Soot Blower

Combustion furnace efficiency improvement by Soot Blower System

2554

 Soot Blower
Combustion furnace efficiency improvement By Soot Blower System

2554

Combustion furnace efficiency improvement By Soot Blower System

NUTTHAWUT JAIRUCK
SOMPHOB JONGARAMRUENG
SARANUT
MUANKHOKSOONG

A PROJECT SUBMITTED IN PARTIAL FULFILLMENT OF REQUIREMENTS

FOR THE DEGREE OF BACHELOR OF TECHNOLOGY
MAJOR OF ELECTRICAL AND ELECTRONIC TECHNOLOGY
BURAPHA UNIVERSITY 2011

Soot Blower Soot Blower



: , ,Soot Blower

ii

Abstract
In the study of the approach to increase efficiency of furnace oil combustion process by
using "Soot Blower", Soot Blower is an equipment which is used furnace oil cleansing and helps
eliminate soot stain in the furnace tube. The cleansing process of soot blower leads to efficient
heat exchange and saving of fuel used in the combustion process, and can be done while the
furnace is running. Therefore, costs of production can be reduced; as well as, efficiency of
furnace oil combustion process can be boosted.
Key words: the distillation of crude oil, construction of boilers, Soot Blower

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.......................................................................................................................................
Abstract........................................................................................................................................
.........................................................................................................................
.. .......................................................................................................................................
.....................................................................................................................................
................................................................................................................................

i
ii
iii
iv
vi
viii

1 ................................................................................................................................
1.1 ........................................................................................................................
1.2 ...............................................................................................................
1.3 .................................................................................................
1.4 ....................................................................................................
1.5 ..........................................................................................

1
1
1
1
2
2

2 ..............................................................................................................
2.1 ..................................................................................
2.2 ...................................................................................................
2.3 (Boiler) .................................................................................
2.4 ...............................................................................
2.5 ...................................................................
2.6 ...............................................................................................
2.7 SOOT BLOWER ..........................................................................................
2.8 ..............................................................................
2.9 ............................................................................

3
3
4
5
6
10
11
11
15
17

3 ...............................................................................................................
3.1 .................................................................................
3.2 Steam () ...........................................................................................................
3.3 Flow Chart ...............................................................................................
3.4 Temperature zones .............................................................
3.5 ..................................................................................

22
22
28
29
35
35

()

4 ....................................................................................................................
4.1 .............................................................................
4.1.1 ...................................................................................................
4.1.2 ...............................................................................
4.2 .............................................................................
4.2.1 ( ) ..............................................
4.2.2 () .................................................................................
4.2.3 (NG) .......................................................
4.2.4 ( NG ) ....................................................................................
4.2.5 Soot Blower.........................................................
4.3 ......................................................................................................
4.4 Fuel Soot blower ......................................................................
4.5 . .......................................................................................................

36
36
36
37
38
38
38
40
40
42
42
43
44

5 .............................................................................................................................
5.1 .................................................................................................
5.2 ...........................................................................................................
5.3 ...............................................................................................................

45
45
45
45

.................................................................................................................................

46

.....................................................................................................................................
Data sheet flow chart control diagram Soot blower ...................................

47
48

..................................................................................................................

