Journal articles: 'Recovery boiler'

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TRAN, HONGHI, and DANNY TANDRA. "Recovery boiler sootblowers: History and technological advances." January 2015 14, no. 1 (February 1, 2015): 51–60. http://dx.doi.org/10.32964/tj14.1.51.

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Sootblowing technology used in recovery boilers originated from that used in coal-fired boilers. It started with manual cleaning with hand lancing and hand blowing, and evolved slowly into online sootblowing using retractable sootblowers. Since 1991, intensive research and development has focused on sootblowing jet fundamentals and deposit removal in recovery boilers. The results have provided much insight into sootblower jet hydrodynamics, how a sootblower jet interacts with tubes and deposits, and factors influencing its deposit removal efficiency, and have led to two important innovations: fully-expanded sootblower nozzles that are used in virtually all recovery boilers today, and the low pressure sootblowing technology that has been implemented in several new recovery boilers. The availability of powerful computing systems, superfast microprocessors and data acquisition systems, and versatile computational fluid dynamics (CFD) modeling capability in the past two decades has also contributed greatly to the advancement of sootblowing technology. High quality infrared inspection cameras have enabled mills to inspect the deposit buildup conditions in the boiler during operation, and helped identify problems with sootblower lance swinging and superheater platens and boiler bank tube vibrations. As the recovery boiler firing capacity and steam parameters have increased markedly in recent years, sootblowers have become larger and longer, and this can present a challenge in terms of both sootblower design and operation.

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Saari, Jussi, Ekaterina Sermyagina, Juha Kaikko, Markus Haider, Marcelo Hamaguchi, and Esa Vakkilainen. "Evaluation of the Energy Efficiency Improvement Potential through Back-End Heat Recovery in the Kraft Recovery Boiler." Energies 14, no. 6 (March 11, 2021): 1550. http://dx.doi.org/10.3390/en14061550.

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Sustainability and energy efficiency have become important factors for many industrial processes, including chemical pulping. Recently complex back-end heat recovery solutions have been applied to biomass-fired boilers, lowering stack temperatures and recovering some of the latent heat of the moisture by condensation. Modern kraft recovery boiler flue gas offers still unutilized heat recovery possibilities. Scrubbers have been used, but the focus has been on gas cleaning; heat recovery implementations remain simple. The goal of this study is to evaluate the potential to increase the power generation and efficiency of chemical pulping by improved back-end heat recovery from the recovery boiler. Different configurations of heat recovery schemes and different heat sink options are considered, including heat pumps. IPSEpro simulation software is used to model the boiler and steam cycle of a modern Nordic pulp mill. When heat pumps are used to upgrade some of the recovered low-grade heat, up to +23 MW gross and +16.7 MW net power generation increase was observed when the whole pulp mill in addition to the boiler and steam cycle is considered as heat consumer. Combustion air humidification proved to yield a benefit only when assuming the largest heat sink scenario for the pulp mill.

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MAAKALA, VILJAMI, and PASI MIIKKULAINEN. "Dimensioning a recovery boiler furnace using mathematical optimization." February 2015 14, no. 2 (March 1, 2015): 119–29. http://dx.doi.org/10.32964/tj14.2.119.

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Capacities of the largest new recovery boilers are steadily rising, and there is every reason to expect this trend to continue. However, the furnace designs for these large boilers have not been optimized and, in general, are based on semiheuristic rules and experience with smaller boilers. We present a multiobjective optimization code suitable for diverse optimization tasks and use it to dimension a high-capacity recovery boiler furnace. The objective was to find the furnace dimensions (width, depth, and height) that optimize eight performance criteria while satisfying additional inequality constraints. The optimization procedure was carried out in a fully automatic manner by means of the code, which is based on a genetic algorithm optimization method and a radial basis function network surrogate model. The code was coupled with a recovery boiler furnace computational fluid dynamics model that was used to obtain performance information on the individual furnace designs considered. The optimization code found numerous furnace geometries that deliver better performance than the base design, which was taken as a starting point. We propose one of these as a better design for the high-capacity recovery boiler. In particular, the proposed design reduces the number of liquor particles landing on the walls by 37%, the average carbon monoxide (CO) content at nose level by 81%, and the regions of high CO content at nose level by 78% from the values obtained with the base design. We show that optimizing the furnace design can significantly improve recovery boiler performance.

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LEPPÄNEN, AINO, and ERKKI VÄLIMÄKI. "Improving recovery boiler availability through understanding fume behavior." March 2016 15, no. 3 (April 1, 2016): 187–93. http://dx.doi.org/10.32964/tj15.3.187.

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Unexpected recovery boiler shutdowns are rare, but they can cost millions of dollars in lost income. Sometimes the inorganic compounds in black liquor can cause sudden fouling or plugging problems that could not be predicted beforehand. The ash particles can be divided into two main types and size classes: carryover and fume. This paper focuses on the smaller fume particles that form through the condensation of alkali metal vapors and that deposit via different mechanisms than carryover. The location of fume deposition depends on several factors, such as flue gas and superheater temperatures, black liquor composition, and the flow field in the boiler. This paper presents results obtained with a computational method that simulates fume formation in recovery boilers. The paper focuses on the effect of black liquor composition and elemental release on fume behavior and suggests how these observations should be taken into account when designing new boilers or retrofits. Moreover, the paper introduces the possible applications of the modeling method. These include, for example, troubleshooting of fouling problems in existing boilers, designing superheater configurations for new boilers, and positioning soot blowers.

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ANTUNES GUIMARÃES, MATHEUS, HONGHI TRAN, and MARCELO CARDOSO. "A novel method for determining the internal recycled dust load in kraft recovery boilers." August 2014 13, no. 8 (September 1, 2014): 27–34. http://dx.doi.org/10.32964/tj13.8.27.

