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Content
Introduction...................................................................................................... 5
Rise in soot fire incidents................................................................................... 5
Warning triangle risk of soot fire................................................................. 6
Scope of this paper..................................................................................... 6
Basic Information and Boiler Definitions............................................................. 7
Heat balance of a main engine..................................................................... 7
Boiler types................................................................................................. 8
Boiler steam systems................................................................................. 10
The influence of a boilers pinch point......................................................... 11
Sulphuric acid corrosion............................................................................ 12
Steam production influence of ambient temperatures............................... 13
Particulate emissions from diesel engines................................................... 15
Soot fires in exhaust gas boilers................................................................. 15
Boiler Experience and Design Criteria.............................................................. 17
Statistical analyses of soot fires....................................................................... 17
The impact of low gas velocities................................................................. 20
Summary of main reasons for soot fires...................................................... 21
Recommended boiler design criteria.......................................................... 22
Recommended operating conditions.......................................................... 23
Closing Remarks............................................................................................. 25
Reference....................................................................................................... 25
Introduction
tubes.
1986
1988
1990
1992
1994
1996
1998
2000
2002
2004
2006
Year
Fig. 1: Number of soot firedamaged exhaust gas boilers in DNVclassed vessels (ref. about 5,000 vessels)
be removed.
lubricator.
ter II.
chinery deductibles.
(of Ignit
the ion
so
ot)
ke)
2
n O smo
yge as
Ox st g
au
exh
(in
Soot deposits
(on boiler tubes)
be difficult to meet.
used initially.
engines
tioned before.
6S60MCC7
Spark
arrester
p2
Exhaust
gas
silencer
Shaft power
output 50.5%
Lubricating
oil cooler
3.3%
Jacket water
cooler
5.8%
psystem
p3
Exhaust gas
25.0%
Exhaust
gas
boiler
Air cooler
14.6%
Fuel
100%
Heat radiation
0.8%
Fig. 3: Heat balance of main engine 6S60MC-C7 IMO Tier I at 80% SMCR
T/C
Fig. 4: Permissible exhaust gas backpressure at 100% SMCR
Gilled tubes
Pinned tubes
requirements,
the
Plain tubes
Spiral tubes
Water tubes
Exhaust gas
Fig. 5: Exhaust gas boiler water tube type. The boiler shown is the vertical type without steam drum
Steam drum
(Space)
pressure loss.
Water
Smoke
tubes
tion boxes.
Boiler types
23 mm.
Exhaust gas
main groups:
drum.
sive.
time.
Exhaust
gas boiler
evaporator
Saturated
steam for
heating services
Exhaust gas
Oil-red
boiler with
steam drum
Atmospheric
surplus
condenser
Feedwater
pumps
Circulating
pumps
Hot well
Smoke tube boilers
In smoke tube boilers, the gas is con
ducted through a bundle of tubes with
C Temperature T
300
Preheater
Saturated
steam for
heating
services
Oil-red
boiler with
steam drum
Heat
exc.
Evaporator
Superheater
Exhaust gas
Turbogenerator
(steam turbine)
Condenser
Condensate pumps
Atmospheric
surplus
condenser
250
Superheated
steam
Saturated
steam
150
Fig. 8: Special exhaust gas boiler system with turbo generator for electricity
production. Single pressure steam system with preheater, evaporator and
superheater sections
Pinch
point
Steam/water 7 bar abs
100
Feed
water
pump
Hot well
Exhaust gas
Feedwater
50
0
0%
Superheater
Heat transmission Q
20% 40% 60% 80% 100%
Evaporator
Preheater
bogenerator
shown in Fig. 7.
10
fer surface
this section.
pinch point
sur
fac
e
t tr
an
sfe
r
%
125
Temperature
C
110
105
100
230
75
220
190
180
25
200
St
ea
pro
du
175
n
c t io
150
141
125
100
tle
tg
as
tem
pera
ture
Ou
210
200
50
232
225
He
a
Relative steam
production
Relative heat
transfer surface
Example:
132% larger exhaust gas
boiler required to produce
10% more steam at 5 C
pinch point compared
with 15 C
170
160
Steam temperature
80 60 50 40
30
75
50
25
0
20
15
10
Pinch point C
Fig. 10: Influence of a boilers pinch point, relative to 15oC. The graph shows the relative influence of the pinch point on an exhaust gas boilers heat transfer
surface (size and investment) and steam production [3]
11
140
130
120
This is what happened with the more
efficient exhaust gas boiler design dur
110
100
0
3
4
5 wt %
Sulphur (S) content in fuel
Fig. 11: Sulphuric acid dew point of exhaust gas shown as a function of the sulphur content in the fuel
300
250
200
30
40
50
60
70
80
90
100 110 % SMCR
Engine shaft power
Fig. 12: Influence of ambient air temperature on the exhaust gas temperature after turbocharger for a
6S60MCC7
12
to establish.
