PresentationtoIndiaPAPERTECH2010

SOUND BLAST
SONIC SOOT BLOWER
FACILITATING ENERGY MANAGEMENT THROUGH SONIC SOOT
BLOWING IN HIGH PRESSURE BOILERS RELATED TO PULP
AND PAPER PLANTS

SOUNDBLASTSONICPOWERCOMPANYLIMITED

PAPERTECH2010v01

CongratulationstoOrganisersof
PAPERTECH2010
foramostsuccessfuleventandwish
IndianPulpandPaperIndustry
d
l
d
d
participantstodayandallstakeholders
continuoussuccessandprosperity

With 600 paper mills in operation, a 7.8% projected annual

growth, and an estimated nationwide paper demand of 10.5
million tonnes in year 2010, the Pulp and Paper Industry plays
an important role in the Indian economy and the next step
forward is to become world class.
However, this industry is also the 5th largest energy consumer
and the need is acute to better conserve and manage energy
with minimum ecological impact.

Sonic soot blowing is a low investment, cost effective way of

cleaning the boiler tubes and restore equilibrium conditions to
improve
p
heat absorption
p
and facilitate energy
gy management.
g

Most Paper
p Plants meet its heat and p
power needs byy inhouse
thermal power boilers and waste heat recovery boilers; yet
ineffective removal of ash deposits from boiler tubes have in
many occasions lead to boiler in
inefficiency,
efficiency, capacity reductions,
tube overheating failures, and unscheduled shut downs.

Sticky ash in Kraft recovery boilers aside, most ash deposits in

these boilers are friable, less sticky and less tenacious, and are
removable by sonic soot blowing or a combination thereof with
existing soot blowing systems in boilers.

So, what is sonic soot blowing and what sets it apart from other
soot blowing systems? Is it feasible to target zero unscheduled
outages through sonic soot blowing?

Whatissonicsootblowing
Sonicsootblowingiscleaningof
fouledsurfacesbycompressedair
operatedsonicsootblowers.
Soundwavessentinsideboiler
Sound
waves sent inside boiler
propagateinalldirectionsand
impartenergytoashparticulates
which fluidize and jump up from
whichfluidizeandjumpupfrom
fouledsurfacestobecarriedaway
bythefluegasstream.
Cleaningiseffectiveevendeep
intotubebundlesleavingnodead
cornersunclean.

Sonic soot blower

Flue gas stream

Tube bundle

Sonicsootblowingcleanswithtimesetting
Sonicsootblowingoperatescontinuously
onlineinsuccessiveshortcycles where
cleaningeffectiscontrolledbycycletime
setting(ontimeisinseconds,andoff
timeisinminutes).
Ahelpfulanalogytoexplainistoimagine
cleaningyourtableonceayear,oroncea
month,oreveryday.Ofcourse,cleaning
thetabledailyrequiresmuchlesseffort
tokeepitspotless!
Now,applythistoyourboilerandcleanit
sayevery20minutes,or90timesaday
i
insteadofjust3timesdaily.
d fj 3 i
d il

Cleaning with time

Cleaningwithtime
On

Off

Time

Cleantubesabsorbmoreheatandreduceoverheating
Cleaning90timesdaily
withsonicsootblowing
Designconditionsofcleanliness
Cleantubesimproveheatabsorption
andreduceoverheatingfailures

Heatabsorbed
H
b b d
fromfluegas
0
0

8
8

16
16

24 h
24hr

Cleaning3timesdaily

Moreheatlossinfluegasand
tubesarepronetooverheating

16

24hr

Whatiscleaninginsuccessiveshortcycles

Initially, ash
particulates
land on tube
surfaces and
stay there.

Since off time in the

cleaning cycle is short,
only a small quantity
of ash particulates
can land and will
remain quite loose as
there is not enough
time for it to compact.

When cleaning cycle

starts, sound waves
come in and clean up
easily. The cycle
repeats every few
minutes successively
to keep the tube
surfaces always clean.

Pre requisitestooperateinsuccessiveshortcycles
1. Itmustnotcauseanydamagestoboiler
tubesevenwhenthesootblowerfails
duringoperation.
(sonicsootblowerneverdamagetubes)
2. Costofsootblowingmediummustbe
lowanditsproductionmustnotleave
ecologicalfootprints.
l i lf t i t
(compressedairisinexpensive)
3. Sootblowingmediummustcreatenoill
effectsatboilerexit.
(compressed air is neutral and friendly)
(compressedairisneutralandfriendly)

4. Sootblowingequipmentmustbereliable,easytomaintain,
g q p
,
y
,
andcapableoffullservicebetweenplannedoutages.
(withonlyonemovingpart,sonicsootblowerispractically
maintenancefreeforlongtermoperation)
a te a ce ee o o g te ope at o )

5. Sootblowingsysteminvestmentmustbelowandpayback
periodmustbeshortandrealizable;andsystemmustbe
capableofbeinginstalledinneworexistingboilerseasily.
p
g
g
y
(sonicsootblowingsystemmeetstheserequirements)

Reducingairpollutionasasidebenefit
Cleaning90timesdaily
withsonicsootblowing

16

Levelsoutsootdischarge
Levels
out soot discharge
peakstosmallbatches
foreasycaptureormore
effectivedispersion
p

24hr

Cleaning3timesdaily
Sootblowingdischargepeaks
Soot
blowing discharge peaks
aredifficulttocaptureor
disperseandformseriousair
p
polluters3timesdaily
y
0

16

24hr

SOUNDBLAST sonicproducts

SOUNDBLASTsonic
sootblowingsystemis
capable of seamless
capableofseamless
integrationtoDCS
withindustrystandard
communication
communication
protocols.

