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  

Unit size:
130 Megawatts.

Fuel:
Coal (Twenty-mile) – Peabody Energy.
11,200 Btu per pound with low sulfur and ash content.

 

Operating Load:
Variable load between 60 – 120 Megawatts.

Plant Issues:
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.

Superheater Pendent - Before CleaningSuperheater Pendent – Before Cleaning

Tubes Above Burners – Before CleaningTubes Above Burners – Before Cleaning

Wall Tubes - Before CleaningWall 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 CleaningSuperheater Pendent – After Cleaning

Tubes Above Burners – After CleaningTubes Above Burners – After Cleaning

Wall Tubes - After CleaningWall 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 InjectionBottom Ash Pile – Before Injection

Material Characteristics ChangeMaterial Characteristics Change

Bottom Ash Pile – End ResultBottom 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.

Injection-SystemInjection System

Concentrate-Feed-TankConcentrate Feed Tank

Manual-Injection-LanceManual 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

Unit size:
370 Megawatts.

Fuel:
Coal – Westmoreland.
9,100 Btu per pound with low sulfur content.

 

Operating Load:
Base Load at 370 Megawatts.

Plant Issues:
Slagging and fouling of combustion area boiler tubes and upper superheater pendent section. Heavy clinker formations and tube bridging.


Before Polarchem


After Polarchem