Tag Archives: Cleaning

New Liquor to Liquor Lean Concept for Boiler Outages

Planning for a boiler outage can be a stressful and time-consuming process. At Valmet we understand the challenges you face, and have developed a new lean concept for liquor to liquor recovery boiler outages.  This streamlined process will make the boiler outage period easier for you by utilizing efficient techniques and steps that have proven successful.

In the past, the boiler shutdown process has been an incoherent operation with many of the necessary steps being performed without any sense of order or purpose.  With our new streamlined process we have created a Liquor to Liquor Lean Concept that organizes the boiler shutdown period in an ordered and economical fashion.  This is one bundle of services that will make the process simple and easy for you.

Liquor to Liquor Lean Concept for Boiler Outages

  • Step 1: Boiler Outage Planning: During the planning process we can handle technical coordination and spare-parts support. We can identify the maintenance needs, and work on the distribution of tasks with the mill team.
  • Step 2: Smelt-X: The Smelt-X boiler cleaning process uses custom designed ejectors made for each furnace arrangement to extend from spouts to the lowest point in floor for max extraction. With it smelt bed cooling time can be reduced to 4-6 hours from 15-35 hours, while allowing for the recovery of chemicals in the smelt bed, and minimization of wash water volume and alkalinity.
  • Step 3: Wash-X: With our Wash-X process the floor is washed simultaneously with the rest of the boiler using low pressure water sprays and mixing devices installed on the furnace floor. This allows for time spent in recovery to be reduced by 10-30 hours.
  • Step 4: Inspection, Maintenance, Examination: With a full range of inspection and maintenance capabilities, Valmet can manage the maintenance throughout the outage. This includes coordinating and managing a complete portfolio of NDE services including all standard inspections such as ultrasonic thickness surveys, liquid penetrant & magnetic particle inspections, and weld examinations. We also offer a host of advanced inspection capabilities like phased array ultrasonics, near drum inspections, and IRIS tube inspections. To enhance safety and production we can also provide low-energy radiography solutions including conventional, digital, and computed radiography services.
  • Step 5: Chemical Cleaning, Boiler Tube Deposit Inspection: Chemical cleaning services including steam blows, high pressure chemical blasting, hydrolasing and vapor phase cleaning. Also we do boiler tube scale deposit inspection and evaluation.
  • Step 6: Post Maintenance Tests: After the cleaning process is complete we can perform full maintenance tests to evaluate the process, and offer support and information on how to plan and budget future outage work.
  • Step 7: Startup Tuning: With our recovery boiler tuning camera we can inspect the boiler for plugging, tune liquor sprays, emissions troubleshooting, and burner optimization.

Liquor to Liquor Lean concept

The Valmet Liquor to Liquor Lean concept works with a service agreement where a bank of hours can be used in any matter from field service, maintenance management, engineering, emergency call outs and troubleshooting among other areas on an as needed basis.  With multi-year agreement discounts and full transparency on service rates this process is the best value on the market.  We also offer free internet training packages and spare parts discounts along with our lean concept package. For more information about our services and to arrange an in person meeting to discuss how our Liquor to Liquor Lean Concept can work for you, please contact Mike Ward, or speak with us at the BLRBAC Fall 2016 Meeting.

3 Reasons to Choose Wash-X When Cleaning Your Boiler

Each year when it comes time to prepare for a boiler outage, concerns about downtime and potential damage are common.  At Valmet we understand these concerns, and have developed our Wash-X service to make your boiler cleaning process easier and efficient.  Below are three reasons why using Wash-X will change the way you view the boiler cleaning process.

1) Limited Downtime: The timespan of the boiler cleaning process all depends on how long it takes for the smelt bed to cool down.   Wash-X processTypical smelt bed cooling times can be anywhere from 15-35 hours. By using the Wash-X process the smelt bed cooling time can be reduced greatly to 4-6 hours.  This reduced time is accomplished by simultaneously washing the floor with the rest of the boiler using low pressure water sprays and mixing devices installed on the furnace floor.