Sonicsootblowersoperateinclusters
Sonicsootblowersare
usuallyinstalledonboiler
y
LHSandRHSinthetube
bundleservicespacesand
operateinclustersto
enhancecleaningeffect.
AsinCricketfields,itsPA
systembroadcaststhrough
loudspeakerclustersfor
cleartransmissionto
everyoneacrossthefield.
h f ld
Beloware2application
cases.

Constructiveinterferenceeffect

Case1:Pulpmill195t/hrecoveryboiler
Thisisa195t/hpulpmillrecovery
boilerbuiltin1993tofiresludge
and with steel ball cleaning system;
andwithsteelballcleaningsystem;
ithadtobeshutdownevery3~4
monthsformanualcleaning.
4yearsago,16unitsofmodelSB38
sonicsootblowerswereinstalledto
operatein4groups.Today,the
sonicsootblowingsystemrunsat
20sec.on/3min.off;andsteel
ballcleaningisusedonlytwicea
weekfor12hoursandboilercan
lastthroughplannedoutages.The
g p
g
clientisnowarepeatcustomer.

Case1reallifephotos

Case2:Industrial490t/hCFBCboiler
Thisisanindustrial490t/hcoal
firedCFBCboilerbuiltin2004;
foulingpersistedevenwithLRSB
cleaningandtheboilercouldonly
operateatabout90%MCR.
5yearsago,40unitsofsonicsoot
blower models SB60 and SB38
blowermodelsSB60andSB38
wereinstalledandoperatedin7
groups.TogetherwiththeLRSB
system the boiler returned to
systemtheboilerreturnedto
operateatabout95%MCR.
Theclientwasarepeatcustomer.

Case2reallifephotos

Exampleonfinancialsavings
210MWecoalfiredboiler
Coalconsumptionp.a.
Cost of coal to site
Costofcoaltosite
Annualcoalcost

:1.03milliontons(approx.)
: ~INR3,000/ton
:
INR 3 000/ton
:INR3.09billion

Sonicsootblowing:
Directsavings@0.75%
Indirectsavings@1%
Totalsavingsp.a.

:INR23.2million
:INR30.9million
:INR54.1million(INR5.41Crores)

Sonicsootblowingsystempaybackperiod
Inmostcasesandconsideringbenefitsfromefficiencygainsonly,
sonicsootblowingsystempaybackperiodisusuallywithin2years.
Anyadditionalbenefitsfromimprovedperformanceandreduced
maintenance would further shorten this payback period.
maintenancewouldfurthershortenthispaybackperiod.

TypicalLRSB

SSonicsootblower
i
t bl
(samerange)

SonicsootblowinginPulpandPaperIndustry
TotalCleaningConcept

Sonicsootblowingsystemcanbeappliedtodifferent
i
installationsinPulpandPaperPlanttofacilitate
ll i
i
l
d
l
f ili
systemoperationandenergymanagement
B il
BoilerAPHESPBagFilterI.D.Fan
APH ESP B Filt
ID F

Benefitsofsonicsootblowing
1. Facilitateenergymanagement:reduceunscheduled
outages,boilerdamages,andincreaseoverallplant
safety,availability,reliability,andproductionstability.
2 Improve
2.
Improveoperationeconomy:betterboilerefficiency,
operation economy: better boiler efficiency
lesscapacityreduction,andsustainssuperheated
steamtemperaturetoimproveturbineperformance.
3. Reduceconsumption:ofsteam,IDFanpower,and
lesssystemmaintenanceneeds.
4. Reduceairpollution:throughsuccessiveshortcycle
cleaning to level out soot discharge peaks
cleaningtoleveloutsootdischargepeaks.

Customerreferencelist
ReferenceinIndia:
InfinalstagesofapplyingSOUNDBLASTsonicsootblowermodelSB38
In
final stages of applying SOUND BLAST sonic soot blower model SB38
toa117t/hAFBCBoilerinSheshasayeePaper&Boards,TamilNadu.
Referenceinothercountries:

Industrycoalfiredboilercleaningphotos

BeforeandAfter

Industrycoalfiredboilercleaningphotos
Before

After

ESPcleaningphotos
Negativedischargewires
Before

After

ESPcleaningphotos
Positivecollectionplates
Before

After

ESPhoppercleaningphotos
Hopperdischargeduringsonicsootblowing

Contactusforanysootcleaningproblems
SoundBlastSonicPowerCompanyLimited
A1,2/F,65~67BonhamStrand,
Central Hong Kong
Central,HongKong.
Tel:+ 852 25418289
Fax:+ 852 81481175
email:soundblast@soundblast.com
il
dbl @
d bl
Web:http://www.soundblast.com

OurbusinesspartnerinIndia:
KeromiyonsIntechPrivateLimited
#110,RengaVillas,NewDamuNagar,
Coimbatore 641037,TamilNadu,India.
Coimbatore
641 037 Tamil Nadu India
Tel:+914224214124
Fax:+914224214125
e mail: uchandar@keromiyons com
email:uchandar@keromiyons.com
Web:http://www.keromiyons.com

ThankYou