a. at fuel combustion:
S + O2 SO2
2SO2 + O2 2SO3
Steam production
kg/h
ISO ambient conditions (25 C)
Total steam
production
3,000
2,000
Thus, the exhaust temperature af
Surplus steam
1,000
Steam consumption
0
40
50
60
70
80
90
100 %SMCR
Steam production
kg/h
Winter ambient conditions (10 C)
2,000
Total steam
production
1,000
Steam consumption
0
40
50
60
70
80
90 100 %SMCR
Engine shaft power
Fig. 13: Influence of ambient air temperarure on the steam production of an exhaust gas boiler installed
on an Aframax tanker with main engine 6S60MCC7
13
21% O2
79% N2
14.0%
O2
76.2%
N2
4.5% CO2
Heat
Heat
97% HC
Heat
21% O
O2
21%
O2 2
3%21%
S79%
N2
79% N
79% N2 2 9.0 kg/kWh
97% HC
97% HC
HC Air
97%
97% HC
Engine
Exhaust
2.5% CA
3% SS 170.0 kg/kWh
3%
Process
gas
3% S
Fuel oil
0.5% S97% HC
97% HC
97% HC
2.5% CA
CA 0.7 kg/kWh
2.5%
2.5% CA Lube oil
Work
0.5% SS
0.5%
Fig. 14: Typical emissions
0.5% S from an MC/ME type low speed diesel engine
14.0% O
O2
14.0%
5.1%
14.0%
OH22O 2
76.2% N
N22
76.2%
1500
ppm
76.2%
N NOx
4.5% 2CO
CO22
4.5%
4.5%CO
600
ppm
2 SOx
5.1% H
H2O
O
5.1%
5.1%
H2O 2 CO
60 ppm
1500
ppm
NOxx
1500 ppm NO
1,500ppm
ppm NO
180
HC
x
600 ppm
ppm SO
SO
600
xx
600mg/Nm
ppm SO3x part
120
60
ppm
CO
60 ppm CO
60 ppm CO
180 ppm
ppm HC
HC
180
180 ppm HC 3
3
part
120
mg/Nm
120 mg/Nm part
120 mg/Nm3 part
Fig. 14:
14: Typical
Typical emissions
emissions from
from an
an MC/ME
MC/ME type
type low
low speed
speed diesel
diesel engine
engine
Fig.
Fig. 14: Typical emissions from an MC/ME type low speed diesel engine
Stage 11 Ignition
Ignition of
of soot
soot
Stage
Dry soot
300400C
Type
of
soot
Potential ignition
ignition temperature
temperature
Potential
Type of soot
Wet (oily)
Dry soot
soot
Dry
Wet (oily)
(oily)
Wet
and 20C
point,
together
with
based
boilerpinch
design
shows
that too
too
based
boiler
design
shows
that
means
of
the atmospheric
surplus
con
the needed
steam
consumption
for
much
steam will
will
be produced,
produced,
and the
the
much
steam
be
and
heating
services.
The
upper
graph
for
surplus
steam
has
to
be
dumped
by
surplus steam has to be dumped by
ture,
the However,
steam
production
will
be(10C
lower,
shows that
too much
steamtime
will be
pro
denser.
in winter
denser. However, in winter time (10C
whereas
the
steam
consumption
in
duced,
the surplus
steam
haswill
to be
air)
with and
a lower
exhaust
gas tempera
air) with a lower exhaust gas tempera
crease,
thatofthe
oil
fired
boiler
dumped
by means
thewill
atmospheric
ture,
themeaning
steam
production
will
be lower,
lower,
ture,
the
steam
production
be
may
occasionally
have
to start
up
surplus
condenser.
However,
inwill
winter
whereas
the
steam consumption
consumption
will
into
whereas
the
steam
in
supplement
the with
steam
production.
time (10C
air)
lower
gas
crease,
meaning
thatathe
the
oil exhaust
fired boiler
boiler
crease,
meaning
that
oil
fired
temperature,
the have
steam
will
may
occasionally
have to
toproduction
start up
up to
to
may
occasionally
start
be
lower,
whereas
the
steam
consump
supplement
the
steam
production.
supplement the steam production.
tion will increase, meaning that the oil
fired boiler may occasionally have to
on thegraph
steamfor
pressure
of 8
bar abs.,
upper
graph
the ISO
(25C
air)
upper
(25C
air)
surplus
steamforhastheto ISO
be dumped
by
150C (120C)
300400C
300400C
150C (120C)
(120C)
150C
Small
soot
fires
are most likely to occur during
Stage
Small soot
soot fires
fires
Stage
22 Small
manoevring/low
engine
limited
Small soot fires
are load
mostwith
likelyno
to or
occur
during
Small soot fires are most likely to occur during
boiler manoevring/low
damage
engine load with no or limited
manoevring/low engine load with no or limited
boiler damage
damage
boiler
Stage
High-temperature
fires
A small
soot fire may fires
develop into a
Stage
33 High-temperature
small soot
sootfire
fire with
may develop
develop
into aa
hightemperature
the
following
AA small
fire
may
into
hightemperature
fire with
with the
the following
following
reactions
involved:
hightemperature
fire
reactions involved:
involved:
reactions
a.
a. Hydrogen
temperature
> 1,000C
Dissociation
of fire,
water
into hydrogen
and oxygen:
Dissociation of
of water
water into
into hydrogen
hydrogen and
and oxygen:
oxygen:
Dissociation
2H2O 2H2 + O2
O
2H
2H22 ++ O
O22
2H22O
2H
H2O + C H2 + CO
O ++ C
C
H
H22 ++ CO
CO
H22O
H
b.
and CO
CO are
are combustible
combustible
}H22 and
}H
Iron
> 1,100C
b. fire,
Irontemperature
fire, temperature
temperature
1,100C
b.