2) Reduced Risk of Damage: During the boiler cleaning process there is always the risk of damage due to large falling deposits and from mechanical cleaning.  The Wash-X process works with water being sprayed to the flood as soon as safe bed temperatures have been reached.  Then eductors are inserted to start floor washing in parallel with superheater washing.   By using hot water, faster washing occurs and it also is used to dissolve large ash deposits which fall to the floor.   The wash pool that forms also creates a barrier that protects the floor from large deposits which may fall off the wall during the cleaning process.  When the water is drained at the end the remaining deposits can easily be cleaned out, avoiding the need for mechanical cleaning that can cause damage to boiler floor.

3) Unique and Effective: Our Wash-X recovery boiler floor washing service is unique in its ability to wash the floor simultaneously with the rest of the boiler while using low pressure water sprays and mixing devices.   The ability to limit downtime and reduce potential damage is unmatched in the industry.  With successful jobs completed in North America, the Wash-X service will save a huge amount of time and money for companies who need their recovery boiler systems cleaned.

Picture1
Valmet has over 40 years of experience providing full service in the boiler chemical cleaning industry.  Our boiler cleaning services including Smelt-X and Wash-X will save companies time and money and have your boiler operating at full strength much faster than any other process on the market.  For more information about our services and to arrange an in person meeting to discuss how our Wash-X service can work for you, please contact Mike Ward.

 

ChemClean Advisory Services – Boiler Chemical Cleaning

Performing a chemical cleaning of a boiler can be a time-consuming and difficult job.  To make this job easier, Valmet offers Chemical Cleaning Advisory Services which will provide you with a safe and time saving chemical cleaning plan for your boiler.  Valmet can handle the complete job from start to finish, making sure the results are what you are looking for.  With a solid track record of successful projects, and nearly 40 years expertise and experience, Valmet will help you make sure your boiler is chemically cleaned safely and efficiently.

Valmet People

While other companies will only consult and explain to you how you can clean your boiler, Valmet can go further by performing full turn-key services for you.  We will derive the cleaning procedure for any system to be cleaned with reactive chemistry as well as determine deposit weight loading and perform solubility testing.  Our services will provide shorter shutdowns of your boiler, and cleaner boilers when we are finished.

Our expertise include planning, procurement, mechanical preparation, cleaning execution, inspection and reinstatement and startup.  Our thorough up-front planning for safety, technical, mechanical and environmental concerns will prevent time consuming last minute changes.  While working closing with all parties, our planning will allow for other jobs to be performed in the work area while the chemical cleaning is being performed, keeping the outage as short and economical as possible.  Our proven chemical processes are time saving and sludge minimizing and our final passivation  process will limit the amount of time for boiler water cleanup on startup to 24 hours or less.

Based on the job requirements we can provide other services including isometric pipe route drawings, chemical cleaning vendor via subcontract and mechanical contractor for mechanical preparation and reinstatement via subcontract.  As we will be onsite monitoring the entire process, we also provide the post-cleaning inspection of drums, headers, tubes, lines and piping, and a final report of the entire project.

When it comes to boiler chemical cleaning, no company can match the full service job that Valmet does.  Our total project supply and nearly 40 years of experience make us the best option to execute your boiler cleaning project.  Our expertise are not just limited to boilers though, contact us here to learn how Valmet can advise you on the chemical cleaning of other systems including steam systems including superheaters, black liquor evaporators and concentrators and green liquor piping.  We will do the total job for you and will have your system clean and running efficiently.

Smelt-X and Wash-X Services for Chemical Recovery Boilers

When it comes to cleaning and emptying chemical recovery boilers, Valmet has the services required to do it swiftly and safely.  If the recovery boiler cleaning process starts too quickly, the water being used in the washing process may cause an explosion when it comes into contact with the molten smelt.  In the past, this potential threat has been avoided by waiting 15-35 hours to make sure the smelt bed is frozen and safe to clean.  To speed up and improve this procedure, Valmet has developed the Smelt-X and Wash-X processes which change the way recovery boiler cleaning is executed.

