Southwestern Power Stations: Online Polarchem Demonstrations
Online boiler cleaning demonstrations at several coal fired power stations located in the Southwest were conducted using both Polarchem L2K and G3 products. The demonstrations showed the effectiveness of Polarchem in reducing LOI, improving combustion, and removing fouling and slagging from the fireside surfaces of the boilers.
Boiler Demonstration: Single Boiler Power Station
Coal (Twenty-mile) – Peabody Energy.
11,200 Btu per pound with low sulfur and ash content.
Variable load between 60 – 120 Megawatts.
Slagging and fouling of combustion area boiler tubes and upper superheater pendent section. Heavy clinker formations and incomplete combustion at low and mid-range operating loads.
Tubes Above Burners – Before Cleaning
Wall Tubes – Before Cleaning
Heavy slagging was discovered on both tube and fireside surfaces. The injected Polarchem solution was able to easily loosen and remove the heavy slagging and fouling that had been identified on the tube and fireside surfaces by simply adjusting the injection dosage.
Superheater Pendent – After Cleaning
Tubes Above Burners – After Cleaning
Wall Tubes – After Cleaning
The field technician injected two formulations, Polarchem L2K and G3, for a period of 160 hours over 16 days. In the photos above, you can clearly see how the product cleaned the boiler’s fireside tube surface.
Bottom Ash Pile – Before Injection
Material Characteristics Change
Bottom Ash Pile – End Result
Dense hard clinkers containing significant iron oxides and encapsulated unburned carbon were formed as a result of poor combustion prior to the use of Polarchem. As noted above, the composition of the bottom ash visibly changed during the injection of Polarchem.
Concentrate Feed Tank
Manual Injection Lance
Manual injection systems designed and manufactured specifically for the injection of Polarchem were stationed at separate levels. Each system serviced two lances with a total of four lances being active during the demonstration. An automated injection system can be set up for longer term use.
Southwestern Power Station: Results of Using Polarchem
The 370 megawatt power station boiler noted below was experiencing an excessive amount of time offline due to significant fouling and slagging issues. For example, during a 63 day period, the Unit was generating power only 49 % of the time while being offline 51% of that period. Polarchem L2K and G3 products were injected online beginning on the 64th day with the injections continuing for 43days. During the 43 day period, the Unit generated power 96% of the time with 4% of down time that was unrelated to the injection of Polarchem.
Boiler Demonstration: Multiple Boiler Power Station
Coal – Westmoreland.
9,100 Btu per pound with low sulfur content.
Base Load at 370 Megawatts.
Slagging and fouling of combustion area boiler tubes and upper superheater pendent section. Heavy clinker formations and tube bridging.