Iron
fire,
>> 1,100C
Examples
of
reaction
with
iron:
Examples of
of reaction
reaction with
with iron:
iron:
Examples
heat heat
2Fe +2Fe
O2 +
2FeO+
2Fe
+O
O2FeO+
22 2FeO+ heat
}The
boiler
tubes
are
burning
}The}The
boiler
tubes
areare
burning
boiler
tubes
burning
O
FeO+
FeO+
+ heat
Fe
H22O
FeO+
H2 +HHheat
Fe + H
Fe
++
H
2O
22 + heat
Fig.15:
15:Development
Developmentof
sootfire
firein
anexhaust
exhaustgas
gasboiler
boiler
Fig.
15:
Development
ofofaaasoot
soot
fire
ininan
an
exhaust
gas
boiler
Fig. 15: Fig.
Development
of a soot
fire
in an
exhaust
gas boiler
Soot
Deposits
and
Fires
in Exhaust
Exhaust
Gas
Boilers
14
Soot
Deposits
and
Fires
in
Exhaust
gas
Boilers
14 Soot
Deposits
and
Fires
in
Gas
Boilers
14
Fig.
Fig.16:
16:High
Hightemperature
temperaturefire
fireofof
ofaaagas
gasfired
firedwater
watertube
tubetype
typeboiler
boiler
Fig.
16:
High
temperature
fire
fired
boiler
Fig.
16:
High
temperature
fire
of
a gas
gas
firedwater
watertube
tubetype
type
boiler
engines
be left as a nucleus.
oil dosage.
be considered typical.
bons.
lowing.
lube oil
sticky.
sions
fire.
Ignition of soot
15
16
Parameter
Ship type
no
no
no
Fig. 17
no
no
Fig.18
no
Fig. 19
yes
Fig. 20
yes
Fig. 21
yes
Fig. 21
Table 1: Statistical parameter survey of soot fires in exhaust gas boilers Ref.: Nippon Kaiji Kyokai, Tokyo
(NK), 1992
Number of cases
12
Trouble
10
No trouble
L-G
L-MC
K-MC
RND
S-MC
RD
RL
RTA
D E
L KZ
Sulzer
Mitsubishi UE
MAN
Pielstick
and 21.
17
Number of cases
20
Trouble
15
No trouble
10
5
0
100
150
200
250
300
350 C
Inlet gas temperature
200
250
300
350 C
Outlet gas temperature
Number of cases
15
10
5
0
100
150
Fig. 19: Boiler trouble influence of exhaust gas inlet and outlet temperature
Number of cases
60
50
Trouble
No trouble
40
30
20
10
0
Spiral
Square gilled
Gilled
Pinned
Plain
18
Number of cases
15
Trouble
No trouble
10
0
0
10
15
20
25
30
m/s
Design mean gas velocity
Fig. 20: Boiler trouble influence of design mean gas velocity in exhaust gas boiler
such trouble.
sulphur).
sates.
improbable.
19
Number of cases
20
Trouble
15
No trouble
10
ignite.
6
7
8
Water inlet velocity to boiler
Number of cases
15
10
10
12
20
fires
below.
(dry soot).
Wrong
Correct
Soot
deposits
Boiler
tube
section
Boiler
tube
section
Inlet
piping
Recirculation
of gas
Inlet
piping
Exhaust
gas
Uniform
gas
velocity
Exhaust
gas
21
supply of oxygen.
engine,
type/fuel additive)
wet soot.
22
be better.
Referring to ignition
properly.
system
recommendable as a means of de
temperature
monitoring
it starts.
is an indication of a worsening of
necessary.
23
situations
fire.
curred.
noeuvring
ter system.
blowing frequency
Ref. [2].
correctly.
G. The boiler instruction manual must
ommended:
temperatures.
been discovered:
down:
stopped already.
for
cleaning
and
lating pump.
cooling.
line.
24
Reference
nance
[2]
Aalborg
Boilers,
Instruction
hightemperature fire.
Closing Remarks
2009
25
26
27
All data provided in this document is non-binding. This data serves informational
purposes only and is especially not guaranteed in any way. Depending on the
subsequent specific individual projects, the relevant data may be subject to
changes and will be assessed and determined individually for each project. This
will depend on the particular characteristics of each individual project, especially
specific site and operational conditions. CopyrightMAN Diesel & Turbo.
5510-0065-02ppr Sep 2014 Printed in Denmark