3D TRASAR® Technology for Boilers Improves Reliability at - Nalco
3D TRASAR® Technology for Boilers Improves Reliability at - Nalco
3D TRASAR® Technology for Boilers Improves Reliability at - Nalco
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Background<br />
A Kraft Pulp mill loc<strong>at</strong>ed in Scandinavia is part of a<br />
global paper corpor<strong>at</strong>ion, which makes a very public<br />
and top-down commitment to environmental protection.<br />
Globally, the company’s oper<strong>at</strong>ions are seeking<br />
accredit<strong>at</strong>ion to ISO 14001, the environmental<br />
management system standard. It has very clear<br />
sustainability goals in place to conserve energy and<br />
raw m<strong>at</strong>erials, and to reduce emissions and waste.<br />
This world-class global leader in pulp and paper<br />
production also actively works with supplier partners<br />
to jointly develop and implement innov<strong>at</strong>ive solutions<br />
to improve upon existing processes and to reduce<br />
environmental impacts. The mill produces about<br />
200,000 tonnes of environmentally-friendly bleached<br />
and unbleached Kraft pulp per year, and is loc<strong>at</strong>ed<br />
in an environmentally-sensitive area where strict<br />
standards are in place to protect the environment<br />
from the impact of industrial and other oper<strong>at</strong>ions.<br />
Current Situ<strong>at</strong>ion<br />
The plant was oper<strong>at</strong>ing a single recovery boiler to<br />
supply steam to the pulp production process and to<br />
a turbine <strong>for</strong> electricity production. Make-up w<strong>at</strong>er<br />
was softened w<strong>at</strong>er abstracted from a lake nearby,<br />
however the system was designed to accept returned<br />
condens<strong>at</strong>e as a large portion of the total boiler<br />
feedw<strong>at</strong>er. The plant was oper<strong>at</strong>ed <strong>at</strong> full capacity,<br />
however steam output was regularly reduced as<br />
<strong>3D</strong> TRASAR ® <strong>Technology</strong> <strong>for</strong> <strong>Boilers</strong><br />
<strong>Improves</strong> Sustainability Per<strong>for</strong>mance<br />
and <strong>Reliability</strong> of Steam Gener<strong>at</strong>ion<br />
<strong>at</strong> a Kraft Pulp Mill in Europe<br />
a result of process contamin<strong>at</strong>ion of the return<br />
condens<strong>at</strong>e. This immedi<strong>at</strong>ely increased feedw<strong>at</strong>er<br />
conductivity and corrosivity. Without on-line detection<br />
of such changes in feedw<strong>at</strong>er quality, upsets were<br />
only detected by intermittent manual sampling and<br />
labor<strong>at</strong>ory analysis. In the interim, the efficiency of<br />
steam production, and the purity of steam, were<br />
reduced, prejudicing production and turbine oper<strong>at</strong>ion.<br />
Corrective action necessit<strong>at</strong>ed rapid blowdown,<br />
which in turn led to a reduction in boiler cycles,<br />
excess chemical addition to maintain protection from<br />
corrosion, and increased energy consumption and<br />
associ<strong>at</strong>ed greenhouse gas emissions.<br />
The company wanted to learn how <strong>3D</strong> TRASAR<br />
Boiler <strong>Technology</strong> could help to protect its steam<br />
gener<strong>at</strong>ion asset whilst <strong>at</strong> the same time improving<br />
sustainability per<strong>for</strong>mance. This innov<strong>at</strong>ion from<br />
<strong>Nalco</strong> facilit<strong>at</strong>es the measurement of the corrosivity<br />
of the boiler feedw<strong>at</strong>er <strong>at</strong> system temper<strong>at</strong>ure and<br />
pressure and links this variability to any unfavourable<br />
plant oper<strong>at</strong>ing and chemistry conditions. Moreover,<br />