60

vi

2.1 ..................................................................................................
3
2.2 .......................................................................................................
4
2.3 ...............................................................................................................
5
2.4 .................................................................................................... 10
2.5 .................................................... 10
2.6 Long-Retractable Soot Blower ....................................................................................... 12
2.7 Long-Retractable Soot Blower ....................................................... 12
2.8 Rotary Soot blower ........................................................................................................ 13
2.9 Rotory Soot Blower ........................................................................ 13
2.10 .................................................................................................. 14
2.11 ................................................................................ 14
2.12 Soot blower ...................................................... 15
2.13 Boiler 701 ............................................................................................................ 17
2.13 Unit 4100 Steam Distribution ............................................................................ 18
3.1 ................................................................................................................... 22
3.2 .................................................................................................. 23
3.3 ............................................................................................................. 23
3.4 Retractable Soot Blower ........................................................................ 24
3.5 Retractable Soot Blower ........................................................................ 24
3.6 Rotory Soot Blower .............................................................................. 25
3.7 Rotory Soot Blower .............................................................................. 25
3.8 Proximity sensor forward side blower ................................................................. 26
3.9 Proximity sensor re-ward side blower ................................................................. 26
3.10 Main valve (Control valve) ................................................................................. 27
3.11 Drain valve (Control valve)................................................................................. 27
3.12 Safety switch ...................................................................................................... 28
3.13 Flow Chart .............................................................................. 29
3.14 Flow Chart .................................................................................. 30
3.15 Flow Chart .................................................................................. 31
3.16 Flow Chart .................................................................................. 32

vii

()

3.17 Flow Chart ................................................................ 33

3.18 Soot Blower ............................................................. 34
3.19 Soot .............................................................................................. 35
4.1 .................................................................................. 37
4.2 () ............................................................ 39
4.3 (NG) ..................................................................... 41
4.4 Fuel - Soot Blower ............................................................... 43
4.5 Soot Blower ............................................................. 44

viii

1.1 ............................................................................................
2
4.1 Soot Blower ............................................................ 36
4.2 Soot Blower .................................................................... 38
4.3 Soot Blower .................................................. 38
4.4 Soot Blower ............................................................... 41
4.5 Soot blower ............................................................... 45
4.6 Soot blower ............................................................... 45

1.1

( Furnace )





(Heat transfer) 70%
Soot blower
Soot blower



1.2

1. Soot blower
2.
3.

1.3

1.
2.
3.

1.4

1.
2.
3.
4.
5.
6.
7.
2553 2554 4
1.1

1.
2.

3.
4.
5.
6.

7.

1.1

1.5
1.
2.
3.

2.1 steam Boiler

(Boiling point)
(Condensation point)
(Furnace)

(Fractionatingtower) 30
2.5 - 8

2.1

2.2 (Heat Transfer)

(Heat Transfer)
70 % 3

- (Flame Temperature)
- (Flame Shape)
-
(Fouling of Heat Transfer Surfaces)


30%

2.2

2.3

2.3


()

Superheater Reheater Economizer
Air preheater
Aerator (
) Soot blower()






Burner


1000C

Superheater, Reheater, Economizer Air

preheater

Turbine
(Superheated steam)
Superheater
Superheater

Economizer Airpreheater
Economizer
Air preheater

2.4 ( Fire Tube Boiler )

1. ( Fuel Oil System )
2. ( Feed Water System )
3. ( Combustion System )
4. ( Main Steam )


1. ( Fuel Oil System )

( Boiling Point )


Boiler 2 Heavy Fuel Oil and Diesel Oil
( Diesel Oil )
2 1 F.O Circulating Pump

F.O. Sevice Tank 5 kg / cm2 F.O Heater

Burner Pump Burner Pump
20 kg / cm2 Burner ( Igniton )
Burner

2. ( Feed Water System )

- Cascade Tank


60

- Boiler Feed Water Pump Cascade Tank

10 kg / cm2 Catalyst Sulphite Suction
Boiler Feed Water Pump
- Condenser ( Exhaust Steam )
Condenser Cascade Tank

- Feed Water Tank

Cascade Tank
Thor Dynamic

- ( Steam Drum )

( Safety Valve )

- ( Water Drum )

- ( Surface Blow Pipe )


( Surface Blow Valve )

- ( Internal Feed Pipe )


- ( Economizer )




1%
10
3. ( Combustion System )







Oil Burner

- Oil Solinoid Valve ,

- F.O. Circulating Valve
Automizer
Circulat

F.O. Circulating Valve

- Automizer

- Automatic Electric Igniter Sparking

Transfomer 24 V. AC. 10,000 V
- Flame Eye Sparking Igniter
Sparking Photocell Oil Burner Pump
Close Circuit 20 Kg/ cm2
Spark Photocell Oil Burner Pump Spark
3 Photocell Oil Burner Pump

4. ( Main Steam )
Excess Steam Control
( Steam pipe )

1.

