Recovery Boiler Liquor Spraying Practices

Esa K. Vakkilainen
Pyry Forest Industry Oy

1 July 6, 2006
Introduction

The pulp and paper industry needs to control its emissions to air
and improve throughput to maximize the use of its assets
Higher dry solids have improved energy efficiency and boiler
throughput
There is very scant individual recovery boiler firing data
Data was collected from 19 recovery boilers that are located at 16
kraft pulp mills in Finland

2 July 6, 2006
Environmental data 2005
Production SO2 NOx Dust TRS
Mill 1000t [kg/ADt] [kg/ADt] [kg/ADt] [kg/ADt]
16 201 0.83 2.55 2.04 0.03
14 333 1.17 2.21 0.55 0.08
13 193 1.03 1.99 0.66 0.07
6 417 0.99 1.96 0.84 0.05
5 442 0.08 1.97 0.77 0.11
2 579 0.54 1.90 0.40 0.06
1 304 0.12 1.78 1.05 0.04
8 464 0.14 1.77 0.04 0.16
7 461 0.26 1.61 1.15 0.12
15 540 0.15 1.44 0.31 0.14
10 308 0.03 1.34 0.33 0.21
3 902 0.11 1.21 0.12 0.03
4 503 0.18 1.16 0.27 0.15
12 625 0.32 1.14 0.10 0.14
9 297 0.08 1.13 0.83 0.03
11 140 0.16 0.90 0.11 0.04
3 July 6, 2006
Recovery boiler data
Boiler Startup Width, m Depth, m Height, m Area, m2 MCR. tds/d
A 1965 7.6 7.6 15.5 57.8 820
B 1988 8.0 8.0 18.0 64.0 1200
C 1991 12.4 12.8 35.6 159.0 4000
D 1987 10.1 10.4 27.6 105.1 1800
E 1992 13.7 13.3 40.7 182.9 3400
F 1998 12.5 13.3 36.5 166.8 4000
G 1963 6.8 6.4 19.0 48.0 800
H 1976 10.3 10.8 29.0 111.2 1800
I 1985 10.9 10.8 31.6 117.5 2700
J 1996 12.6 12.6 38.5 158.0 4000
K 1990 12.6 11.8 31.5 148.6 3200
L 1988 10.1 10.4 27.8 105.1 2000
M 1977 9.9 9.9 23.0 98.0 2000
N 1957 6.5 6.9 17.0 44.9 680
O 2004 14.4 15.6 41.0 224.6 4500
P 1980 7.438 6.43 22.2 47.8 1100
Q 1977 10.0 10.4 27.0 104.2 2000
R 1992 12.6 11.8 37.4 148.6 3000
S 1968 9.9 7.6 19.3 75.5 1266

4 July 6, 2006
About half of the boilers fire at or over 80 % ds

86

84

82

80
Dry solids, %

78

76

74

72

70

68
0 10000 20000 30000 40000
Liquor firing capacity, tds/d

5 July 6, 2006
Recovery boiler HSL

26.0

Average MCR

22.0
tds/d/m2

18.0

14.0

10.0
A N H G S D E B L Q O R M K I P F C J

6 July 6, 2006
Recovery boiler HHRR

4000

Average MCR.
3500

3000
kW/m2

2500

2000

1500
A N H G S D E B L Q O R M K I P F C J

7 July 6, 2006
Recovery boiler loading

28.0 4000

26.0
3500
24.0

22.0 3000

20.0

kW/m2
tds/d

2500
18.0

16.0 2000

14.0
1500
12.0

10.0 1000
A N H G S D E B L Q O R M K I P F C J

HSL HHRR

8 July 6, 2006
Newer recovery boiler are loaded higher

28.0

24.0
tds/d/m2

20.0

16.0

12.0
1950 1960 1970 1980 1990 2000 2010
Boiler startup

9 July 6, 2006
Studied boilers are on the high end of dry solids and firing rate
4500

Mill operating data

Studied boilers, average
4000
Studied boilers, max.

