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Presentation to India PAPERTECH 2010

SOUND BLAST
SONIC SOOT BLOWER
FACILITATING ENERGY MANAGEMENT THROUGH SONIC SOOT
BLOWING IN HIGH PRESSURE BOILERS RELATED TO PULP
AND PAPER PLANTS

SOUND BLAST SONIC POWER COMPANY LIMITED

PAPERTECH 2010 v01

Congratulations to Organisers of
PAPERTECH 2010
for a most successful event and wish
Indian Pulp and Paper Industry
d
l
d
d
participants today and all stake holders
continuous success and prosperity

With 600 paper mills in operation, a 7.8% projected annual
growth, and an estimated nationwide paper demand of 10.5
million tonnes in year 2010, the Pulp and Paper Industry plays
an important role in the Indian economy and the next step
forward is to become world class.
However, this industry is also the 5th largest energy consumer
and the need is acute to better conserve and manage energy
with minimum ecological impact.

Sonic soot blowing is a low investment, cost effective way of
cleaning the boiler tubes and restore equilibrium conditions to
improve
p
heat absorption
p
and facilitate energy
gy management.
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Most Paper
p Plants meet its heat and p
power needs byy in‐house
thermal power boilers and waste heat recovery boilers; yet
ineffective removal of ash deposits from boiler tubes have in
many occasions lead to boiler in
in‐efficiency,
efficiency, capacity reductions,
tube overheating failures, and unscheduled shut downs.

Sticky ash in Kraft recovery boilers aside, most ash deposits in
these boilers are friable, less sticky and less tenacious, and are
removable by sonic soot blowing or a combination thereof with
existing soot blowing systems in boilers.

So, what is sonic soot blowing and what sets it apart from other
soot blowing systems? Is it feasible to target zero unscheduled
outages through sonic soot blowing?

What is sonic soot blowing 
Sonic soot blowing is cleaning of 
fouled surfaces by compressed air 
operated sonic soot blowers.
Sound waves sent inside boiler 
Sound
waves sent inside boiler
propagate in all directions and 
impart energy to ash particulates 
which fluidize and jump up from
which fluidize and jump up from 
fouled surfaces to be carried away 
by the flue gas stream.
Cleaning is effective even deep 
into tube bundles leaving no dead 
corners unclean.

Sonic soot blower

Flue gas stream

Tube bundle

Sonic soot blowing cleans with time setting
Sonic soot blowing operates continuously 
on‐line in successive short cycles where 
cleaning effect is controlled by cycle time 
setting (“on” time is in seconds, and “off” 
time is in minutes).
A helpful analogy to explain is to imagine 
cleaning your table once a year, or once a 
month, or everyday.  Of course, cleaning 
the table daily requires much less effort 
to keep it spotless!
Now, apply this to your boiler and clean it 
say every 20 minutes, or 90 times a day 
i
instead of just 3 times daily.
d fj 3 i
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Cleaning with time
Cleaning with time
On

Off

Time

Clean tubes absorb more heat and reduce overheating
Cleaning 90 times daily 
with sonic soot blowing
Design conditions of cleanliness
Clean tubes improve heat absorption 
and reduce overheating failures 

Heat absorbed 
H
b b d
from flue gas
0


8


16
16 

24 h
24 hr

Cleaning 3 times daily

More heat loss in flue gas and 
tubes are prone to overheating 





16 

24 hr

What is cleaning in successive short cycles

Initially, ash
particulates
land on tube
surfaces and
stay there.

Since “off” time in the
cleaning cycle is short,
only a small quantity
of ash particulates
can land and will
remain quite loose as
there is not enough
time for it to compact.

When cleaning cycle
starts, sound waves
come in and clean up
easily. The cycle
repeats every few
minutes successively
to keep the tube
surfaces always clean.

Pre‐ requisites to operate in successive short cycles
1. It must not cause any damages to boiler 
tubes even when the soot blower fails 
during operation.                                         
( sonic soot blower never damage tubes)  
2. Cost of soot blowing medium must be 
low and its production must not leave 
ecological footprints.                                                         
l i lf t i t
( compressed air is inexpensive)
3. Soot blowing medium must create no ill 
effects at boiler exit.                        
(compressed air is neutral and friendly)
(compressed air is neutral and friendly)

4. Soot blowing equipment must be reliable, easy to maintain, 
g q p
,
y
,
and capable of full service between planned outages.           
( with only one moving part, sonic soot blower is practically 
maintenance free for long term operation)  
a te a ce ee o o g te ope at o )

5. Soot blowing system investment must be low and payback 
period must be short and realizable; and system must be 
capable of being installed in new or existing boilers easily.                     
p
g
g
y
(sonic soot blowing system meets these requirements)

Reducing air pollution as a side benefit
Cleaning 90 times daily 
with sonic soot blowing

0

8

16 

Levels out soot discharge 
Levels
out soot discharge
peaks to small batches 
for easy capture or more 
effective dispersion
p

24 hr

Cleaning 3 times daily
Soot blowing discharge peaks 
Soot
blowing discharge peaks
are difficult to capture or 
disperse and form serious air 
p
polluters 3 times daily
y
0

8

16 

24 hr

SOUND BLAST sonic products

SOUND BLAST sonic 
soot blowing system is 
capable of seamless
capable of seamless 
integration to DCS 
with industry standard 
communication 
communication
protocols.