2.

- Low Oil Temperature Switch

( Drop ) Switch

- ( Furnace )
1
225
- ( Air Heater or Preheat )

- ( Air Cock )

10

- ( Safety Valve )

2.4
2.5 (economizer)
Economizer (
)

(preheating)

Economizer U

2.5

11

2.6

(Soot Blowers)

2.7 SOOT BLOWER

soot blower



soot blower
2
1. Long-Retractable Soot Blower
2. Rotary Soot Blower

12

1.Long-Retractable Soot Blower

Super heater ,Slag screens, Re-heaters, Economizers
Gas temperature zones Boiler
Heat exchanger Nozzle retractable soot blower Medium-high
pressure steam 4 20 bar

2.6 Long-Retractable Soot Blower

2.7 Long-Retractable Soot Blower

13

2.Rotary Soot Blower

Low heater zones (below 750 C ,Slag screens, Re-heaters, Economizers
Gas temperature
zones Boiler Heat exchanger
Nozzle retractable soot blower Medium pressure steam
4 20 Bar

2.8 Rotary Soot blower

2.9 Rotory Soot Blower

14

2.10

2.11

15

2.12 Soot blower

2.8
3
1.OIL BURNER
,

3
1.1 Air Atomizing
- 9-20 Psi
LPG
1.2 Pressure Atomizing
- 10-30 bar
- Recommended Viscosity at Nozzle head equal 10 CST ( Temp. 120-130C )

16

- Gas

- Primary Air Combustion head

( Excess Air 15 % CO2
13.5% )
1.3 Rotary Cu
- 2 (Secondary air)

- 1
2. GAS BURNER
2 Natural Gas LPG Gas
- CO2 15% Flue Gas
- (
)
- 3
- Double Solenoid
Valve ( 2 ) Valve Proving (
)
- Sound Ness Test
-
- Gas Burner
- Low Pressure Gas (0 - 50 mbar) / Atmospheric Air
- High Pressure Gas (2 bar) / Atmospheric Air
- Pressure Air (25 mbar) / Low Pressure Gas Air Blast (0 Psi)
- Pressure Air / Pressure Gas
- Already Mix, Premix, Partial Premix
3. DUAL BURNER
Magnetic
Clutch -
Oil Gas Burner 2

17

2.9
1. Steam Generation
Steam Generation Steam
Boiler
Steam Generator
Steam Boiler Steam Generator Process

2. Boilers
Water Tube Boiler : Boiler Steam
Steam
Combustion
Steam
Superheat Boiler
Water Tube Boiler 2
2.1. Waste Heat Boiler : Boiler
Flue Gas
(Furnace) Gas Turbine Waste Heat Boiler
1. B-701 2.V-2422 3. V-9422 4. F-2791 5. F-9791 6. B-4015
7. B-4016 8. B-4017

2.13 Boiler 701

18

2.2. Fire Boiler : Boiler

Steam 5 Utility
1. B-40022 2. B-40083 3.B-40094 4.B-40115 5.B-101

2.14 Unit 4100 Steam Distribution

3. Steam Distribution (Unit 4100)
(Header) Steam Steam
Generator Steam Steam Generator
Steam
Design Steam

- High High Pressure Steam (HHP. Steam)

Pressure 105 barg. Temp 500C
- High Pressure Steam (HP. Steam)
Pressure 31 barg. Temp 320C
- Medium Pressure Steam (MP. Steam)
Pressure 14 barg. Temp 238C
- Low Pressure Steam (LP. Steam)
Pressure 2.8 barg. Temp 145C

19

Steam Steam Generator

Steam Generator Utilities Area Process Area
Steam Generator Steam Steam
Generator Steam Steam
Feed Process Steam Header
Pressure Control Temp. Control
Utilities Panel Man Steam