<strong>3D</strong> TRASAR Boiler <strong>Technology</strong> has the capability to<br />
control the cycles of concentr<strong>at</strong>ion and maintain clean<br />
he<strong>at</strong> transfer surfaces in the boiler system, minimising<br />
w<strong>at</strong>er usage and optimising energy efficiency, resulting<br />
in minimised plant emissions and the consumption<br />
of precious n<strong>at</strong>ural resources.<br />
Case Study CH-1001E
The key business drivers <strong>for</strong> the customer included:<br />
• Improve the reliability and availability of the boiler<br />
plant<br />
• Maintain clean w<strong>at</strong>er-side surfaces in the boiler<br />
• Reduce the volume of chemicals required <strong>for</strong><br />
tre<strong>at</strong>ment due to upset conditions<br />
New Programme<br />
Under traditional w<strong>at</strong>er tre<strong>at</strong>ment regimes, where<br />
wet chemistry analyses are only conducted intermittently,<br />
upset conditions can go undetected <strong>for</strong><br />
long periods, during which significant problems can<br />
arise. This is a challenge which can be immedi<strong>at</strong>ely<br />
addressed with <strong>3D</strong> TRASAR Boiler <strong>Technology</strong>,<br />
with the p<strong>at</strong>ented <strong>Nalco</strong> Corrosion Stress Monitor<br />
(NCSM). This can be extremely valuable in protecting<br />
steam gener<strong>at</strong>ion assets, providing real-time<br />
on-line monitoring of system conditions, and an<br />
immedi<strong>at</strong>e alarm and corrective action as soon as<br />
upset conditions start to occur.<br />
At the mill, <strong>Nalco</strong> and the customer worked together<br />
to implement a joint str<strong>at</strong>egy to deliver improved<br />
boiler reliability. <strong>3D</strong> TRASAR Boiler <strong>Technology</strong><br />
was installed, and from start to finish was in full<br />
oper<strong>at</strong>ion after just three hours of install<strong>at</strong>ion and<br />
commissioning.<br />
In keeping with standard practice, the following Key<br />
Per<strong>for</strong>mance Indic<strong>at</strong>ors (KPIs) were established <strong>for</strong><br />
the use of <strong>3D</strong> TRASAR Boiler <strong>Technology</strong> on the<br />
boiler system:<br />
• Ability to determine vari<strong>at</strong>ions in corrosivity of the<br />
feedw<strong>at</strong>er and make a link to specific oper<strong>at</strong>ional<br />
and chemical parameters.<br />
• Ability to control the system variability and provide<br />
maximum asset protection and maximum<br />
availability to gener<strong>at</strong>e steam <strong>for</strong> the production<br />
process.<br />
• Improvement in the service level by <strong>Nalco</strong>, by<br />
providing real-time alarms and communic<strong>at</strong>ion of<br />
upset conditions th<strong>at</strong> require immedi<strong>at</strong>e <strong>at</strong>tention,<br />
allowing plant oper<strong>at</strong>ors to focus on the main<br />
production process.<br />
Since the unit was commissioned, it has oper<strong>at</strong>ed<br />
without major problems, and has required minimal<br />
service and maintenance <strong>at</strong>tention, with just one<br />
regular service and calibr<strong>at</strong>ion after nine months.<br />
<strong>3D</strong> TRASAR Boiler <strong>Technology</strong><br />
<strong>3D</strong> TRASAR Boiler <strong>Technology</strong> is the innov<strong>at</strong>ive<br />
and unique boiler tre<strong>at</strong>ment package, designed to<br />
deliver superior sustainability per<strong>for</strong>mance, oper<strong>at</strong>ional<br />
efficiency, and asset protection. This groundbreaking<br />
modular technology continuously responds<br />
to changes in boiler oper<strong>at</strong>ion and feedw<strong>at</strong>er quality,<br />