Sonic soot blowers operate in clusters
Sonic soot blowers are  
usually installed on boiler 
y
LHS and RHS in the tube 
bundle service spaces and 
operate in clusters to 
enhance cleaning effect.
As in Cricket fields, its PA 
system broadcasts through 
loud speaker clusters for 
clear transmission to 
everyone across the field.
h f ld
Below are 2 application 
cases.

Constructive interference effect

Case 1:  Pulp mill 195 t/h recovery boiler
This is a 195 t/h pulp mill recovery 
boiler built in 1993 to fire sludge 
and with steel ball cleaning system;
and with steel ball cleaning system; 
it had to be shut down every 3~4 
months for manual cleaning. 
4 years ago, 16 units of model SB38 
sonic soot blowers were installed to 
operate in 4 groups.  Today, the 
sonic soot blowing system runs at 
20 sec. “on”/ 3 min. ”off”; and steel 
ball cleaning is used only twice a 
week for 12 hours and boiler can 
last through planned outages.  The  
g p
g
client is now a repeat customer.

Case 1 real life photos 

Case 2:  Industrial 490 t/h CFBC boiler
This is an industrial 490 t/h coal 
fired CFBC boiler built in 2004; 
fouling persisted even with LRSB 
cleaning and the boiler could only 
operate at about 90% MCR. 
5 years ago, 40 units of sonic soot 
blower models SB60 and SB38
blower models SB60 and SB38 
were installed and operated in 7 
groups.  Together with the LRSB 
system the boiler returned to
system the boiler returned to 
operate at about 95% MCR.
The client was a repeat customer.

Case 2 real life photos 

Example on financial savings 
210 MWe coal fired boiler 
Coal consumption p.a.
Cost of coal to site
Cost of coal to site
Annual coal cost

:  1.03 million tons (approx.)
: ~ INR 3,000/ton
:  
INR 3 000/ton
:  INR 3.09 billion

Sonic soot blowing:
Direct savings @ 0.75%
Indirect savings @ 1%
Total savings p.a.

:  INR 23.2 million
:  INR 30.9 million
:  INR 54.1 million (INR 5.41 Crores)

Sonic soot blowing system payback period
In most cases and considering benefits from efficiency gains only, 
sonic soot blowing system payback period is usually within 2 years.  
Any additional benefits from improved performance and reduced 
maintenance would further shorten this payback period.
maintenance would further shorten this payback period.  

Typical LRSB 

SSonic soot blower  
i
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(same range)  

Sonic soot blowing in Pulp and Paper Industry
Total Cleaning Concept 

Sonic soot blowing system can be applied to different 
i
installations in Pulp and Paper Plant to facilitate 
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system operation and energy management
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Boiler     APH     ESP     Bag Filter     I.D. Fan
APH ESP B Filt
ID F

Benefits of sonic soot blowing
1. Facilitate energy management: reduce unscheduled 
outages, boiler damages, and increase overall plant 
safety, availability, reliability, and production stability.
2 Improve
2.
Improve operation economy: better boiler efficiency, 
operation economy: better boiler efficiency
less capacity reduction, and sustains superheated 
steam temperature to improve turbine performance.
3. Reduce consumption: of steam, ID Fan power, and 
less system maintenance needs. 
4. Reduce air pollution: through successive short cycle 
cleaning to level out soot discharge peaks
cleaning to level out soot discharge peaks.

Customer reference list
Reference in India:  
In final stages of applying SOUND BLAST sonic soot blower model SB38 
In
final stages of applying SOUND BLAST sonic soot blower model SB38
to a 117 t/h AFBC Boiler in Sheshasayee Paper & Boards, Tamil Nadu.
Reference in other countries:

Industry coal fired boiler cleaning photos

Before and After

Industry coal fired boiler cleaning photos 
Before

After

ESP cleaning photos
Negative discharge wires
Before

After

ESP cleaning photos 
Positive collection plates
Before

After

ESP hopper cleaning photos 
Hopper discharge during sonic soot blowing

Contact us for any soot cleaning problems
Sound Blast Sonic Power Company Limited
A1, 2/F, 65~67 Bonham Strand,
Central Hong Kong
Central, Hong Kong.
Tel: + 852 ‐ 2541 8289
Fax: + 852 ‐ 8148 1175
e‐mail: [email protected]‐blast.com
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dbl @
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Web: http://www.sound‐blast.com

Our business partner in India:
Keromiyons Intech Private Limited
# 110, Renga Villas, New Damu Nagar,
Coimbatore 641 037, Tamil Nadu, India.
Coimbatore –
641 037 Tamil Nadu India
Tel: +91 422 4214124
Fax: +91 422 4214125
e mail: [email protected] com
e‐mail: [email protected]
Web: http://www.keromiyons.com

Thank You

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