3500

3000
Specific heat load HHRR, kW/m2

2500

2000

1500

1000

500

0
60 65 70 75 80 85
Black liquor dry solids, %

10 July 6, 2006
Environmental performance

Boilers run at low SO2, average at mills ~0.3 kg/ADt

Boilers run at low NOx, average at mills ~1.6 kg/ADt
Boilers run at low dust, average at mills ~0.5 kg/ADt

11 July 6, 2006
Increase in dry solids does not increase NOx

3.00

2.50

2.00
NOx kgNO2/ADt

1.50

1.00

0.50

0.00
68 70 72 74 76 78 80 82 84 86
Dry solids, %

12 July 6, 2006
No boiler produces high SO2

50

45

40

35
SO2, mg/m3n

30

25

20

15

10

0
68 70 72 74 76 78 80 82 84
Dry solids, %

13 July 6, 2006
All but one boiler uses splashplates
Boiler Type from bottom, m Diameter, mm height, mm angle Dry solids, % Pressure, bar Temperature, oC

F A 6.7 34 26 25 80 1.5 138

J B 9.0 32 32 37 78 1.2 134
S B 8.2 32 32 35 73 1.4 126
A B 8.2 32 32 35 80 2.0 138
L B 7.6 34 34 35 80 1.8 138
K B 8.6 34 34 35 82 1.7 136
M A 6.0 32 24 30 80 1.8 140
B A 6.0 24 18 30 70 1.6 124
N A 6.0 18 14 25 75 1.4 133
I A 6.2 28 22 30 77 1.6 137
C A 6.5 38 28 25 80 1.4 138
D A 6.0 22 18 20 74 1.2 123
E B 8.6 28 28 37 74 1.2 123
R B 8.6 32 32 37 74 1.1 122
O A 6.8 49 37 35 84 1.8 143
P C 6.0 16 16 45 75 1.6 128
K B 8.6 34 34 35 82 1.7 136
G B 6.2 16 16 25 77 1.3 127
H B 8.5 20 20 45 77 1.2 127
M A 6.0 32 24 30 80 1.8 140
Q A 6.0 28 22 30 76 1.53 123
B A 6.0 24 18 30 70 1.6 124
I A 6.2 28 22 30 77 1.6 137

14 July 6, 2006
Firing temperature as function of dry solids

145

140
Pine
Mixed
135 Birch
BPR
Temperature, oC

130

125

120

115

110
68 70 72 74 76 78 80 82 84
Dry solids, %

15 July 6, 2006
Firing pressure as function of dry solids

3.0

2.5
Pine
Mixed
Pressure at ring header, bar(g)

Birch
2.0

1.5

1.0

0.5

0.0
68 70 72 74 76 78 80 82 84
Dry solids, %

16 July 6, 2006
Firing pressure as function of boiler size

3.0

2.5
Pine
Mixed
Pressure at ring header, bar(g)

Birch
2.0

1.5

1.0

0.5

0.0
0 50 100 150 200 250
Bottom area, m2

17 July 6, 2006
Bigger boilers require bigger nozzles

40

35
Nozzle diameter, mm

30

25

20

15

10
500 1000 1500 2000 2500 3000 3500 4000 4500
Solids load, tds/d

18 July 6, 2006
Bigger boilers require bigger nozzles

40

35
Nozzle size, mm

30

25

20
Fully open
15 Partially open

10
500 1000 1500 2000 2500 3000 3500 4000 4500
MCR, tds/d

19 July 6, 2006
Bigger boilers require low pressures

2.2

2
Nozzle pressure, bar

1.8

1.6

1.4

1.2

1
500 1000 1500 2000 2500 3000 3500 4000 4500
MCR, tds/d

20 July 6, 2006
Air splits versus age -
new boilers have higher tertiary and lower primary

100 %

90 %

80 %

70 %

60 %

Tertiary
50 %
Secondary
40 %
Primary

30 %

20 %

10 %

0%
N G A S H M Q P I D L B K C E R J F O

21 July 6, 2006