisites to operate in successive short cycles1. It must not cause any damages to boiler tubes even when the soot blower fails during operation.                                         ( sonic soot blower never damage tubes)  2. Cost of soot blowing medium must be low and its production must not leave l i l f t i tecological footprints.                                                         ( compressed air is inexpensive)3. Soot blowing medium must create no ill effects at boiler exit.                        (compressed air is neutral and friendly)(compressed air is neutral and friendly)
  10. 10. 4. Soot blowing equipment must be reliable, easy to maintain, g q p , y ,and capable of full service between planned outages.           ( with only one moving part, sonic soot blower is practically maintenance free for long term operation)  a te a ce ee o o g te ope at o )5. Soot blowing system investment must be low and payback period must be short and realizable; and system must be capable of being installed in new or existing boilers easily.                     p g g y(sonic soot blowing system meets these requirements)
  11. 11. Reducing air pollution as a side benefitLevels out soot dischargeCleaning 90 times daily with sonic soot blowingLevels out soot discharge peaks to small batches for easy capture or more effective dispersionp0 8 16  24 hrSoot blowing discharge peaksCleaning 3 times dailySoot blowing discharge peaks are difficult to capture or disperse and form serious air polluters 3 times dailyp y0 8 16  24 hr
  12. 12. SOUND BLAST sonic productsSOUND BLAST sonic soot blowing system is capable of seamlesscapable of seamless integration to DCS with industry standard communicationcommunication protocols.
  13. 13. Sonic soot blowers operate in clustersSonic soot blowers are  usually installed on boiler yLHS and RHS in the tube bundle service spaces and operate in clusters to enhance cleaning effect.As in Cricket fields, its PA system broadcasts through loud speaker clusters for clear transmission to h f ldeveryone across the field.Below are 2 application cases. Constructive interference effect
  14. 14. Case 1:  Pulp mill 195 t/h recovery boilerThis is a 195 t/h pulp mill recovery boiler built in 1993 to fire sludge and with steel ball cleaning system;and with steel ball cleaning system; it had to be shut down every 3~4 months for manual cleaning. 4 years ago, 16 units of model SB38 sonic soot blowers were installed to operate in 4 groups.  Today, the sonic soot blowing system runs at 20 sec. “on”/ 3 min. ”off”; and steel ball cleaning is used only twice a week for 12 hours and boiler can last through planned outages.  The  g p gclient is now a repeat customer.
  15. 15. Case 1 real life photos 
  16. 16. Case 2:  Industrial 490 t/h CFBC boilerThis is an industrial 490 t/h coal fired CFBC boiler built in 2004; fouling persisted even with LRSB cleaning and the boiler could only operate at about 90% MCR. 5 years ago, 40 units of sonic soot blower models SB60 and SB38blower models SB60 and SB38 were installed and operated in 7 groups.  Together with the LRSB system the boiler returned tosystem the boiler returned to operate at about 95% MCR.The client was a repeat customer.
  17. 17. Case 2 real life photos 
  18. 18. Example on financial savings 210 MWe coal fired boiler Coal consumption p.a. :  1.03 million tons (approx.)Cost of coal to site : ~ INR 3 000/tonCost of coal to site :    INR 3,000/tonAnnual coal cost :  INR 3.09 billionSonic soot blowing:Direct savings @ 0.75% :  INR 23.2 millionIndirect savings @ 1% :  INR 30.9 millionTotal savings p.a. :  INR 54.1 million (INR 5.41 Crores)
  19. 19. Sonic soot blowing system payback periodIn most cases and considering benefits from efficiency gains only, sonic soot blowing system payback period is usually within 2 years.  Any additional benefits from improved performance and reduced maintenance would further shorten this payback period.maintenance would further shorten this payback period.  Typical LRSB S i t blSonic soot blower  (same range)  
  20. 20. Sonic soot blowing in Pulp and Paper IndustryTotal Cleaning Concept Sonic soot blowing system can be applied to different i ll i i l d l f iliinstallations in Pulp and Paper Plant to facilitate system operation and energy managementB il APH ESP B Filt I D FBoiler     APH     ESP     Bag Filter     I.D. Fan
  21. 21. Benefits of sonic soot blowing1. Facilitate energy management: reduce unscheduled outages, boiler damages, and increase overall plant safety, availability, reliability, and production stability.2 Improve operation economy: better boiler efficiency2. Improve operation economy: better boiler efficiency, less capacity reduction, and sustains superheated steam temperature to improve turbine performance.3. Reduce consumption: of steam, ID Fan power, and less system maintenance needs. 4. Reduce air pollution: through successive short cycle cleaning to level out soot discharge peakscleaning to level out soot discharge peaks.
  22. 22. Customer reference listReference in India:  In final stages of applying SOUND BLAST sonic soot blower model SB38In final stages of applying SOUND BLAST sonic soot blower model SB38 to a 117 t/h AFBC Boiler in Sheshasayee Paper & Boards, Tamil Nadu.Reference in other countries:
  23. 23. Industry coal fired boiler cleaning photosBefore and After
  24. 24. Industry coal fired boiler cleaning photos Before After
  25. 25. ESP cleaning photosNegative discharge wiresBefore After
  26. 26. ESP cleaning photos Positive collection platesBefore After
  27. 27. ESP hopper cleaning photos Hopper discharge during sonic soot blowing
  28. 28. Contact us for any soot cleaning problemsSound Blast Sonic Power Company LimitedA1, 2/F, 65~67 Bonham Strand,Central Hong KongCentral, Hong Kong.Tel: + 852 ‐ 2541 8289Fax: + 852 ‐ 8148 1175il dbl @ d ble‐mail: soundblast@sound‐blast.comWeb: http://www.sound‐blast.comKeromiyons Intech Private Limited# 110, Renga Villas, New Damu Nagar,Coimbatore 641 037 Tamil Nadu IndiaOur business partner in India:Coimbatore – 641 037, Tamil Nadu, India.Tel: +91 422 4214124Fax: +91 422 4214125e mail: uchandar@keromiyons come‐mail: uchandar@keromiyons.comWeb: http://www.keromiyons.com
  29. 29. Thank You

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