Design Steam
Steam Turbine
Process Tracing Steam, Heating Coil Heat Exchanger

4. Unit 4200 Refinery Fuel Oil/Fuel Gas System
Unit 4200 Rundown Production Process Refinery
Fuel Process

Refinery Fuel 2
1. Refinery Fuel Oil Fuel Oil -> FO.
2. Refinery Fuel Gas Fuel Gas -> FG.
FO. FG. Process
Process Refinery Fuel
Refinery Fuel
Unit 4200 Back up Run down
Process Process Shortage Process
Rundown Process Fuel Back up
Utilities Unit 4200 Fuel Production, Fuel
Consumption Fuel Back up

20

5. Refinery Fuel Oil (FO.)

FO. 2
1. Main Fuel Oil : Refinery Fuel Oil
Short Residue (High Vacuum Unit) 3

- SR1 HVU-1
- SR2 HVU-2
- SR3 HVU-3
2. Stand by Fuel Oil : Refinery Fuel Oil Long
Residue FO. Circulation
Main FO. Back up Main FO. Shortage
6. Refinery Fuel Gas (FG.)
Refinery Fuel Gas Gas Process
Pressure Process
(Furnace)
Excess Gas Process Fuel Gas
FG. compressor
Swing Buffer Vessel Smooth
Excess Gas Process
Shortage Trouble FG. Process
"Gas Back up" FG. LPG. NG.
. Back up Shortage FG.
7. Unit 4400 Tempered Water System
Tempered Water System Cooling (Close System)
Cooling Tempered
Water Cooling Cooldown
60C Cooling Shock Temp. Product
Product Cooldown
Tempered Water Residue Temp. 220-270C
Residue Shock Temp. Residue

21

Product

8. Duty of Plant
Tempered Water 2
1 Supply Coolers TOC-1, TOC-2 TOC-3 Pump Supply 3
P-4402 A/B/C Coolers
2 Supply Exchanger TOC-5 Revamp Tempered Water
Pump Supply 2 TOC-5 P-4403 A/B
Exchangers TOC-5
9. CO BOILER
450 27
450 Steam
1. Unit 700
1.1 Flue gas (Waste heat)
1.2 (CO.) Flue gas
2. Fuel gas system Auxiliary fuel gas
2.1 Gas CO.
2.2 Steam
Flue gas (Combustion Chamber)
Pressure Regenerator CO Flue gas Auxiliary
Fuel gas O2
Force draft fan Auxiliary fuel gas,
CO Flue gas Boiler feed water
(Steam) Superheat Steam De-superheat Steam
HP. Steam system .

22

3.1
- Panel Control
- Main power supply
- Soot blower
- Limit switch
- Main valve & drain Valve
- Safety switch
- Steam

3.1

23

3.2 Soot Blower

3.3 PLC

24

3.4 Long-Retractable Soot Blower

3.5 Long-Retractable Soot Blower

25

3.6 Rotary Soot Blower

3.7 Rotory Soot Blower

26

3.8 Proximity sensor forward side

Soot blower Soot
blower

3.9 Proximity sensor re-ward side

Slide Soot blower re-wards

27

3.10 Main valve (Control valve)

- Steam Soot blower

3.11 Drain valve (Control valve)

Blow out steam

28

3.12 Safety switch

Soot blower

3.2 Steam ()

Steam , ,
,
Steam

Steam 4

Low Pressure Steam

3 - 5 Bar
150 C
Medium Pressure Steam
13 -15 Bar
200 C
High Pressure Steam
30
Bar
300 C
High High Pressure Steam 105 Bar
500 C
High High Pressure Steam (Generator)

29

3.3
Flow Chart Soot blower

Drain valve

NO
YES
Main valve

pressure steam

>= 600s

NO

YES
Drain valve

Soot blower Long-reactable

3.13 Flow Chart Soot blower 1

30

Flow Chart Soot blower

1

Forward

Limit SW.

