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CheMinFouling vs. Availability
Prewin Meeting at Coventry, June 19th-20th 2012 1
Fouling versus Availability
Introduction to Prewin Meeting, June 2012 on Fouling
(in a parallel session: the Fifa Euro 2012 at Poland and Ukraine)
Thomas Herzogwww.chemin.de
Fouling versus Availability
Introduction to Prewin Meeting, June 2012 on Fouling
(in a parallel session: the Fifa Euro 2012 at Poland and Ukraine)
Thomas Herzogwww.chemin.de
CheMinFouling vs. Availability
Prewin Meeting at Coventry, June 19th-20th 2012 2
...the accumulation of unwanted material on solid surfaces to the detriment of function. Other terms used in the literature to describefouling include: • deposit formation, • encrustation, • deposition, • scaling, • scale formation, • slagging, • etc.
Source: Wikipedia
Fouling is...
Final-superheater, cladding besidecoating, reliable operation time: 18-
24 month
CheMinFouling vs. Availability
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Availability is...
...this raises interest to prolong the operation time from 12 to 18 or 24 month
Availability is the most important factor...
relative %
Cost of Capital(Investment)
Staff Costs
Electr. & Gas/Oil
Consumables & Residues
Maintenance
Troughput,Tonnage of
Waste
RecoveredEnergy
100
90
80
70
60
50
40
30
20
10
0Expenditures Revenues
Directlyproportional to
throughput
Prices decrease
Overcapacities & decrease of
available wastequantities
Each ton of waste andeach day of operationincreases availability,
and the revenues
Increasing
Increasing
Increasing
Increasing
Decreasing
Zickert 2009
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...why is it interesting, to prolong the operation period?
Availability 90% to 95% :
• Operation period of 12 month at 95% availability: 18 days for maintenance
• Operation period of 24 month at 95% availability: 36 days for maintenance
This is not enough to do proper maintenance work andto have further days for short inspection and cleaning jobs
Enough for proper maintenance work andfor further days for short inspection and cleaning jobs
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Efficiency (Heat Recovery) is one aspect of availability...
Q.
Fouling
Water/ Steam
Flue Gas
Fouling reduces the heat recovery...
...high fouling rates increase the demand for cleaning stops = Loss of availability....waste, refuse derived fuels, biomass cause severe fouling in general.
...and culminates in blockages
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Fouling influences availability in many ways
kick-off
Fuel Firing
Fouling
Red Team ‚Difficult Fuels‘ Blue Team ‚Availability‘
beat availability by fouling
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Fouling influences availability in many ways
Fuel Firing
Fouling
Design
Tactic 1: Generate fouling Defense: Designed for solid fuels
goal keeper
CheMinFouling vs. Availability
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Designs for high fouling rates in biomass incineration...
Source: Burmeister & Wain Energy A/S
...biomass incineration with superheaters using the radiative heat transfer in the 1st pass
...typical technique used in Scandinavia for straw firing (potassium)
...high alloyed steels are required for parts or for full construction of the platen*
*): Published materials are e.g. X3CrNiMoN17-13, TP347CG, TP347FG, 12Cr1Mo1W, 13Cr13Mn, Esshete 1250, HCM12, X20CrMoV121, AC66, Sanicro 28/ 63, Sandvik 8RE
CheMinFouling vs. Availability
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Designs for high fouling rates in waste-to-energy plants...
...test phase in German wte-plant
...commonly used steel tubes protected by rear-ventilted tiles
Projekt TUF01HTO-32881 „Steigerung der Energieeffizienz von Verbrennungsanlagen für Nicht-Regelbrennstoffe durch
Strahlungsüberhitzer im ersten Kesselzug“CheMi
n
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Fuel Firing
Corrosion
Tactic 2: Corrosion under deposits
Design
Fouling
Cause damage,reduce life time of components,
reduce operation time andtroughput of waste
CheMinFouling vs. Availability
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Tube
Fluegas
subsequent corrosion
Chlorides inside the deposits release corrosive chlorine gas
matterheat
°Ctemperature activatesreactive salts(vapour pressure)
barrierCladding
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Investigations on fouling rates and corrosion with cooled deposition probes
Analysis of:...Fuel & firing condition...Fouling rate...Heat Transfer [W/m2]...Corrosion mechanism...Material tests (coating, cladding)...Different temp. on one probe...Analysis of flue gas flow pattern
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Fuel Firing
Corrosion
Tactic 2: Corrosion under deposits Defense: Corrosion protection
Design
+ manymore
...expensive players,which are reliable
Fouling
Cladding
Refract.
Coating
Standard results must be:1:0 for corrosion protection
CheMinFouling vs. Availability
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Fuel Firing
Tactic 3: Confuse the defenseby nasty center players
Design
Corrosion+ manymoreCladding
Refract.
Coating
Fouling
DischargePressure
DropRaw Gas Qual.
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Fouling is not a stable condition, it changes continuously (15 min/ picture)
Cladding
Rear-ventilatedtile
Back-filledtile
Left Side Front Wall Right Side
High
Low
Heatflux q.
kW/m2
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Fuel Firing
Fouling
Tactic 3: Confuse the defenseby nasty center players Defense: Online cleaning
DesignMan to man cover:Individual defense
at individual positions
ShowerWaterBlower Explosion
Corrosion+ manymoreCladding
Refract.
Coating
DischargePressure
DropRaw Gas Qual.
CheMinFouling vs. Availability
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Fuel Firing
Fouling
Tactic 4: Cause more confusion!
Design
DischargePressure
DropRaw Gas Qual.
Provocation of a self-goalShowerWater
BlowerExplosion
Corrosion+ manymoreCladding
Refract.
Coating
CheMinFouling vs. Availability
Prewin Meeting at Coventry, June 19th-20th 2012 18
Online cleaning
CheMinFouling vs. Availability
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Online cleaning
Water Blower
CheMinFouling vs. Availability
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Online cleaning
Laser inside theWater Blower
CheMinFouling vs. Availability
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Fuel Firing
Fouling
Design
Discharge
PressureDropRaw Gas
Qual.
ShowerWaterBlower Explosion
Corrosion+ manymoreCladding
Refract.
Coating
IR-Camera HeatfluxMeasurem.
Control fouling to achieve availability
CheMinFouling vs. Availability
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Thank you for your attentionThank you for your attention
Fouling is not bad at all, it contains e.g. up to 5-7 weight% copper and might be an ore deposit.
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CheMin stands for “Chemistry” and “Mineralogy” since 1996
Structure:• Owned by Dr. Wolfgang Spiegel• Situated in the south of Germany (Bavaria), in the city of Augsburg• 4 project manager working in teams of 2-5 persons • External senior experts provide knowledge the the 1970ies• In total: approx. 35 employed mineralogists, chemists and engineers
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CheMin stands for “Chemistry” and “Mineralogy” since 1996
Activities:
• In incineration plants for solid (waste, refuse derived, biomass, coal...) and gaseous fuels
• On the fuels, firing conditions, materials and residues
• Grate and fluidized-bed, in boiler/ superheater and flue gas treatment
• Hot topics: Boiler efficiency (dewpoint corrosion on ECO), operation period 18 to 24 month
• In D (many), A (6), NL (4), CH (4), RUS (2), DK (1) ...UK (not yet)
• Mostly for plant owners (from municipalities and industries to energy giants)
frequently for plant manufacturers and deliverers (refractory lining, cladding and coatings)
• German legal status of “Sachverständiger” (expert witness) – neutral status
• Research and development together with several German companies
• Networks: German association VGB and European Network PREWIN