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BOILER CLEANING SYSTEMS for Improved Availability of Biomass and Waste Incineration Boilers

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Page 1: BOILER CLEANING SYSTEMS · exploited for their energy content, there are countless combinations of the ash composition. The ash tends to contain few self-cleaning elements such as

BOILER CLEANING SYSTEMSfor Improved Availability of

Biomass and Waste Incineration Boilers

Page 2: BOILER CLEANING SYSTEMS · exploited for their energy content, there are countless combinations of the ash composition. The ash tends to contain few self-cleaning elements such as

The Clyde Bergemann Power Group is a glob-al enterprise providing innovative prod-ucts and services for energy related industries.

“Clean Energy Solutions” describes a powerful portfolio of products and systems summarized in three business fields:

Boiler Efficiency – improved boiler efficiency and effective on-load boiler cleaning

Materials Handling – dry bottom ash handling

Energy Recovery – efficient heat exchange solutions

Centre of excellence for boiler cleaning

Clyde Bergemann GmbH in Wesel (Germany) is the competence centre for Boiler Efficiency within the Clyde Bergemann Power Group. The products are typically applied in thermal energy conversion processes based on coal, oil, waste and/or biomass. For over 70 years, the company has focused on developing and produc-ing equipment to efficiently remove combustion residue from the heating and reaction surfaces of boilers during operation.

Improved boiler availability

Controllable deposit build-up regardless of varying fuel quality

Effective and efficient boiler cleaning

Professional consultancy for all aspects of boiler cleaning

Comprehensive service: from the planning and exe-cution of the installation, through commissioning to services provided over the full service life of the boiler cleaning equipment

Staff training by Clyde Bergemann experts

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MATERIALS HANDLING

BOILER EFFICIENCY

Clean Energy Solutions

ENERGY RECOVERY

Your Benefits

Range of Services for On-load Boiler Cleaning

3

Furnace Superheater/Reheater

Economiser

Applications

On-load Boiler Cleaning Systems

Instrumentation & Controls

Customer Service

SMART Cannon

SMART SCS

Oscillating Sootblower

Retractable Sootblower

Part Retractable Sootblower

SMART RS

SMART Helix Water

Rapping System

Part Retractable Sootblower

Rotating Element Sootblower

Rapping System

Steam/air as cleaning medium Water as cleaning medium No cleaning medium

Significant slagging can form in the furnace and se-vere fouling can build up on the convective heating surfaces of waste and biomass boilers. These deposits reduce heat transfer and also favour corrosion resulting

in limited plant availability and reduced efficiency. Clyde Bergemann boiler cleaning systems cover all the significant zones in the boiler.

Page 3: BOILER CLEANING SYSTEMS · exploited for their energy content, there are countless combinations of the ash composition. The ash tends to contain few self-cleaning elements such as

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Mastering Specific Challenges

Fuels

The fuels used in biomass and waste incineration boil-ers have a significant influence on the formation and characteristics of slagging. Because of the broad range of biomass fuels and waste constituents that may be exploited for their energy content, there are countless combinations of the ash composition. The ash tends to contain few self-cleaning elements such as silicon, aluminium or calcium. Elements which promote fouling such as potassium, sodium and chlorine predominate.

The behaviour of biomass/waste ash differs significant-ly from that of coal. The usual ash analysis methods are therefore only of limited use in the analysis of the tendency to slagging and fouling. Clyde Bergemann therefore works with specific ash/fuel analysis methods, taking account of the heavily corrosive properties of the ash from biomass and waste in developing its cleaning concept.

Boiler Geometry

Particular challenges in respect to the formation of coat-ings arise depending on the actual design of the boiler. Very tight gap pitches increase the risk of blockages, particular areas can be hotspots for fouling.

Our Solution

Clyde Bergemann has developed a series of boiler cleaning systems with cleaning parameters that can be adapted flexibly to changing deposit situations. Some cleaning systems such as SMART Helix Water and the Shower Clean System have been specially developed for biomass and waste incineration boilers. The control concepts deployed allow targeted cleaning. All these measures lead to an improvement in plant availability.

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Heavy deposit build-up when burning biomass

Sootblowers for Boiler Cleaning with Steam or Air

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Description Model Travel Cleaningzone

Operating principle

Retractable Sootblowerè for use in the superheater and

reheaterè with heavy foulingè flue gas temperatures up

to 1,500° C

VX-HSMART RSPS-H

0.5 - 2.4 m4 - 12 m0.3 - 10 m

360°0 - 360°360°

Oscillating Sootblowerè for use in heat exchangers, focused

on specific cleaning areas in super-heater and reheater

è with light to medium foulingè flue gas temperatures up

to 1,100° C

PS-PRS-PPS-PBRS-PB

0.3 - 6 m0.5 - 6 mup to 6 m0.5 - 6 m

60 - 360°

Part Retractable Sootblowerè for use in superheater and reheaterè with light to medium foulingè flue gas temperatures up

to 800° C

PS-HB up to 6 m 360°

Rotating Element Sootblowerè for cleaning of heat exchanger

surfaces in the economiserè with light foulingè temperatures < 500° C

DB - 30 - 360°

Timber Rubbish Bark Needles Willow Grasses

Lucerne Rape Barley Wheat RC summer RC spring

Peat 1 Peat 2 Domestic

waste Coal 1 Coal 2

Source: A. Nordin (1994) Biomass and Bioenergy, Vol.6(5), 339-347

Page 4: BOILER CLEANING SYSTEMS · exploited for their energy content, there are countless combinations of the ash composition. The ash tends to contain few self-cleaning elements such as