Reward

Limit SW.

Soot blower Rotary

Counter = 2

NO

YES
Soot blower Rotary
2
Soot blower
3

3.14 Flow Chart Soot blower 2 3

31

Flow Chart Soot blower

2

Counter = 2

NO

YES
Soot blower Rotary
3
Soot blower
4

Counter = 2

NO

YES
Soot blower Rotary
4
Soot blower
5

Counter = 2

NO

YES
3

3.15 Flow Chart Soot blower 4 5

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Flow Chart Soot blower

Soot blower Rotary

5
Soot blower
6

Counter = 2

NO

YES
Soot blower Rotary
6
Soot blower
7

Counter = 2

NO

YES
4

3.16 Flow Chart Soot blower 6 7

33

Flow Chart Soot blower

Soot blower
7
Main valve close

Drain valve Open

NO
YES
System Complete

3.17 Flow Chart Soot blower

34

Soot Blower

3.18 Soot Blower

1. start Drain valve Soot

2. Main valve Pressure steam (4 bar

20bar) >= 600
3. Drain valve Soot blower Long- reactable
1 Forward limit switch Reward Limit
switch Soot blower rotary 2
4. Soot blower rotary 2 2 ( counter )
Soot blower rotary 3 Soot blower rotary 2
5. 7 ()
6. Soot blower rotary 7 Main valve close Drain
valve Open 1

35

3.4 Temperature zones

1. Retractable soot blower Super heater 250
2. Rotary soot blower Low heater
3.5

3.19 Soot Blower

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4.1
Soot Blower 1 / 1 1 / 2 1 / 3
B-4002 Utility

Soot Blower

1 /

1 / 2

1 / 3

182

182 / 2

182 / 3

4.1 Soot Blower

4.1.1 ( B-4002)
12 kW 2 ( Long-Retractable Soot Blower)
8 kW 10 ( Rotary Soot Blower )
B- 4002 Soot blower 30
(12 kW x 2)+(8kW x 10) = 104 kW
Soot 30 hr 104 kw x hr = 52 kw.hr
1kWH 1 3.50
52 kw x 3.50 = 182
Soot blower 1 182 ***
- Soot Blower 1 / 1
182 x 365 = 66,430 /
- Soot Blower 1 / 2
182 x (365/ 2 ) 33,215 /

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- Soot Blower 1 / 3
182 x (365 / 3 ) 22,143.3 /
4.1.2
Soot Blower 1 / 2 66,430 - 33,215 = 33,215 /
Soot Blower 1 / 3 66,430 - 44,286 = 22,143 /

70,000
60,000
50,000
40,000
30,000

20,000
10,000
0

1 /

1 / 2

1 / 3

66,430

33,215

22,143

4.1

38

4.2 Soot Blower

Soot Blower

1 /

1 / 2

1 / 3

()

24 Ton / day

24.002 Ton / day

24.007 Ton / day

(NG)

24 Ton / day

24.002 Ton / day

24.007 Ton / day

4.2 Soot Blower

Soot Blower

1 /

() 759,120
(NG)

252,000

1 / 2

1 / 3

759,183

759,341

252,021

252,073

4.3 Soot Blower

4.2.1
Soot blower 1 / 759,120

Soot blower 1 / 2 759,183

Soot blower 1 / 2 759,341

4.2.2 ( )

1 / 1 24 Ton / day x (31.63)

= 759,120

1 / 2 24.002 Ton / day x (31.63) = 759,183

1 / 3 24.007 Ton / day x (31.63) =759,341

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Soot Blower 1 / 2
63 / 23,090
(1 / - 1 / 2 ) = 759,120 759,183 = 63
= 63 x 365 = 23,090

Soot Blower 1 / 3
221 / 80,665
(1 / 1 / 3 ) = 759,120 759,341 = 221
= 221 x 365 = 80,665

()

