Recovery boilers burning black liquor used by the pulp and paper industry can develop tube leaks and over minutes may lead to explosions via mixing water with molten smelt laden with sodium. If detected early, tube failures may be repaired before catastrophic damage occurs. Early repairs will cost a fraction of those associated with late detection and catastrophic damage. Repair times may further be reduced if the location of the leak is identified before repairs are initiated.  

Exergetic Systems’ Input/Loss Methods of monitoring recovery boilers provides rapid detection of tube failures and the location of the affected heat exchanger within the recovery boiler without need for direct instrumentation. Tube failures are detected through use of system stoichiometrics, in combination with an ability to correct effluent data through use of optimization procedures. The location of the failure within a recovery boiler is determined through energy balances, high accuracy boiler efficiency and iterative techniques. Further, the model also indicates the stoichiometric mechanism leading to the leak.  

Input/Loss’s identification of tube failures have been demonstrated at a detection sensitivity of ±2,000 lbm/hr level or 0.05% of feedwater flow. This statement is based on proof-of-process testing at a large conventionally-fired steam generator. See the paper “Detection of Tube Leaks and Their Location Using Input/Loss Methods” for more details.
   

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