The Complete Water Cleaning Portfolio

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Description Model Travel Cleaningzone

Operating principle

SMART Cannon – Water Lance Blowerè for the cleaning of furnace wallsè with heavy slaggingè flue gas temperatures up to 1,600° C

SMARTCannon

- 90° horizontal90° vertical

SMART Helix Waterè for use in superheater and reheater è with heavy foulingè Flue gas temperatures up

to 1,500°Cè Advance and rotation operate

separately from one another thanks to their individual drives

è Go-Stop-Clean-Go Operation

SMART Helix Water

4-12 m 0-360°

Shower-Clean Systemè uses water as cleaning medium è for use in furnaces and empty

passesè flue gas temperatures up

to 1,200°C

SMART Shower- Clean System (SCS)

- 360°

SMART Shower-Clean System (SCS) – for Cleaning Different Types of Deposits in Empty Passes

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Suited for Different Deposit Characteristics

The SMART SCS uses water as the cleaning medium. Located on the boiler roof, it removes deposit from the lower side, the membrane walls, the pendant heater and superheater surfaces.

The cleaning nozzle is mounted on a flexible, tempera-ture-resistant metal hose. The nozzle enters the boiler guided by a flange, which is opened and closed through an electropneumatic valve.

The surfaces of deposits are characterised by different properties. Their development depends on the chemi-cal composition of the fly ash in combination with the actual flue gas temperature. The cleaning nozzle forms a water jet with a defined spectrum of water droplets and momentum. To achieve successful cleaning, it is im-portant that the frequency of cleaning, water impact and quantity hitting the deposits are specifically set to match the requirements of each individual plant. When using waste and biomass as the fuel, the cleaning ef-fectiveness of a water based on-load boiler cleaning system depends on the actual fuel composition and the consequential deposit characteristics. By using different nozzle designs and cleaning parameters, the cleaning efficiency can be adjusted to specific surface depoist characteristic.

Three Different Versions are Available:

Stand-Alone: recommended for open passes with small, uniform cross-section

Single-Row: recommended for boilers with rectangu-lar cross-section

Multiple-Row: recommended for boilers with com-plex geometry - flanges are arranged in multiple rows across the boiler roof, by using a crane runway, differ-ent areas can be cleaned

Increased plant availability due to reliable cleaning of the open passes which are important for efficient plant operation

Stable flue gas temperature

Lower risk of high-temperature corrosion

and reduced corrosion rate

Shorter revision period as time-consuming manual primary cleaning is almost eliminated

The construction of SMART SCS allows cleaning of narrow designed open passes

Corrosion protection of the flange by appling sealing air

Your Benefits

Page 5: BOILER CLEANING SYSTEMS · exploited for their energy content, there are countless combinations of the ash composition. The ash tends to contain few self-cleaning elements such as

SMART Cannon – The Most Effective Way to Remove Slag Formation with Water

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Water: An Alternative has Proved Itself

As a specialist for the boiler cleaning, we early recog-nised the benefits of cleaning with water and developed it ready for market launch.Worldwide SMART Cannon has proved itself as an ef-fective system for cleaning of combustions chambers and empty passes. The prevailing high temperatures as well as the immediate combustion processes result in deposits and sometime in difficult to remove clinkers on the membrane walls. The cleaning effect of water ist the ideal solution for removing slagging. SMART Can-non has been particulary successful in the removal of severe and/or high volume deposits. Its design considers the technial demand, high reliability and particular feau-res needed in combustion chambers and empty passses.

A Broad Area of Application

The following table shows all application features of SMART Cannon.

Targeted use of water to remove slagging Concentrated water jet quality Precise, reproducible and flexibly adaptable cleaning

patterns Even difficult areas can be cleaned e.g. funnels,

central sections High-duty cleaning systems Compact design with integrated easy maintenance

Your Benefits

Range of applications SMART Cannon

Boiler area Fuel Slagging characteristics

furnace empty pass flue gas recirculation pass lateral gas passes hopper centre wall

lignite coal hard coal biomass biomass co-gasification waste / substitute fuel fuel of these sources of energy

solid, difficult to remove partially melted tenacious voluminous liquid slag cornice build

SMART Helix Water – Ideal for Severe Fouling in the Superheater

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Intensive Cleaning Effect of Water Applied Gently

The severe deposit build-up in the convective area can also mean that conventional steam sootblowers will not work effectively. Consequently, the fouling will contin-ue to increase, causing unplanned outages and reduced boiler availability. Water as the cleaning medium is capa-ble of producing the required intensive cleaning effect. To perform the cleaning as gently as possible on the heat exchanger pipes, specially designed hardware and software components and two gear motors with high-resolution resolvers ensure that the SMART Helix Water moves precisely to the cleaning position within the space between the heat exchanger tubes. Water is released for cleaning between the tubes only. This new cleaning method is also called “Go-Stop-Clean-Go“.

