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BOILER TESTING & MONITORING SERVICES

Services to Improve Boiler Efficiency, Heat Rate and Performance

Boiler inspection cameraWe understand the difficulty that coal-burning utilities face and offer testing services and assistance with interpreting your operational data necessary to be proactive in today’s energy market. With more than 20 years of experience, we’re ready to roll up our sleeves and provide the service package that’s best for you.

The benefits of Fuel Tech's boiler service expertise are: 

  • Supplement current testing and provide an outside perspective
  • Dedicated service technicians with years of experience
  • Custom data analysis and reports of findings
  • Fuel Tech provides all required equipment


 Three Service Package Options:

 

Boiler services

High Slagging Services

Bi-Monthly Service Visits to monitor slag and fouling tendencies, while providing recommendations to achieve optimal performance and meet economic goals.

 

High Sulfur Services

Quarterly Service Visits to monitor impact of high sulfur on boiler operations, while providing recommendations to minimize corrosion and fouling.

 

High Slagging / High Sulfur Combined Service

Bi-Monthly or Quarterly Service Visits to monitor impact of slagging and fouling tendencies, along with high sulfur effects on boiler operations.

Testing Services Include:

  • Slag Inspections
  • Infrared Camera (IR) Inspections
  • High Temperature Slag & Corrosion Monitoring
  • Low Temperature Corrosion Probe
  • HVT Testing
  • FEGT Measurement
  • CEGRIT Ash Sampling
  • High Volume Ash Sampling
  • Cold End Corrosion
  • Low Light Camera
  • SO3 Testing
  • NH3 Testing
  • Key Performance (KPI) Data Analysis

HClear® – HCl Abatement Programs

Effective Alternative to Conventional DSI

HClear HCl ReductionGraph 400The Utility MATS and Boiler MACT Rules have outlet emission requirements that require HCl control. HClear is an alternative to conventional DSI, and can reduce potential PM issues while providing a solution for chloride emissions.

Fuel Tech’s HClear® program is a complete operating program, supported by highly trained engineers and technicians and designed using our extensive computational fluid dynamics (CFD) modeling and process experience. The HClear system injects a liquid for HCl abatement, and requires no capital investment. The HClear program relies on the injection of a stable aqueous solution into gas streams to reduce gaseous HCl emissions.

HCl emissions must often be reduced from environments with high concentrations of SO2. Some dry sorbents concurrently react in the flue gas with SO2 where typical concentrations are 300 to 3,000 ppmv, and also with HCl where typical concentrations are 1 to 100 ppmv. Some DSI sorbents are not selective in terms of reactivity, which can result in lower HCl removal efficiencies or higher injection rates.

Demonstration Results Show That the HClear Program Offers Significantly More Efficient HCl Reduction Over Other Technologies with the Following Benefits:

  • Stable liquid product
  • Low capital investment
  • Full service operation
  • No impact on fly ash
  • No interference with mercury control programs
  • Selective towards HCl reduction
  • Over 20 years of chemical injection experience

HClear is Selective for HCl with Several Benefits

HClear PerformanceGraph3 400

The HClear technology is selective for HCl, resulting in high HCl removal efficiencies, low chemical injection doses, and no impact on particulate loading. Additionally, HClear programs have no impact on fly ash chemistry or pH. Consequently, injection of the HClear program does not increase the leachability of toxic metals from fly ash. HClear programs also contain a mild mercury oxidant and does not impact the performance of powdered activated carbon injection for mercury control.

Fuel Tech has expertise utilizing CFD modeling to predict flow characteristics and chemistry. CFD modeling enables our engineers to design an HClear injection system to maximize performance.

 


Blue dropRedox-Hg

Enhance Mercury Removal Capabilities of Wet FGDs

Redox-Hg is a suspension of highly amorphous iron sulfide particles used to enhance the total mercury removal capabilities of wet FGD scrubber systems. Through a combination of adsorption, chemical reduction, precipitation, and conversion to stable sulfide and iron-sulfide precipitates, Redox-Hg removes oxidized and elemental mercury from liquid and gaseous streams.

Features and Benefits:

  • Fast-acting response during startup, ORP and SCR excursions
  • Works within existing scrubber conditions with a small footprint
  • Reduces arsenic and selenium in water
  • Eliminates the potential of leachable heavy metals in solids
  • Non Toxic, easy to handle, low odor

 

Cost-effective alternative to wet Scrubber Additives (WSA)

Redox-Hg enhances the mercury removal capabilities of wet FGDs and is employed as the mercury control chemical of choice at plants generating over 9,000MW of power.

