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Bezrukov
Alexey
Director of Marketing and Technological Development
Dementiev
Alexey
Development Director
Denisov
Yuriy
Chief executive
Fedyakov
Denis
Commercial director

 

 

 

External cleaning of pipes of Furnaces, Waste Heat Boilers, Boilers in a mode of the working equipment

   CJSC "MAGICROT" offers a completely new type of service on the Russian market - cleaning the exterior surface of the pipes of radiant and convection sections of fired heaters and the pipes of waste heat boilers and boilers.

Chemical cleaning technology of the exterior surfaces of tubes of fired heaters (and/or WHBs) is a high-technology service, based on the use of chemical reagents, made ​​in online mode - without interrupting the process of fired heaters (and/or WHBs) operation and is the most cost effective and appropriate method of service of fired heaters (and/or WHBs) with a high efficiency of the subsequent operation.

 

   This technology has been successfully applied in the refining, petrochemical and chemical industries, and also at thermal power plants and waste incineration plants. Regular and planned injection of reagent restores optimum operating parameters of the fired heaters (and/or WHBs) operation. The average time of reagent injection work at a unit is 3-5 days.

On-Line cleaning the exterior surface of the pipes

Problems encountered in the operation of fired heaters, waste heat boilers and boilers.
   Fired heaters, waste heat boilers and boilers in their work are often faced with the problems of heat transfer degradation and loss of efficiency, especially when using a liquid or a mixed type of fuel burned in the burners.

1) Deposits on exterior surface of the pipes.

In the combustion process, and depending on the type of fuel and temperature, vanadium, alkali-metal sulfates and aluminum silicates form hard deposits.

Unburnt carbon and sulfur form a softer and sometimes more sticky deposits to which stick other unburned particles, thereby increasing yet more the thickness of the deposits. This leads to heat transfer reduction blocking the flue pipe.

Incomplete combustion in fired heaters and boilers, leads to the formation of deposits on heat transfer surfaces. These deposits contain unburned carbon, alkali-metal sulfates, aluminum silicates or sulfuric acid and vanadium. Flue gases contain finely-divided carbon, sulfur dioxide, sulfur trioxide and nitrogen oxides.

 

2) Corrosion damage:

  • Low-temperature corrosion:

Some sulfur in the fuel is oxidized to sulfur trioxide, which reacts with water vapor to form sulfuric acid condensable at the surface when its temperature is below the dew point. This situation, in addition, may arise where flue gas temperature is above its dew point and combustion dust isolates heat exchange surface.

Air heaters, technical pipelines and stacks are particularly vulnerable to this type of corrosion.

 

  • High-temperature corrosion:

Vanadium oxide with a very low melting point forms super-hard deposits primarily in the areas of particularly high heat. Such deposits are very difficult to remove and they are a source of corrosion.

Vanadium oxide is also a catalyst of the reaction for the conversion of sulfur dioxide to trioxide.

 

3) Emission

Emissions of unburnt carbon, dust, sulfur dioxide, nitrogen oxides cause anxiety of people living near the production, and often exceed the allowable level. The main cause of acid emissions - unburnt carbon, carrying sulfuric acid from stacks. The smoke carries the remains of combustion, which fly out from those stacks where precipitators are not installed or are not effective. Amount of sulfur dioxide formed is direct relationship to the sulfur content in the fuel and oxygen in the air mixture. The higher combustion temperature, forms more nitrogen oxides. Level of emission of these substances into the atmosphere is strictly regulated by national legislation.

 

Production practice shows that the problems with deposits on the exterior surface take place in the following cases:

-Work on the mixed fuel (liquid fuel, natural gas, fuel gas);

-Work on natural gas, but previously could be used mixed composition or liquid fuel;

-Work on natural gas, in case radiant tubes and mostly tubes of convection section have deposits (mainly unburnt carbon and products of metal oxide of tubes).

 

The problem is increased bigger when the fired heater is operating at high load for a long time. Deposits on the external coils surface create a lot of problems, such as reduced heat transfer, interferences of gas flow, high surface temperatures, reduced productivity or increased consumption of fuel gas / fuel oil, coke formation accelerated, decrease of conversion, etc.

These problems often lead to unexpected shutdowns for future maintenance and reduce the residual operation life of the pipes due to the high-and low-temperature corrosion.

The traditional way to solve the problem - cleaning fired heater when it stopped.

 

   However, many refineries and petrochemical plants have 2 years or more overhaul life.

   The deposits in the convection section are difficult to approach and hard to remove because of the risk of lining damage when use of standard procedures, such cleaning with water/steam, cleaning using abrasives.

 

Effect of the reagent:

  •  oxidation of unburned carbon
  •  neutralization of sulfur trioxide
  •  neutralization of the harmful effects of vanadium oxide
  •  adsorbtion into the crystal lattice of deposits and decrease of their adhesion
  •  reduction of emissions

Reagent effect description:

   Reagent proposed by CJSC "MAGICROT" will oxidize unburned carbon, neutralize the harmful effects of vanadium oxide, loosen the structure of deposits, reducing their adhesion to the heat exchange surface of the pipes. Effect of the reagent also reduces the emissions. The efficiency of the reagent increases with the use of steam, air or other type of blowers systems.

Advantages of the technology:

  •  Increase of coefficient of efficiency of units and improved heat transfer
  •  Reduce fuel burn
  •  Increase in capacity
  •  Reduce low-temperature and high-temperature corrosion
  •  Reduce the cost of repairs and maintenance
  •  Reduction of using of air blowers systems per unit time
  •  Cleaning is carried out in the mode of operating equipment without breaking technological standards
  •  Reduce damage of pipes, wall linings and equipment
  •  Reduce emissions
  •  Ability to preventive treatments

On-Line cleaning the exterior surface of the pipes

    Reagent passed State Registration and is recorded in the Register of State Registration Certificates (№ RU.32.БО.21.008.Е.000681.11.11 от 01.11.2011)

   Effect of the reagent has been repeatedly confirmed by numerous works made in the last 25 years of application of this technology in the world.

 

 

Description of the technology:

   Injection of water solution of a proprietary chemical reagent with manual or automatic dosing is conducted through the injection rods with the necessary spray nozzles into the interior of fired heaters and boilers.

     Working solution with pressure 6.7 atm is used in injection that has the effect of spray reagent as a fine "mist". Injection rods are introduced into inside zone of fired heaters and boilers through viewing windows or hatches access.

   Reagent injection in the manual mode is carried out successively from one window to another, using one window at a time.

The results of performed services:

On-line cleaning of fireside surfaces of Fire Heater Convection Section on Pyrolysis Unit
(Petrochemistry)

On-Line cleaning of fireside surfaces of Furnace Convection Section of Aromatics Complex
(Refining)

On-Line cleaning of heating surfaces of Waste Heat Boiler of Crude Oil Distillation Unit (CDU)
(Refining)

 


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