reducing system corrosion, ensuring clean w<strong>at</strong>erside<br />
surfaces, and minimising w<strong>at</strong>er and energy resource<br />
use. The result is continuity of production, conserv<strong>at</strong>ion<br />
of resources, minimis<strong>at</strong>ion of emissions including<br />
Greenhouse Gases (GHG), and improved cost<br />
management.<br />
<strong>3D</strong> TRASAR boiler technology control module
<strong>3D</strong> TRASAR Boiler <strong>Technology</strong> is used by leading<br />
corpor<strong>at</strong>ions around the world to secure improvements<br />
in their environmental and economic per<strong>for</strong>mance,<br />
optimise boiler efficiency, meet sustainability<br />
goals, specifically in the areas of w<strong>at</strong>er and energy<br />
use reduction, and to protect assets, a key driver in<br />
boiler management and steam gener<strong>at</strong>ion.<br />
<strong>3D</strong> TRASAR Boiler <strong>Technology</strong> also meets the requirements<br />
of the Best Available Techniques<br />
<strong>for</strong> energy efficiency under the EU Integr<strong>at</strong>ed<br />
Pollution Prevention & Control (IPPC) legisl<strong>at</strong>ion<br />
in the c<strong>at</strong>egories of increasing overall energy<br />
efficiency, reducing w<strong>at</strong>er use, reducing emissions<br />
to air, and reducing emissions to w<strong>at</strong>er.<br />
Results<br />
The implement<strong>at</strong>ion of <strong>3D</strong> TRASAR Boiler<br />
<strong>Technology</strong> delivered immedi<strong>at</strong>e improvements<br />
in boiler reliability and availability, detecting any<br />
upset conditions due to process contamin<strong>at</strong>ion in<br />
real-time, and prompting immedi<strong>at</strong>e corrective<br />
action in order to maintain steam production.<br />
This allowed maximis<strong>at</strong>ion of the volume of return<br />
condens<strong>at</strong>e, and minimis<strong>at</strong>ion of the volume of<br />
feedw<strong>at</strong>er tre<strong>at</strong>ment required. Overall this improved<br />
the sustainability per<strong>for</strong>mance of the plant by<br />
conserving precious w<strong>at</strong>er and energy resources,<br />
and reducing the associ<strong>at</strong>ed greenhouse gas<br />
emissions. This also led to continuity of pulp<br />
production, electricity gener<strong>at</strong>ion, a lower total<br />
cost of oper<strong>at</strong>ion <strong>for</strong> the asset.<br />
Conclusions<br />
<strong>3D</strong> TRASAR Boiler <strong>Technology</strong> proved to be<br />
a valuable diagnostic and management tool<br />
delivering desired levels of boiler reliability. Moreover<br />
the technology allowed the plant to oper<strong>at</strong>e<br />
safely and efficiently meeting production demand<br />
whilst assuring and improving sustainability per<strong>for</strong>mance.<br />
<strong>3D</strong> TRASAR Boiler <strong>Technology</strong> offers<br />
real-time control, protecting the environment, plant<br />
profitability, and productivity.<br />
NalCo CompaNy opEr<strong>at</strong>ioNs<br />
North america: Headquarters –1601 West Diehl Road • Naperville, Illinois 60563 • USA<br />
Energy Services Division – 7705 Highway 90-A • Sugar Land, Texas 77487 • USA<br />
Europe: Ir.G.Tjalmaweg 1 • 2342 BV Oegstgeest • The Netherlands<br />
Asia Pacific: 2 Intern<strong>at</strong>ional Business Park • #02-20 The Str<strong>at</strong>egy Tower 2 • Singapore 609930<br />
l<strong>at</strong>in america: Av. das Nações Unidas 17.891 • 6° Andar 04795-100 • São Paulo • SP • Brazil<br />
www.nalco.com<br />
<strong>Nalco</strong> Corrosion Stress Monitor, <strong>3D</strong> TRASAR, NALCO and the logo are Trademarks of<br />
<strong>Nalco</strong> Company<br />
©2010 <strong>Nalco</strong> Company All Rights Reserved 9-10