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In kraft recovery boiler operation, fly ash or dust generated from black liquor combustion is mixed with the virgin black liquor in a mix tank and returned to the boiler with the as-fired black liquor. This internal recycled dust stream varies widely from boiler to boiler and from time to time and can have a great impact on the as-fired black liquor flow and properties and, ultimately, on the boiler thermal performance. A new method has been developed to quickly and accurately determine the amount of internal recycled dust in recovery boilers. The method is based on the difference between the total organic carbon content of the virgin black liquor and that of the as-fired black liquor. Tests using the method were performed on recovery boilers at three of Fibria’s mills in Brazil. The results show that while the specific virgin black liquor solids produced at these mills were about the same, the internal recycled dust load varied widely, from as low as 4 wt% of as-fired black liquor solids fired in the boiler at one mill to as high as 15 wt% at another mill. Instead of total organic carbon values, heating values may also be used, but the result is not as accurate.

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Harila, P., and V. A. Kivilinna. "Biosludge Incineration in a Recovery Boiler." Water Science and Technology 40, no. 11-12 (December 1, 1999): 195–200. http://dx.doi.org/10.2166/wst.1999.0712.

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An activated sludge process is an effective tool against effluent emissions in a pulp mill. It has only a few features which can be regarded deficiences. One of them is that effluent treatment of a modern pulp mill creates some 10-20 tonnes dry solids of biosludge per day. This sludge is difficult to burn due to its high moisture content. The most common way is to mix biosludge with primary sludge, to dewater the mixture in presses and finally to burn it in a solid fuel boiler. This type of sludge treatment incurs rather high costs and does not produce any net energy. Also combustion emissions vary depending on the boiler type. The Metsä-Botnia Kemi Pulp Mill was the first mill in the world to burn biosludge in a recovery boiler. The system start-up was in 1993 and it has been in operation ever since. Mechanically dewatered biosludge is mixed with weak black liquor and concentrated in a conventional evaporation plant equipped with a pressurized superconcentrator unit. In a modern recovery boiler, firing conditions are well controlled and monitored. Better emission control than in most bark fired boilers is achieved. Accumulation of nonprocess elements, corrosion, plugging, scaling and some other operational problems were expected. A lot of experience has been gathered during the years of operation and reviewed in this presentation. The achieved benefits of the system are discussed. Disposal of biosludge in a recovery boiler offers an economically and environmentally attractive alternative. Probably the best evidence from this is the fact that Metsä-Botnia has applied the same process solution in the recent reconstruction of the recovery departments at the Jouteno Mill.

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Fialko, Nataliia, Raisa Navrodska, Malgorzata Ulewicz, Georgii Gnedash, Sergii Alioshko, and Svitlana Shevcuk. "Environmental aspects of heat recovery systems of boiler plants." E3S Web of Conferences 100 (2019): 00015. http://dx.doi.org/10.1051/e3sconf/201910000015.

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The results of studies on improving the environmental characteristics of boiler plants of municipal heat-power engineering in the application of technologies for the deep recovery of heat from exhaust-gases of gas-fired boilers are presented. The data on the reduction of environment by reducing the amount and temperature of harmful emissions resulting from fuel combustion are given. The data are given for boiler plants equipped with complex heat-recovery systems characterized by cooling the exhaust-gases below the dew point of the water vapor contained in them. It is shown that the decrease in emissions is due to a decrease in fuel consumption in boilers due to the beneficial use of the heat of exhaust-gases in these systems and the dissolution of nitrogen and carbon oxides in the condensate, formed in the heat-recovery equipments. The analysis of improving the environmental safety of boiler plants when used in heat-recovery technologies of corrosion protection systems for chimneys has been performed. Anticorrosion protection is provided by preventing condensate formation in the exhaust-gas ducts of boiler plants when using technologies for the deep recovery of exhaust-gas heat. To prevent condensate formation, the method of pre-drying cooled exhaust-gases in a heat exchanger-preheater installed after heat-recovery equipment is used. It is also shown that the use of complex heat-recovery systems provides in the boiler plant additional water in the form of condensate formed during condensation of moisture from exhaust-gases. Receipt of this condensate is another ecological effect of heat-recovery, which allows reducing the consumption of natural water resources for supply municipal heat networks.

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Mao, Xiaosong, and Honghi Tran. "Formation of blue deposits in kraft recovery boilers." March 2016 15, no. 3 (April 1, 2016): 195–203. http://dx.doi.org/10.32964/tj15.3.195.

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Fireside deposits in recovery boilers are typically white, red, pink, grey, black, or occasionally yellow, depending on where they are in the boiler, the mechanisms by which they are formed, and the environment to which they are exposed. Although rare, blue deposits have been reported, and some were “bluer” than others. This study systematically examines the cause of the blue coloration of deposits in recovery boilers. The results show that for a deposit to become blue, it must a) contain sodium carbonate, b) contain a small amount of manganese, c) be molten or partially molten, and d) have exposure to an oxidizing atmosphere. Because deposits always contain sodium carbonate and manganese, these requirements suggest that blue deposits can form only in the superheater region of the recovery boiler when oxidizing conditions prevail. Blue coloration is thus more likely to be observed in boilers operating at a reduced firing load with a high excess oxygen target.

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Tuński, Tomasz, Cezary Behrendt, and Marcin Szczepanek. "Mathematical Modeling of the Working Conditions of the Ship’s Utilization Boiler in Order to Evaluate Its Performance." Energies 12, no. 16 (August 13, 2019): 3105. http://dx.doi.org/10.3390/en12163105.

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The paper presents a mathematical model allowing the determination of the amount of saturated steam produced in marine water tube boilers and smoke tube boilers. The mathematical model includes the impact of the exhaust gas temperature and its amount, ambient temperature, engine power load, and location of boiler tubes. In addition to the amount of steam generated in a boiler, it is also feasible to establish flow resistance of the exhaust gas in the boiler determined by the boiler tubes’ arrangement and the thickness of scale deposits and the exhaust gas temperature after the exhaust gas boiler. Due to the model universality, it may be applied not only to make calculations for existing boilers, but also to perform numerical experiments in order to determine the amount of steam produced by the entire range of boilers used in the waste heat recovery systems in power marine systems and the adopted limit values, such as exhaust gas flow resistance and their temperature, after the boiler. The reliability of the obtained results has been revised by comparing them with the outcomes of the experiments performed on the ships.