Program Benefits

  • Lowers total stack mercury by over 95%
  • Does not effect quality of fly ash or gypsum
  • Effective over a wide range of ORP (-200 to +700 mV) and pH (pH 4.5-7)

 

Plant data showing real-time quick response of Redox-Hg chemical injection

RecoveryChem

RECOVERY CHEM®

Comprehensive Fireside Slag and Fouling Control Programs for Black Liquor Recovery Boilers

 

The design and use of black liquor recovery boilers has caused a significant boost in efficiency and a reduction in pollution over the past several decades. Changes in market conditions have led to boiler design modifications in order to achieve higher solids in the black liquor, which can be problematic for boiler operators. Conventional fuel treatment programs attempt to reduce slagging, fouling, erosion and slag falls by injecting reagents into the liquor or the salt cake tank or blowing it into the furnace adjacent to tertiary air ports. Most problem areas receive minimal treatment; typically these programs are not economical and result in poor performance.

Operational Benefits to Black Liquor Recovery Boilers:

  • Reduces fireside deposition, erosion and corrosion problem areas
  • Reduces slagging and fouling
  • Reduces shut downs, resulting in significant ROI

Boiler problem areas RECOVERY CHEMHow It Works

RECOVERY CHEM® programs reduce fireside deposition, erosion and corrosion problems by application of a comprehensive treatment plan. Our programs enhance mechanical removal mechanisms by targeting the reagent at the problem areas of the radiant and convection sections, while ensuring adequate reaction times. This allows efficient boiler operation and can help mitigate deposits.

After gaining a thorough understanding of a customer’s needs, a problem analysis is conducted. This includes the collection of unit operating and boiler design data and deposit samples. Our proprietary computational fluid dynamics (CFD) computer modeling and data visualization processes are then used to generate a boiler-specific program. Our engineers study these models to identify the placement of injectors resulting in the most efficient arrays to meet performance requirements.

These results are used to generate process design, equipment design, specifications, layout, predicted program performance, program cost and return on investment (ROI).

Program Design:

Comprehensive survey of boiler

  • Design parameters
  • Furnace geometry
  • Mass inputs
  • Operating practice

CFD Model: In Furnace View

  • CFD model data set exported to virtual reality engine
  • Temperature profiles and gas flows determined, injector placements are selected
  • Manipulation of injector location, spray characteristics, droplet size, droplet velocity
  • Data is used to design injection strategy for maximum coverage

Program Application:

  • Stabilized magnesium hydroxide is received in bulk trucks and is transferred into the bulk tank by plant operators. The chemical is recirculated through a heat exchanger and then on to chemical metering pumps.
  • Chemical is pumped to the boiler injectors using a custom made pump and control system. The pumps feed chemical to the injectors on the appropriate boiler floor level. A water booster pump is provided for reliable chemical injection performance.
  • The chemical program is then injected into the fireside of the boiler at specific locations based on the CFD model of the boiler.

TIFI Bio

Improve Biomass Unit Performance & Efficiency with the Flexibility to Switch Fuels

BiomassPlant3 250Conventional fuel treatment programs attempt to control slagging and fouling by applying liquid and/or dry chemicals onto the fuel or randomly into the boiler without regard for ensuring proper chemical reactions and the avoidance of interfering chemical reactions. This frequently leads to increased slag and fouling or no improvement in operating life. By failing to address the problem areas or the chemistry issues directly, these non-specific programs rarely meet customer performance expectations.

TIFI Bio Performance Benefits

  • Targeted towards problem areas and proper reaction chemistry
  • Increase time between cleaning cycles
  • Safest process to control slag and fouling

 

TIFI Bio Downtime Performance vs. Conventional Treatment

TIFI downtime reduction

TIFI Bio Treatment (2016)

  • 180 Hours of Annual Maintenance

Conventional Treatment (2015)

  • 300 Hours of Annual Maintenance

 

 

Our Approach

Our process begins with the development of a TIFI Bio™ program for each unique boiler application and circumstance. Computation fluid dynamics modeling is employed as required to develop a program for each individual application’s circumstances.

One or more chemicals are either applied to the fuel, or injected into the furnace to target the problem areas and the correct chemical reactions. Unlike other chemical treatment programs, TIFI Bio has shown no adverse impact on overall unit operations.

TIFI Bio offers significant operating cleanliness and lower corrosion advantages while firing a greater variety of biomass waste fuels, including:

  • Yard Waste
  • Demo Waste
  • Logging & Mill Residue
  • Wood Chips
  • Switch Grass
  • Forest Residue