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On the diagnosis of a fouling condition in a kraft recovery boiler: combining process knowledge and data-based insights, TAPPI Journal March 2023
ABSTRACT: Fouling is still a major challenge for the operation of kraft recovery boilers. This problem is caused by accumulation of ash deposits on the surfaces of heat exchangers in the upper part of the boiler over time. The first consequence is the reduction of steam production due to loss of heat transfer and, finally, the shutdown of the boiler due to clogging. The present work investigated the operational condition of a modern kraft boiler under a critical fouling condition. This boiler had even faced a manual cleaning due to a clogging event. This analysis combined process knowledge, plant team experience, and a data-driven approach, given the complexity of the process. In this sense, historical data covering this critical period of operation were collected. After a cleaning procedure, they were used to obtain a predictive neural network model for the flue gas pressure drop in the boiler bank, which is an indirect measure of ash deposit accumulation. Once validated, it was used for sensitivity analysis, with the aim of quantifying the effects of the model inputs. Five variables out of eighteen accounted for nearly 60% of the total effect on pressure drop. Namely, primary air temperature (21.6% of the total effect) and flow rate (11.1%), black liquor flow rate (9.9%) and temperature (8.4%), and white liquor sulfidity (8.6%). The analysis of these results mainly suggested an excess of carryover, which composes the ash deposits. Recommended actions to mitigate the fouling condition involved adjustments to the primary air system before the more drastic solution of reducing the boiler load.
Journal articles
Linking Pulp Variations to TMP Operation by Better Selection
Linking Pulp Variations to TMP Operation by Better Selection and Treatment of Process Data
Journal articles
Editor's Notes: Ready for a Test Drive, TAPPI JOURNAL, Novem
Editor's Notes: Ready for a Test Drive, TAPPI JOURNAL, November, 2006
Journal articles
Magazine articles
Editor's Note: An Ideal Raw Material for Pulp and Paper, TAP
Editor's Note: An Ideal Raw Material for Pulp and Paper, TAPPI JOURNAL March 2010
Journal articles
Editor's Notes: Ready for a Test Drive, TAPPI JOURNAL, Novem
Editor's Notes: Ready for a Test Drive, TAPPI JOURNAL, November, 2006
Journal articles
Smartmill: BIOCIDE: New chlorine dioxide technology,Paper360° September 2009 09seppa22
New Chlorine Dioxide Technology, Paper360º September 2009
Journal articles
To Err is Human - To Predict is Design, Frontline Focus, Volume 5, Issue 2
Frontline Focus, February 2009
Journal articles
Smartmill: UPGRADE: Getting more power from black liquor and scraps, Paper360o December 2006 06DECPA18
Getting more power from black liquor and scraps, Paper360º, December 2006
Journal articles
TAPPI JOURNAL Summaries, Paper360° May/June 2010
TAPPI JOURNAL Summaries, Paper360º May/June 2010
Journal articles
intouch: WHATâ??S NEW ON PAPER360.ORG 14SEPPA45
Whats New on Paper360.org, Paper360º September/October 2014