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10

Fialko, N. M., G. A. Presich, G. A. Gnedash, S. I. Shevchuk, and I. L. Dashkovska. "INCREASE THE EFFICIENCY OF COMPLEX HEAT-RECOVERY SYSTEMS FOR HEATING AND HUMIDIFYING OF BLOWN AIR OF GAS-FIRED BOILERS." Industrial Heat Engineering 40, no. 3 (September 7, 2018): 38–45. http://dx.doi.org/10.31472/ihe.3.2018.06.

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The work is devoted to increase of thermal and ecological efficiency of water-heating gas-fired boilers of municipal heat-power engineering. To improve thermal efficiency, heat-recovery technologies are used in which deep cooling of the exhaust-gases from boilers with the realization of the condensation mode of the heat recovery equipment is ensured. To implement this regime throughout the heating period, it is advisable to use complex heat-recovery systems in which several heat transfer agents are heated with sufficiently different thermal potentials. To enhance the environmental effect when using complex systems, it is possible to carry out combustion air humidifying in them, which contributes to the reduction of NOx emissions to the environment by the boiler plants. The work suggests improvement of the known complex heat-recovery system for heating and humidifying the blown air by introducing into its comprise an additional element - water heater of chemical water-purification system. Such the technological solution will ensure a reduction in the thermal losses of the boiler plant and improve the operating conditions of the gas ducts of the boiler house by preventing the condensate from falling out of the wet exhaust-gases. The aim of the work is to investigate the operating parameters of the complex heat-recovery system for heating and humidifying the blown air and preheating the water for chemical water-purification and comparing its basic heatly and humidity characteristics with the corresponding complex system without preheating the water. The results of the investigations are presented in a wide operating range of the load variation of the water-heating boiler respectively the boiler plant temperature graph and are shown graphically. The analysis of the obtained data showed that due to the proposed modernization by preheating the water of the chemical water-purification system in the complex heat-recovery system for heating and humidifying the blown air, an increase of coefficient the use heat of fuel of boilers is provided, depending on their load from 11% to 17%. For this improved heat-recovery system with preheating the water of the chemical water-purification system in comparison with the system without such preheating, the total heating capacity of the complex system increases by 1.3÷1.6 times, and the coefficient the use heat of fuel of the boiler increases by 5.2%.

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11

Yanai, Eiji, and Tetsuzo Kuribayashi. "Waste heat recovery boiler." Atmospheric Environment (1967) 22, no. 2 (January 1988): ii. http://dx.doi.org/10.1016/0004-6981(88)90065-0.

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12

Ozaki, N., K. Harayama, W. Shinohara, and S. Hayashi. "Recovery boiler intelligent control." IFAC Proceedings Volumes 24, no. 10 (September 1991): 139–43. http://dx.doi.org/10.1016/b978-0-08-041698-4.50027-5.

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13

Harrell, Greg. "Boiler Blowdown Energy Recovery." Energy Engineering 101, no. 5 (September 2004): 32–42. http://dx.doi.org/10.1080/01998590409509277.

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Ozaki, N., K. Harayama, W. Shinohara, and S. Hayashi. "Recovery boiler intelligent control." Annual Review in Automatic Programming 16 (January 1991): 139–43. http://dx.doi.org/10.1016/0066-4138(91)90023-5.

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TRAN, HONGHI, and ANDREW JONES. "Formation mechanisms of “ jellyroll” smelt in kraft recovery boilers." October 2017 16, no. 10 (2017): 597–606. http://dx.doi.org/10.32964/tj16.10.597.

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Molten smelt normally flows smoothly down the smelt spout of a recovery boiler like water, but at times it suddenly becomes sluggish and forms a viscous blob on the spout trough that partially or completely blocks the smelt flow. This form of smelt is commonly referred to as “jellyroll” smelt. How such smelt forms has been a puzzle to boiler operators and mill personnel for years. Numerous mill observations and the results of a recent study performed on both smoothly flowing smelt and jellyroll smelt collected from a recovery boiler suggest that that jellyroll smelt can form through three main mechanisms: i) the freezing of the molten smelt, ii) the melting of fallen deposits, and iii) the inclusion of a large amount of unburned char in the molten smelt. These mechanisms are consistent with mill experience that jellyroll smelt tends to form in older recovery boilers burning liquor with low solids and low sulfidity.

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VÄHÄ-SAVO, NIKLAS, NIKOLAI DEMARTINI,, and MIKKO HUPA. "Fate of biosludge nitrogen in black liquor evaporation and combustion." September 2012 11, no. 9 (October 1, 2012): 53–59. http://dx.doi.org/10.32964/tj11.9.53.

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At many mills, biosludge, which has a high nitrogen content, is added to black liquor and burned in kraft recovery boilers. The aim of this work was to determine the fate of biosludge nitrogen in the high solids black liquor concentrators and in the recovery boiler. Specifically, does biosludge addition result in higher nitric oxide (NO) and cyanate formation during black liquor combustion? To obtain this information, samples were collected from the chemical recovery cycle of a Finnish kraft pulp mill along with relevant process data. Laboratory combustion experiments clearly showed an increase in NO formation for the mill black liquor with biosludge, but no clear increase in nitrogen oxide emissions was detected in the recovery boiler after biosludge addition. Analysis of the green liquor samples from the dissolving tank showed a significant increase in nitrogen exiting the recovery boiler as cyanate. This finding was supported by laboratory tests studying cyanate formation. The increased cyanate results in increased ammonia formation in the recausticizing cycle, which can lead to higher NO emissions, as seen in the noncondensible gas incinerator at the mill.

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SINGH, PREET M., VIKAS R. BEHRANI, and JAMSHAD MAHMOOD. "Corrosion of Carbon Steel Tubes in the Mid-Furnance of Kraft Recovery Boilers--Environmental Characterization." April 2009 8, no. 4 (May 1, 2009): 23–29. http://dx.doi.org/10.32964/tj8.4.23.

