Applications Examples on choosing the cleaning...

© C

BW

Cly

de B

erg

em

ann W

ese

l 10.2

007

-Rev. 5

Applications

-

Examples on choosing the

cleaning strategy

March 13, 2020Chemistry in Energy Technology

Åbo Akademi University

© CBW Clyde Bergemann Wesel - Alle Rechte vorbehalten

Choosing a Cleaning Strategy

27 - Applications

Conventional Selection and Design of Cleaning Systems

Clyde Bergemann experience

Installation of cleaning systems in more than 3000 plants

Installation of more than 2000 heat flux sensors

Conventional analysis of deposition characteristics

Visual observations by plant personnel

Deposit analysis during outages

Boiler inspection camera


Choosing a Cleaning Strategy

37 - Applications

Simulation of the boiler at the actual operational condition

Combustion simulation

Heat flux distribution

Ash deposition map

Ash deposition analysis in furnace

Designing a cleaning strategy

Choice and positioning of diagnostic tools

Choice and positioning of cleaning systems

Realisation of the cleaning strategy

Advanced Selection and Design of Cleaning Systems


Example 1 – Operational Problems

47 - Applications

Actual Situation

Major problems with ash deposition within

the entire furnace

Severe and continous slagging in ash hopper region

Consequences

Unscheduled outages up to 20 times per year

Manual removal of slag deposits in the ash hopper region

High risk for accidents and inefficient operation

Boiler with russian T-design

Fuel: Bitumious coal

Thermal power: 150 MW

No cleaning systems installed in furnace


5

Basic Boiler Simulation:Boiler with T-design

7 - Applications


6

Basic Boiler Simulation:3D-Boilermodel

Burner: 1.4 Mio. Zellen

(Resolution: 0,5 – 6 cm)

Furnace: 2.9 Mio. Zellen

(Resolution : 4 – 25 cm)

Convective Zone: 0.3 Mio. Zellen

(Resolution : 20 – 35 cm)

7 - Applications


Velocity

[m/s]

77 - Applications

FW

RW

FW

RW

Basic Boiler Simulation: Velocity Distribution


8

Temperature

[°C]

FW

RW

7 - Applications

Basic Boiler Simulation: Temperature Distribution


9

Heat Flux

[kW/m2]

0 4 8 12 16 20 24 28 32 36

32

28

24

20

16

12

8

4

Furn

ace H

eig

ht [m

]

Front Wall L.H. Side Wall Rear Wall R.H. Side Wall

7 - Applications

Basic Boiler Simulation: Wall Heat Flux Distribution


Basic Boiler Simulation: Results

107 - Applications

Simulation Measurement

FEGT [°C] 1200 1202

Fluegas after ECO [°C] 380 376

CO [mg/Nm3] 13 ~ 10

NOx [mg/Nm3] 920 855 – 910

UBC [Mass-%] 1.25 2.4


11

0 4 8 12 16 20 24 28 32 36

32

28

24

20

16

12

8

4

Furn

ace H

eig

ht [m

]


Deposition rate

[g/m2s]

Ash deposition simulation with critial viscosity: 105 Pa·s

Fraction of ash deposited:

10.2 %

7 - Applications

Design Online-Cleaning System:Ash Deposit Map


12

0 4 8 12 16 20 24 28 32 36

32

28

24

20

16

12

8

4

Furn

ace H

eig

ht [m

]


7 - Applications

Total need for cleaning

Design Online-Cleaning System: : Cleaning Need in Furnace


Deposition rate

[g/m2s]


10.2 %


13

0 4 8 12 16 20 24 28 32 36

32

28

24

20

16

12

8

4

Furn

ace H

eig

ht [m

]


7 - Applications

Realised cleaning region

Design Online-Cleaning System:Realised Cleaning in Furnace


Deposition rate

[g/m2s]


10.2 %


147 - Applications

1. SMART Furnace System incl. SMART Flux Sensors

2. Water Cannons for cleaning furnace and hopper region

Design Online-Cleaning System:Diagnostics and Cleaning Device


15

0 4 8 12 16 20 24 28 32 36

32

28

24

20

16

12

8

4

Furn

ace H

eig

ht [m

]


7 - Applications

Design Online-Cleaning System:Positioning of Sensors

SMART Flux Sensor


Deposition rate

[g/m2s]


10.2 %


0 4 8 12 16 20 24 28 32 36

32

28

24

20

16

12

8

4

Furn

ace H

eig

ht [m

]


16

Heat flux

[kW/m2]

7 - Applications

SMART Flux Sensor

Design Online-Cleaning System:Positioning of Sensors


177 - Applications

SMART Flux Sensor

Design Online-Cleaning System:Realisation

Water Cannons

installation


Example 2 – The situation

7 - Applications

SMART Clean for 350 MW hard coal – tower type boiler

Uncontrollable slagging and fouling

Erosion of heat exchangers

Interruption during

boiler operation

Costs of maintenance

Boiler cleaning following

fixed time criteria

18


Example 2 – The solution

7 - Applications

= selected SMART Clean module

Diagnostics

SMART Flux sensors in the furnace

SMART Gauge sensors in the

convective area

Analysis

SMART Furnace

SMART Convection

Thermodynamic modelling (TDM)

Matrix Clean

Decision

CLEANING MANAGER

Activation of suggest cleaning actions corresponding to defined priorities

19


20

SMART Clean - Diagnostics

7 - Applications

Main beam

Subcarrier

Collector

Hanger rod

Hanger rod

Supporting

tube

SMART Gauge

Sensors


217 - Applications

SMART Clean - Analysis


Example 2 – Achieved results

7 - Applications

SMART Clean avoids increase of boiler off gas temperature

(which is 25 °C without SMART Clean after 3 month boiler operation)

35% reduction of cleaning operations, 40% reduction of steam

consumption

Reduction of erosion on

heat exchanger bundles

Prevention of unscheduled

boiler shut downs

uncontrolled deposit

22


237 - Applications

www.clydebergemann.com

Applications Examples on choosing the cleaning...

Documents

Transcript of Applications Examples on choosing the cleaning...