Smelt-X

The Smelt-X process has been specifically designed to alleviate the recovery boiler cleaning process.  The bottom section of the recovery boiler furnace is heated during load reduction so that the whole smelt bed becomes molten, and the smelt is extracted from the floor to the dissolving tank using air-operated ejectors.  Our custom designed ejectors for each furnace arrangement are made to extend from spouts to lowest point in floor for max extraction.  This custom design is unique in the industry, and can’t be matched by our competitors.  Our typical extraction time is 1-3 hours and smelt does not touch spouts during the extraction process.  The Smelt-X process also allows for chemicals in the smelt bed to be recovered and the amount of strongly alkaline waste water is minimized resulting in savings in both make-up and neutralization chemicals.  Due to these features, Smelt-X can be carried out safely in the middle of the operation cycle as well, and the operation can continue with the same spouts without any additional risk of spout failures during the rest of the cycle.

The Smelt-X process

 

 

 

 

 

 

 

Other benefits include:

  • faster cooling – boiler bank and superheater washing can begin sooner
  • recovery of chemicals in the smelt bed
  • minimisation of wash water volume and alkalinity
  • savings in makeup chemicals for black liquor
  • savings in neutralization chemicals in waste water plant
  • faster floor cleaning for inspection and repairs
  • safer floor cleaning – reduced need for mechanical cleaning and/or high pressure washing
  • shorter mill shutdown – increase in pulp production

 

Wash-X

Valmet has also developed a washing service for recovery boilers called Wash-X in which the floor is washed simultaneously with the rest of the boiler using low pressure water sprays and mixing devices installed on the furnace floor.  Once the super heaters are clean, the mixing devices are removed and floor is emptied of wash water using smelt ejectors.

The typical Wash-X arrangement for mixing devices and wash water sprays:

Wash-X arrangement for mixing devices and wash water sprays

  • 1 or 2 mixing devices in each spout (operated with pressurized air)
  • 8 – 18 primary air port sp rays connected to feedwater or warm water system (depending on floor size)
  • black liquor sprays (at least) in front wall (not shown here) spraying warm wash water

 

 

 

The Smelt-X and Wash-X services will save a huge amount of time for companies who need their recovery boiler systems cleaned.  Our process will do no damage to your boiler and have you back operating at full strength much faster than any other process on the market.  Please contact Mike Ward to arrange an in person meeting to discuss how our Smelt-X and Wash-X services can work for you.

Valmet DeckHandTM Smelt Spout Robot

Robot TOP

Efficiency, productivity, and operator safety is always at the top of the priority list for any recovery boiler operations superintendent. And superintendents at mills which have experienced serious operator injuries on the spout deck understand that more than anyone. They know the dangers associated with cleaning smelt spouts and they are also aware that time spent cleaning spouts, is time not spent on numerous other recovery boiler tasks. Wondering what other options you may have? Valmet has the solution.

Keeping smelt spouts clean is dirty, dangerous, and time consuming work. Let the Valmet DeckHandTM Smelt Spout Robot take care of that for you instead. The robot is available in a standing or hanging position, depending on your boiler spout deck layout, and is able to move laterally on a sliding rail system to clean all spouts, just like an operator would. The robot has several cleaning options, including; thorough trough cleaning, spot cleaning and opening plugged spouts. These are preprogrammed cleaning patterns set to run at specific intervals. The robot optimizes spout operation with frequent cleaning cycles while allowing the operators to focus on their other tasks. The operators also have the option to initiate additional cleaning of specific problem areas at the push of a button.

Valmet’s DeckHandTM Smelt Spout Robot is a Jack-of-all-trades: Mounted with a camera, the operators can closely inspect operational issues, shatter jet performance and cleaning results from the comfort of the control room. While cleaning, the robot is programmed to, under no circumstances, touch the spout surface which reduces wear from over-rodding and improves spout performance by allowing the frozen smelt layer to remain intact.  The robot also has the ability to clean the hood internals and shatter jet using a water lance. Smelt samples can be taken on a scheduled basis or as required by the robot for use in evaluating operational improvements such as reduction efficiency. As an added safety feature, the robot is able to plug a smelt spout in an emergency situation. This keeps operators from entering harm’s way to attempt it manually.

SpoutRobot_Picture1

Optical and/or physical safety barriers are installed around the robot for operator protection on the spout deck. If the barrier is broken, the robot will immediately freeze to insure it does not injure any personnel in the vicinity.

Contact Valmet today to see if the DeckHandTM Smelt Spout Robot is right for you.