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Carbon steel tubes in the mid-furnace of kraft recovery boilers have experienced accelerated corro-sion in recent years. Gaseous environments in the mid-furnace of kraft recovery boilers were generally considered to be oxidizing and not very corrosive to the carbon steel waterwall tubes. However, mid-furnace corrosion has occurred above the cut line where composite tubes that have a stainless steel outer layer used in the lower furnace are welded to the carbon steel waterwall section. This study characterized the local environments in three boilers to find the reasons for accelerated corrosion of waterwalls in the mid-furnace. Gas sampling ports were installed in the mid-furnace with high and low corrosion rates of carbon steel waterwall tubes. During boiler operation, gases were sampled and analyzed using a specially designed gas chromatograph. In each boiler, the areas with higher corrosion rates had higher concentrations of reducing gases and sulfur-containing gases at the waterwall surface than in the low-corrosion areas. Results from this study indicate that accelerated mid-furnace corrosion likely results from changes in the boiler operation, such as decreases in the air supply at the lower air port levels of the furnace. These changes also might result in higher local gas temperatures and local thermal cycling in the mid-furnace of boilers.

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Navrodska, Raisa, Nataliia Fialko, Georgii Presich, Georgii Gnedash, Sergii Alioshko, and Svitlana Shevcuk. "Reducing nitrogen oxide emissions in boilers at moistening of blowing air in heat recovery systems." E3S Web of Conferences 100 (2019): 00055. http://dx.doi.org/10.1051/e3sconf/201910000055.

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Considered indicators of reducing harmful emissions into the environment by gas-fired water-heating and steam boilers of the municipal heat-power engineering, which are equipped with heat-recovery systems of boiler exhaust-gases. The results of studies on the relative decrease of emissions of nitrogen oxides and other harmful substances generated during fuel combustion in boilers when used for boilers complex heat-recovery plants for heating heat-network water and water for a chemical water-purification system of a boiler plant, as well as for heating and humidifying combustion air are presented. It is shown that the use of such complex heat-recovery systems, due to the useful heat of exhaust-gases from boilers, provides a reduction in fuel consumption and, consequently, the volumes of harmful emissions generated during its combustion, by 8–12%, depending on the mode of operation of boilers during the heating period. The efficiency of using combustion-air humidifying in these installations to decrease the level of formation of nitrogen oxides in the combustion area of boilers is considered. It is also shown that the use of these systems provides a decrease emissions of nitrogen oxides to the environment by up to 60% by reducing the combustion temperature in the combustion area at moisture introduction with the combustion air and, as a result, suppression of formation these oxides during fuel combustion in boilers. The substantiation of the accuracy of the obtained calculated values of the levels of relative decrease of emissions of nitrogen oxides with the moisture introduction into the boiler by comparing them with experimental data is given. Comparative of the results shows a good agreement between the calculated and experimental data.

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Sharpe, R. D. "Support structure design for New Zealand Forest Products Ltd's No. 5 Recovery Boiler." Bulletin of the New Zealand Society for Earthquake Engineering 20, no. 1 (March 31, 1987): 2–6. http://dx.doi.org/10.5459/bnzsee.20.1.2-6.

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Internationally, the seismic resistance of large industrial boilers appears to be addressed by the most simple application of relatively low equivalent static lateral forces which are resisted elastically. This paper describes measures taken to ensure a predictable and controlled seismic performance of such a boiler during a major earthquake. Inelastic time-history methods of analysis were used to confirm that the desired performance would be achieved. As a result the client was able to purchase a relatively standard boiler in the international marketplace and still achieve a level of seismic resistance consistent with the best NZ practices.

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THARRAULT, YVON, and MOULOUD AMAZOUZ. "Multiple faults detection and isolation approach applied to a kraft recovery boiler." January 2014 13, no. 1 (February 1, 2014): 33–41. http://dx.doi.org/10.32964/tj13.1.33.

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Recovery boilers play a key role in chemical pulp mills. Early detection of defects, such as water leaks, in a recovery boiler is critical to the prevention of explosions, which can occur when water reaches the molten smelt bed of the boiler. Early detection is difficult to achieve because of the complexity and the multitude of recovery boiler operating parameters. Multiple faults can occur in multiple components of the boiler simultaneously, and an efficient and robust fault isolation method is needed. In this paper, we present a new fault detection and isolation scheme for multiple faults. The proposed approach is based on principal component analysis (PCA), a popular fault detection technique. For fault detection, the Mahalanobis distance with an exponentially weighted moving average filter to reduce the false alarm rate is used. This filter is used to adapt the sensitivity of the fault detection scheme versus false alarm rate. For fault isolation, the reconstruction-based contribution is used. To avoid a combinatorial excess of faulty scenarios related to multiple faults, an iterative approach is used. This new method was validated using real data from a pulp and paper mill in Canada. The results demonstrate that the proposed method can effectively detect sensor faults and water leakage.

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Ozaki, N., K. Tateoka, S. Hayashi, and W. Shinohara. "Recovery Boiler Intelligent Control System." JAPAN TAPPI JOURNAL 47, no. 8 (1993): 983–87. http://dx.doi.org/10.2524/jtappij.47.983.

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Arunkumar, S., R. Prakash, N. Jeeva, M. Muthu, and B. Nivas. "Boiler Blow down Heat Recovery." IOSR Journal of Mechanical and Civil Engineering 11, no. 4 (2014): 83–85. http://dx.doi.org/10.9790/1684-11478385.

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Nozaki, Kenji. "Combustion Improvement of Recovery Boiler." JAPAN TAPPI JOURNAL 62, no. 4 (2008): 403–6. http://dx.doi.org/10.2524/jtappij.62.403.

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KEISER, JAMES R., W. B. A. SANDY SHARP, DOUGLAS A. SINGBEIL, LAURIE A. FREDERICK, and CURTIS CLEMMONS. "Performance of alternate superheater materials in a potassium-rich recovery boiler environment." TAPPI Journal 12, no. 7 (August 1, 2013): 45–56. http://dx.doi.org/10.32964/tj12.7.45.