Only the deposit surfaces are hit by the water and this is solely done at the time of cleaning. Heat exchang-er pipes are not thermally loaded and the amount of water poured into the boiler is reduced to a necessary minimum.

If no cleaning is required, the water flow is used to cool the retractable lance tube in a closed cooling circuit.

Removal of severe deposits on convective heating surfaces

Cleaning with water without thermal loading of heat exchanger pipes (“Go-Stop-Clean-Go“ mode)

On demand release of the water jet for cleaning minimises the amount of water poured into the boiler

Even narrow passes are cleaned reliably

Flue gas temperature remains in the rated range

Extension of boiler availability

More flexibility as to the fuel mix since cleaning intensity can be adjusted to the fouling condition at any time

No steam required for cleaning

Your Benefits

GO GO

CLEAN

STOP

CLEANCLEAN

STOPSTOP GO GO

Page 6: BOILER CLEANING SYSTEMS · exploited for their energy content, there are countless combinations of the ash composition. The ash tends to contain few self-cleaning elements such as

Rapping Devices – Gentle Removal of Deposits Without Use of a Cleaning Medium

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Application

Especially horizontal boiler passes such as those found in waste incineration plants, can be cleaned with rapping devices. They can be applied to remove deposits from the heating and reaction surfaces of the convection area and economisers without any additional cleaning media like steam, air or water.

Function

Rapping systems may use mechanical hammers or pneu-matically driven impact cylinders. Pneumatic single rap-pers have been proven in practice, as the impact energy can be adapted to the specific conditions of the plant. By rapping the fouled convection heating surfaces the bank tubes are caused to vibrate so that the deposited layer falls off. Cleaning of each heating surface can be controlled variably and as a function of the process.

The pneumatic rapping systems are developed and manufactured in collaboration with Norgren.

Optimum cleaning – extends the boiler availability

Neither air nor steam is required as a cleaning medium, hence maintenance costs are lower

Simple operation and messages from and to the control room

Controlling deposits in flexible boiler operation and with varying fuel mixtures or variable fuel quality

®®

Description Model Operating principle

Rapping systemè Cleaning of heating surfaces and economisers in facilities

with varying fuels and loose deposits

PKL

Your Benefits

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Plant FuelIn Operation Since

Cleaning Systems Used

Cubillos, Spain Biomass 2018

20 x DB Rotating Element Sootbower28 x PS-H Retractable Sootblower 4 x PS-HB Part Retractable Sootblower 2 x SMART Cannon 8 x SMART Flux Sensors

Asnaesverket, Denmark Biomass 2017

9 x PS-HB Part Retractable Sootblower12 x PS-H Retracatable Sootblower 2 x PS-AR Rake Sootblower 2 x SMART Cannon

Teesside, United Kingdom Biomass 201720 x PS-H Retractable Sootblower20 x PS-HB Part Retractable Sootblower 8 x PS-AR Rake Sootblower

Hagen, Germany Biomass 2017 2 x SMART Helix Water

Tilbury, United Kingdom Biomass 2015 6 x SMART Cannon 1 x Shower-Clean System SCS

Majachnij, Russian Federation Waste 2015 4 x PS-H Retractable Sootblower20 x DB Rotating Element Sootblower

Clermont Ferrand, France Biomass 2013 1 x Steam Sootblower System 1 x Shower-Clean System SCS

Herten, Germany Waste 2012 2 x Shower-Clean System SCS 4 x Pneumatic Rapping Systems in Superheater 4 x Pneumatic Rapping Systems in Economiser

AEB Amsterdam, Netherlands Waste 2012 4 x Shower-Clean System SCS 12x Water Lance Blower WLB

Pfeiffer & Langen, Jülich,Germany Biomass 2012 4 x SMART Helix Water

Baku, Azerbaijan Waste 2011 2 x Shower-Clean System SCS

Twence, Netherlands Waste 2010 1 x SMART Helix Water

Brescia, Italy Waste 2009/1995 28 x PS-SL Retractable Steam Sootblowers 1 x PS-AT Traverse Sootblower

Selection of our References

Page 7: BOILER CLEANING SYSTEMS · exploited for their energy content, there are countless combinations of the ash composition. The ash tends to contain few self-cleaning elements such as

Clyde Bergemann is represented in over 40 countries worldwide.

Clyde Bergemann GmbH

Schillwiese 20 D-46485 Wesel

Phone: +49 281 815-0

Internet: www.cbpg.com eMail: [email protected]

For information about the Clyde Bergemann companies and contact details please visit http://www.cbpg.com C

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Clyde Bergemann Companies Clyde Bergemann Associates Clyde Bergemann Headquarters