Ton/Day

24.008
24.006
24.004
24.002
24
23.998
23.996
1 /

1 /

1 /2

1 /3

24

24.002

24.007

4.2 ()

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4.2.3 (NG)

Soot blower 1 /

25,200

Soot blower 1 / 2 25,021

Soot blower 1 / 3 25,073

4.2.4 (NG)

1 / 24 Ton / day

x Gas (10.50 ) =252,000

1 / 2 24.002 Ton / day x Gas (10.50) = 252,021

1 / 3 24.007 Ton / day x Gas (10.50) = 252,073

Soot Blower 1 / 2
21 / 7,665
(1 / 1 / 2 ) = 252,000 - 252,021 = 21
= 21 x 365 = 7,665

Soot Blower 1 / 3
73 /
(1 / 1 / 3 ) =252,000 252,073= 73
= 73.5 x 365 = 26,827.5

41

(NG)

Ton/Day

24.008
24.006
24.004

24.002
24
23.998
23.996

1 /

1 /2

1 /3

24

24.002

24.007

1 /

4.3 (NG)

2552

2553

2554

2555

UNIT

27.19

29.99

28.89

31.63

Baht / L

GAS

8.50

8.50

8.50

10.50

Baht / kg

4.4 Soot Blower

42

4.2.5 Soot Blower ( Gas NG )

Soot Blower 1 / 2

23,090

(NG)

7,665

23,090 + 7,665 = 30,755 /

Soot Blower 1 / 3

80,665

(NG)

26,827.5

80,665+ 26,827.5 = 107,492 .5 /

4.3

1 / 1 / 2
33,215 /
30,755 / 1 / 2
(-)( 33,215 30,755) = 2,460 /
Soot Blower 1 / 1 / 3
107,492.5 / Soot Blower 1 / 3
( - ) 44,286-107,492.5
= - 63,205 / 63,206
Soot Blower 1/ 3

43

4.4 Fuel Soot blower

- Main fuel gas Soot blower 1 Ton/ day
- Main fuel oil Soot blower 1 Ton / day
Description
Main fuel gas
Main fuel oil

Description
Main fuel gas
Main fuel oil

Minimum

Normal

Maximum

Unit

24
25
26
24
25
26
4.5 Soot blower
Minimum

Normal

Ton/day
Ton/day

Maximum

Unit

23
24
25
23
24
25
4.6 Soot blower

Ton/day
Ton/day

Ton / Day
25.2
25
24.8
24.6
24.4
main fule oil
24.2

main fule gas

24
23.8
23.6
23.4
Soot Blower

Soot Blower

4.4 Fuel - Soot Blower

44

/
140,000
120,000
100,000
80,000

107,492.5

60,000
40,000

30,755

66,430

20,000

33,215

1 /

1 / 2

22143

1 / 3

4.5 Soot Blower

4.5
Soot blower 1 / 2 66,430 63,970
2,460 / Soot blower 1/
Soot blower

45

5.1

5.2
1.
( Soot blower)
2. Soot blower Soot
blower

5.3
1.
2.
3. Fuel oil Fuel gas
Soot blower

46

[1] http://www.promma.ac.th/main/chemistry/boonrawd_site/crude_distrillation.htm

[2] http://replicainspection.blogspot.com/2011/02/economizer-of-boiler.html
, Soot Blower
[3] http://www.gotoknow.org/blogs/posts/320939

[4] http://www.gmcworkshop.com/new_bolier/EnergyWorldJournal.htmb

[5] http://www.cs-inspected.com/boiler.html

[6] http://www.burnerandboiler.com/index.php?lay=show&ac=article&Id=109682&Ntype=4

[7] http://compare.industryboiler.com/standards-applicable-to-furnace-controls.html

[8] http://www.pttplc.com/TH/news-energy-fact-oil-price-bangkok.aspx

47

48

Data Sheet
Flow Chart Control Diagram
Soot Blower System

49

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56

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(.) . .

. .

. .