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One method to significantly improve the efficiency of biomass-fired boilers is to increase the temperature and pressure of the steam generated. However, this requires operating the superheater tubes at considerably higher temperatures than can be tolerated by conventional structural materials. The limiting temperature for conventional materials is primarily determined by corrosion of the superheater tubes that is promoted by interaction with the relatively low melting point deposits that accumulate on the tubes. An air-cooled deposit probe was used to collect samples of the deposits that accumulated on tubes in the superheater area of a recovery boiler in a mill processing primarily hardwood. These deposits were found to be enriched in potassium. Subsequently, a corrosion probe containing multiple samples of nine different alloys was exposed for 2000 h in the same location of the superheater area of the same recovery boiler. The temperature of samples in the probe ranged from a low of about 400°C (752°F) to temperatures above 620°C (1148°F), compared to the boiler’s estimated maximum tube temperature of 470°C (878°F). Following exposure, sections were taken from each of the 30 samples and examined using light microscopy and scanning electron microscopy. Results of the examination of these samples showed significant differences among the corrosion rates at temperatures 100°C above the current upper superheater tube temperature. A brief comparison is made to data from a parallel laboratory study.

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Joshi, Pratik M., Shekhar T. Shinde, and Kedarnath Chaudhary. "A Case Study on Assessment Performance and Energy Efficient Recommendations for Industrial Boiler." International Journal of Research and Review 8, no. 4 (April 6, 2021): 61–69. http://dx.doi.org/10.52403/ijrr.20210410.

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As India is a developing country, industrialization is increasing day by day and there is a great need for industry energy audit. Audit helps to maintain and save energy from being wasted and helps in achieving highest efficiency of industrial equipment. This paper contains an actual industry audit report on boiler performance. This paper contains a report on Thermal analysis of boilers, thermal skin heat loss of boilers, O2 percentage control in flue gases to standard values, effect of coal additive, etc. This paper also contains a report on waste heat recovery options for thermal boiler, flue efficiency monitor, infrared thermometer, ultrasonic peak detector IR thermal imager. These equipment are used for energy assessment of boilers. Thermography survey of boiler surface is carried out to estimate the radiation and the other losses and the result of this total annual saving after insulation repairing or maintenance is Rs.8.48 lakh and investment is around Rs.6.31 lakh. Economizer performance of both the ISGEC and Thermax boiler can be improved with the help of suggested measures. It will help to save approximately rupees Rs.38.42 Lakh annually and investment on maintenance cost is negligible. In short, this paper deals with assessment of all boilers, evaluates their efficiencies and losses to identify energy saving opportunities and presents them in a report with their payback periods. Keywords: Energy, Energy audit, assessment, boiler.

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Fialko, N. M., R. A. Navrodskaya, G. A. Presich, G. A. Gnedash, S. I. Shevchuk, and O. V. Martiuk. "INCREASE OF ECOLOGICAL EFFECTIVENESS OF COMPLEX HEAT-RECOVERY SYSTEMS FOR BOILER PLANTS." Industrial Heat Engineering 40, no. 2 (June 20, 2018): 27–32. http://dx.doi.org/10.31472/ihe.2.2018.04.

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It is revealed that the humidifying of blown air in complex heat recovery systems of gas-fired boiler plants provides the significant reduction in the concentration of nitrogen oxides in exhaust-gases due to the suppression of their formation in the boiler furnace when moisture is introduced with this air. Problems of environmental protection and energy-saving became priority in world practice. The main directions of deciding these pressing problems in municipal heat-power engineering is to improve the environmental indicators of heating boiler plants and increase the efficiency of using fuel in them through the use of technologies for deep recovery of the exhaust-gases heat. The relevance of scientific problems in these directions is increasing due to the steady increase in the fuel-energy costs and the strengthening of requirements to reducing environmental pollution. When using these technologies of deep heat-recovery of exhaust-gases, the condensation mode of the heat-recovery equipment is realized, when, apart from to the so-called clear heat of these gases, the latent heat of condensation of the water vapor contained in them is also used. The condensation mode implementation also improves the ecological indicators of the boiler due to the reduction of fuel consumption and the dissolution in the resulting condensate of a part of harmful emissions formed during its combustion. The use of modern heat-recovery technologies for the gasfired boiler plants with complex use of recovered heat for the preheating of boiler water, water of the chemical waterpurification system and blowing air makes it possible to reduce fuel consumption in the boiler and, accordingly, its harmful emissions by 8...12 %. Humidification of the blowing air through the use of the recovery heat also provides a reduction of nitrogen oxides emissions to 60 % by suppressing their formation in the boiler combustion chamber.

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Shelygin, B. L., S. A. Pankov, and G. V. Ledukhovsky. "Development of simplified mathematical model of P-88 recovery boiler for operating modes at loads near the nominal." Vestnik IGEU, no. 1 (February 28, 2021): 5–13. http://dx.doi.org/10.17588/2072-2672.2021.1.005-013.

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To improve the design of the elements of combined-cycle plants, and their structural and mode optimization, mathematical models are required. These models show energy efficiency indicators of the equipment under changing operating conditions. Modeling of recovery boilers is traditionally carried out with the application of specialized software systems that implement submodels of thermal-hydraulic calculations of the elements of the boiler water-steam and gas paths. This approach makes it difficult to solve practical tasks, since it requires licensed software and appropriate qualifications of an engineer. The current direction of solving this problem is statistical processing of the results of calculation data obtained with the application of specialized software systems, and development of a simplified mathematical model in the form of regression dependencies of boiler performance on variable parameters. In this study, the problem is solved in relation to the P-88 boiler of the combined-cycle plant-325 power unit in the load range near the nominal one. The initial mathematical model is developed with the application of the software package “TRAKT” designed for verification and engineering design of boilers. The simplified mathematical model is based on the methods of regression analysis of statistical data. The accuracy of the model is estimated based on the operational data of the combined-cycle plant -325 power unit. The authors have developed the mathematical model of the P-88 recovery boiler, which allows to determine the main performance indicators of the boiler when the electric power of the gas turbine and the outdoor air temperature are changing at the loads near the nominal value. The performance indicators are determined without application of specialized software for design calculation of the boiler. The accuracy of the initial mathematical model implemented in the software package “TRACT” is characterized by deviation of the calculation results data from the operational data in the corresponding modes of no more than 2 %. The additional uncertainty value introduced into the calculation results data does not exceed 1,5 % when we transfer from the initial mathematical model to the simplified one. The resulting mathematical description will allow solving the problems of mode optimization and evaluating the efficiency of the recovery boiler and the power unit under changing operating conditions.

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MANSIKKASALO, JARMO. "Improving energy efficiency of existing recovery boilers." February 2015 14, no. 2 (March 1, 2015): 105–17. http://dx.doi.org/10.32964/tj14.2.105.

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Due to the increased global energy demand, increased electricity price, and incentives for renewable energy, it is in many cases profitable to maximize electricity output both from power boilers and from recovery boilers. Another motive for maximizing electricity output from recovery boilers is to decrease fuel input to power boilers. In cases where the saved fuel is fossil fuel, the carbon footprint of the mill can be decreased as well. In recent years, many different electricity efficiency increasing features have been installed on new and existing recovery boilers. In this paper, these recovery boiler-related, so-called high power features are applied to existing recovery boilers. The goal is to show how different kinds of mills with existing recovery boilers benefit from high power features. Some of these features can have certain limitations due to constraints set by the existing boilers, and these limiting factors are also discussed. In this study, electricity generation of two example cases are calculated with the following high power features: high black liquor dry solids, air preheating, fully pressurized feedwater tank, feedwater preheating, heat recovery from vent gases, heat recovery from flue gases, and high main steam parameters.

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Kovalev, Dmitrii A. "THE ANALYSIS OF POSSIBLE FAULTS OF TECHNOLOGICAL PROCESSES IN THE RECOVERY BOILER." Bulletin of the Saint Petersburg State Institute of Technology (Technical University) 56 (2021): 108–11. http://dx.doi.org/10.36807/1998-9849-2020-56-82-108-111.

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The analysis of technological processes for a real control object-a recovery boiler is performed in order to determine faults and possible emergency situations. The recovery boiler is considered as a complex control object (in which a chemical reactor is combined with a steam power boiler), which is advisable to decompose into several interconnected subsystems. The study was carried out in accordance with the HAZOP application manual in the form of a qualitative analysis of faults and possible abnormal situations in the recovery boiler. The study was conducted in accordance with the decomposition of the recovery boiler for each constituent of the interconnected subsystems. As a result of research, for each of the subsystems of the recovery boiler, HAZOP work tables were developed that allow you to identify root frames-linked to specific causes of possible faults.

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Stecco, S. S., and U. Desideri. "Considerations on the Design Principles for a Binary Mixture Heat Recovery Boiler." Journal of Engineering for Gas Turbines and Power 114, no. 4 (October 1, 1992): 701–6. http://dx.doi.org/10.1115/1.2906645.

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The use of a binary mixture as a working fluid in bottoming cycles has in recent years been recognized as a means of improving combined cycle efficiency. There is, however, quite a number of studies dealing with components of plants that employ fluids other than water, and particularly binary mixtures. Due to different specific volume, viscosity, thermal conductivity, and Prandtl number, heat recovery boilers designed to work with water require certain modifications before they can be used with binary mixtures. Since a binary mixture is able to recover more heat from the exhaust fumes than water, the temperature difference between the hot and the cold fluids is generally lower over the whole recovery boiler; this necessitates greater care in sizing the tube bundles in order to avoid an excessive heat transfer surface per unit of thermal power exchanged. The aim of this paper is to provide some general criteria for the design of a heat recovery boiler for a binary mixture, by showing the influence of various dimensional parameters on the heat surface and pressure drop both in the cold and the hot side. Heat transfer coefficients and pressure drops in the hot side were computed by means of correlations found in the literature. A particular application was studied for an ammonia-water mixture, used in the Kalina cycles, which represents one of the most interesting binary cycles proposed so far.

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31

Vernica, Sorin Gabriel, Aneta Hazi, and Gheorghe Hazi. "Experimental Determination of the Heat Recovery Boiler Effectiveness of a Gas Turbine Plant." Applied Mechanics and Materials 659 (October 2014): 503–8. http://dx.doi.org/10.4028/www.scientific.net/amm.659.503.

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Increasing the energy efficiency of a gas turbine plant can be achieved by exhaust gas heat recovery in a recovery boiler. Establishing some correlations between the parameters of the boiler and of the turbine is done usually based on mathematical models. In this paper it is determined from experimental point of view, the effectiveness of a heat recovery boiler, which operates together with a gas turbine power plant. Starting from the scheme for framing the measurement devices, we have developed a measurement procedure of the experimental data. For experimental data processing is applied the effectiveness - number of transfer unit method. Based on these experimental data we establish correlations between the recovery boiler effectiveness and the gas turbine plant characteristics. The method can be adapted depending on the type of flow in the recovery boiler.

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Zhao, Hai Qian, and Zhong Hua Wang. "Study on Novel Thermal Insulation Structure of Thermal Recovery Boiler." Advanced Materials Research 512-515 (May 2012): 1311–14. http://dx.doi.org/10.4028/www.scientific.net/amr.512-515.1311.

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Based on the existing problem of thermal insulation structure of thermal recovery boiler , a novel thermal insulation structure of thermal recovery boiler is designed. The novel thermal insulation structure was used on a boiler in field test, and its thermal insulation characteristics were tested. According to the test data, thermal conductivities of the novel and the conventional thermal insulation structure were calculated. Contrast analyses indicated that thermal insulation characteristic of the novel thermal insulation structure for thermal recovery boiler was better than that of the conventional thermal insulation structure.

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33

Kawada, Shin, and Hideo Ibuka. "The Babcock Hitachi Kraft Recovery Boiler." JAPAN TAPPI JOURNAL 45, no. 6 (1991): 644–55. http://dx.doi.org/10.2524/jtappij.45.644.

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Shiomi, Toshio, Masami Yada, and Michimasa Yagi. "Introduction of Mitsubishi Chemical Recovery Boiler." JAPAN TAPPI JOURNAL 47, no. 9 (1993): 1100–1112. http://dx.doi.org/10.2524/jtappij.47.1100.

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Miyamoto, Yoshiyuki. "Operation Experience of Large Recovery Boiler." JAPAN TAPPI JOURNAL 47, no. 5 (1993): 594–600. http://dx.doi.org/10.2524/jtappij.47.594.

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Schwade, Hans, and Tetsuro Kawai. "Optimized Cleaning Systems for Recovery Boiler." JAPAN TAPPI JOURNAL 48, no. 1 (1994): 148–54. http://dx.doi.org/10.2524/jtappij.48.148.

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Yoshida, K. "Heat recovery boiler for coal gasification." Fuel and Energy Abstracts 43, no. 4 (July 2002): 273. http://dx.doi.org/10.1016/s0140-6701(02)86386-x.

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Korhonen, Ilkka, and Jero Ahola. "Microwave attenuation in kraft recovery boiler." IET Microwaves, Antennas & Propagation 12, no. 2 (January 8, 2018): 241–45. http://dx.doi.org/10.1049/iet-map.2017.0263.

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Hoizumi, Shinichi, and Tsugutom Teranishi. "5109665 Waste heat recovery boiler system." Environment International 19, no. 1 (January 1993): II. http://dx.doi.org/10.1016/0160-4120(93)90032-d.

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White, Martin. "4448136 Boiler with waste heat recovery." Journal of Heat Recovery Systems 5, no. 2 (January 1985): iv. http://dx.doi.org/10.1016/0198-7593(85)90057-8.

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TRAN, HONGHI, ANDREW K. JONES, and THOMAS M. GRACE. "Understanding recovery boiler smelt runoff phenomena." January 2015 14, no. 1 (February 1, 2015): 41–50. http://dx.doi.org/10.32964/tj14.1.41.

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There is considerable interest in the nature and causes of heavy smelt runoff from recovery boilers because of the role it has played in numerous dissolving tank explosions and for personnel safety around the dissolving tank. Most mills have experienced runoff problems, which can be caused by cleaning plugged spouts, burning down a large bed, low sulfidity smelt, startup with a bed in the unit, and improper firing practices. The peak smelt flow during a runoff is often 3 to 5 times normal and may be much greater in severe cases. Heavy runoffs are self-limiting and typically last less than 30 min. The geometry of the lower furnace plays a significant role in runoff events. Sloped floor units are more vulnerable to smelt pool buildup and heavy runoff when released. Decanting bottom units are inherently more tolerant of smelt pool buildup. Low sulfidity results in smelt with a high melting temperature, making the smelt easy to freeze and difficult to flow. Sulfate-rich slag/deposits falling on the hearth from the upper furnace can contribute significantly to runoff problems by causing dams and spout plugging, increasing the load of smelt pool to be removed, decreasing bed temperatures, and lowering the sulfidity of the smelt leaving the furnace.

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LEPPÄNEN, AINO, ERKKI VÄLIMÄKI, and ANTTI OKSANEN. "Modeling fine particles and alkali metal compound behavior in a kraft recovery boiler." July 2012 11, no. 7 (August 1, 2012): 9–14. http://dx.doi.org/10.32964/tj11.7.9.

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Under certain conditions, ash in black liquor forms a locally corrosive environment in a kraft recovery boiler. The ash also might cause efficiency losses and even boiler shutdown because of plugging of the flue gas passages. The most troublesome compounds in a fuel such as black liquor are potassium and chlorine because they change the melting behavior of the ash. Fouling and corrosion of the kraft recovery boiler have been researched extensively, but few computational models have been developed to deal with the subject. This report describes a computational fluid dynamics-based method for modeling the reactions between alkali metal compounds and for the formation of fine fume particles in a kraft recovery boiler furnace. The modeling method is developed from ANSYS/FLUENT software and its Fine Particle Model extension. We used the method to examine gaseous alkali metal compound and fine fume particle distributions in a kraft recovery boiler furnace. The effect of temperature and the boiler design on these variables, for example, can be predicted with the model. We also present some preliminary results obtained with the model. When the model is developed further, it can be extended to the superheater area of the kraft recovery boiler. This will give new insight into the variables that increase or decrease fouling and corrosion

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Xiao, Zhong Zheng, Shu Zhong Wang, and Jian Ping Yang. "Research on Recovering Waste Heat from Liquid Produced in Heavy Oil Exploitation by SAGD Technology." Advanced Materials Research 960-961 (June 2014): 410–13. http://dx.doi.org/10.4028/www.scientific.net/amr.960-961.410.

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In order to enhance the economy of steam assisted gravity drainage (SAGD) technology, researches were conducted on the technology for recovering heat from liquid produced from oil wells. In this study, spiral-plate heat exchanger has been chosen after comparison and analysis, which is used to recover the heat from the produced liquid and raise the temperature of the softened water used in steam injection boilers. The procedures are liquid produced from the wellhead enters a metering and transfer station for degasification and then enters a centralized heat exchanger station where its temperature is reduced to 100°C from 170°C and the temperature of softened water used as boiler feed water is increased to 110°C from 70°C. The result shows that the fuel gas consumption will drop by 907200Nm3 for each boiler annually when the liquid heat recovery technology is adopted.

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MCCABE, F. DONALD, DAVID SAVOY, CHRIS HALCROW, and HONGHI TRAN. "Optimizing operation to increase recovery boiler throughput." September 2010 9, no. 9 (October 1, 2010): 39–44. http://dx.doi.org/10.32964/tj9.9.39.

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The recovery boiler at the Irving Pulp and Paper Saint John, NB, mill has been through several major retrofits to increase its original firing capacity of 1100 metric tons/day of black liquor dry solids to the present level of 1680 metric tons/day. Many problems have been encountered over the years, including tube corrosion and cracking, as well as plugging of flue gas passages, but they all have been overcome through operational changes and process optimization. The latest challenge is to increase throughput without experiencing high total reduced sulfur (TRS) levels that would impact the environment and jeopardize compliance. An optimization program has been in place at the mill since December 2008 to further increase boiler production while maintaining environmental performance. The program, which automates liquor addition at full capacity according to targeted stack gas O2 and TRS levels, enables the boiler to operate at lower stack gas O2 targets and to achieve a 2%-3% increase in liquor throughput, while keeping TRS emissions under compliance.

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Polewangi, Yudi Daeng. "Analisis Sistem Perawatan Boiler di PT. Dewa Rencana Perangin-Angin." JOURNAL OF INDUSTRIAL AND MANUFACTURE ENGINEERING 2, no. 1 (April 29, 2019): 29. http://dx.doi.org/10.31289/jime.v2i1.2428.

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<pre>Boilers are closed vessels made of steel that use to produce steam and be used for heating, turbine driving and so on. Good maintenance for boiler will make the efficiency of boiler higher and save general operational cost. Boiler condition in PT. Dewa Rencana Perangin-angin experiences a decrease in performance and if left constantly will suffer damage which will ultimately lead to downtime. Problems arising from this downtime include production delays, loss of effective time to produce, thus affecting the productivity of the company. The results show the lowest availability ratio value occurred in September 2017, this is because the total downtime is high during 4610 minutes due to trouble and waiting time during 1920 minutes for recovery. Performance efficiency ratio of the amount of fuel used is high at 35 Kg /cm3due to recovery from the beginning. Rate of quality machine shows good results, this is because no reject is happening.</pre>

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Kornienko, Victoria, Mykola Radchenko, Roman Radchenko, Dmytro Konovalov, Andrii Andreev, and Maxim Pyrysunko. "Improving the efficiency of heat recovery circuits of cogeneration plants with combustion of water-fuel emulsions." Thermal Science, no. 00 (2020): 154. http://dx.doi.org/10.2298/tsci200116154k.

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When using modern highly efficient internal combustion engines with lowered potential of exhaust heat the heat recovery systems receive increasing attention. The efficiency of combustion exhaust heat recovery at the low potential level can be enhanced by deep cooling the combustion products below a dew point temperature, which is practically the only possibility for reducing the temperature of boiler exhaust gas, while ensuring the reliability, environmental friendliness and economy of power plant. The aim of research is to investigate the influence of multiplicity of circulation and temperature difference at the exit of exhaust gas boiler heating surfaces, which values are varying as 20, 15, 10?C, on exhaust gas boiler characteristics. The calculations were performed to compare the constructive and thermal characteristics of the various waste heat recovery circuits and exhaust gas boiler of ship power plant. Their results showed that due to application of condensing heating surfaces in exhaust gas boiler the total heat capacity and steam capacity of exhaust gas boiler increases. The increase of exhaust gas boiler heat capacity is proportional to the growth of its overall dimensions. A direct-flow design of the boiler provides a significant increase in heat efficiency and decrease in dimensions. In addition, a direct-flow boiler circuit does not need steam separator, circulation pump, the capital cost of which is about half (or even more) of heating surface cost.

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Bichevin, Vladislav, and Nina Sosnovskaya. "PROTECTION AGAINST CORROSION OF THE TECHNOLOGICAL EQUIPMENT OF THE OIL REFINING ENTERPRISE." Modern Technologies and Scientific and Technological Progress 2020, no. 1 (June 16, 2020): 23–24. http://dx.doi.org/10.36629/2686-9896-2020-1-23-24.

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A method for slowing down the corrosion of heat exchangers in the T-104 and T102 heat recovery boiler blocks is considered. PK-1 Aminate was selected as the most suitable inhibitor for process heat exchangers of the waste heat recovery boiler unit

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Jaroudi, Ezzat, Ivan Sretenovic, Greg Evans, and Honghi Tran. "Factors affecting particulate removal efficiency of kraft recovery boiler electrostatic precipitators: a technical review." May 2018 17, no. 05 (June 1, 2018): 273–83. http://dx.doi.org/10.32964/tj17.05.273.

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Electrostatic precipitators (ESPs) are used in most pulp mills to remove particulate from recovery boilers, power boilers, and lime kilns. As environmental regulations have become increasingly stringent in recent years, maintaining high ESP performance is of vital importance in mill operation. This paper discusses results of a literature review of the ESP technology used in industrial combustion units, including recovery boilers, as well as results of a parametric study using the well-known Deutsch-Anderson equation to correlate recovery boiler operating conditions with ESP collection efficiency. The results show that for particles up to about 0.3 μm, the ESP collection efficiency decreases drastically with increased particle size and with decreased temperature. For particles larger than 0.5 μm, however, the trend reverses; the collection efficiency increases with increased particle size and decreased temperature. The results also suggest that the particle concentration (or loading) in the flue gas has no effect on collection efficiency and that sodium chloride particles are more readily captured than sodium sulfate particles. The latter prediction, however, appears to be in contradiction with mill experience that sodium chloride particles are more difficult to capture.

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Kosorukov, Dmitriy, and Andrey Aksenov. "Use of condensing economizers with developed surfaces to improve the energy efficiency of conventional gas-fired heat generators in boilers." E3S Web of Conferences 263 (2021): 04024. http://dx.doi.org/10.1051/e3sconf/202126304024.

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The current financial and economic programme in the Russian Federation is aimed at increasing energy efficiency in all areas of society. The most effective way of increasing the efficiency of boiler plant operation is to improve the technology of deep heat recovery from the heated flue gas from the chimney system of hot-water boilers. The physical essence of this phenomenon consists in cooling the escaping high-temperature combustion products of gaseous fuel, through contact with the cold surface of the heat exchanger, to a temperature below the dew point under the pressure in the convective bundle of the boiler. In this regard, we set a goal to develop the most efficient design of condensing economizer, which would allow us to obtain fuel economy of gas boiler at the level of operation of condensing heat generators. A practical model of a condensing economizer for increasing the efficiency of heat generators based on convection-type gas boilers has been created. A study has been carried out, the results of which allow us to conclude on the effectiveness of its use for individual and local heating of residential and public buildings.

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TÔRRES RIBEIRO, JULIO CÉSAR, MARCELO CARDOSO, and HONGHI TRAN. "Smelt spout corrosion in a recovery boiler." August 2010 9, no. 8 (September 1, 2010): 39–45. http://dx.doi.org/10.32964/tj9.8.39.

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Severe corrosion led to an in-service failure of one of the six spouts on a recovery boiler at Cenibra. The failure resulted in a large amount of cooling water entering the boiler and contacting smelt around the spout opening, but fortunately no smelt-water explosion occurred. An extensive investigation was conducted to determine the causes of the spout failure. The failure was caused by insufficient cooling water flow to the smelt spout, which, in turn, was caused by a sequence of events that occurred after a general blackout of an electrical energy system at the mill. The experience has led to the development and placement of operating and maintenance procedures that ensure adequate cooling water flows to smelt spouts to prevent future failures.

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Journal articles on the topic 'Recovery boiler'

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