Process Recovery Boilers Reliable and effi cient steam producti on for the pulp and paper industry Since 1929, when The Babcock & Wilcox Company (B&W) developed the world’s fi rst Kraft recovery boiler with G.H. Tomlinson, our recovery boiler design has evolved with many new features and customer benefi ts. Our recovery boilers off er high availability with safe operati on and low maintenance. Proven experience to meet the energy requirements of today’s pulp and paper mills B&W’s recovery boilers pro- vide owners and operators with increased effi ciency, reliability and fl exible operati on that lowers your overall boiler lifecycle cost. B&W PR boiler design benefi ts: • Increased effi ciency The latest process recovery (PR) boiler design from • High availability Babcock & Wilcox (B&W) is the leading-edge technology • Improved safety in the industry. • Low emissions (CO, NOx, SO2 and VOC parti culate) With the largest installed base in the world of more • High solids fi ring for opti mized than 350 recovery boilers, B&W is committed to thermal effi ciency the pulp and paper industry by helping today’s energy- • Advanced steam drum internals and riser/supply systems for circulati on intensive mills become more competi ti ve and profi table. safety margin • Reduced constructi on costs and greater Our recovery boiler customers benefi t from B&W’s schedule certainty with modularized design industry leadership in uti lity boiler design. We can apply • Overall lower boiler lifecycle cost uti lity boiler technology advancements such as high- temperature/pressure designs, advanced materials, and reheat steam cycles to PR boilers whenever it is appropriate, assuring you of the most up-to-date Largest Installed Base of Recovery design for your plant. Boilers in the World 2 Lowering the total cost of ownership B&W’s recovery boiler design includes features that lower the total cost of ownership with high availability, increased effi ciency and reduced maintenance. Reduced Constructi on Costs B&W’s longfl ow economizers (shown here) and generati ng banks provide eff ecti ve heat transfer and are modularized for easy installati on, reducing constructi on costs. High-Temperature Superheater Longfl ow economizer circulati on design margin for normal The boiler’s high-temperature super- • Two-gas/two-water pass arrangement and upset mill conditi ons. B&W heater metallurgy and modular heati ng provides eff ecti ve heat transfer from provides circulati on margin in the surface provide a fl exible design for the counter fl ow of gases across the design phase using COMO, our initi al and future mill operati ng tubes. proprietary computer modeling conditi ons. Because the primary • Bott le headers serve as integrally system. Our patented low pressure superheater is located downstream designed lift ing devices, eliminati ng drop internals, and B&W specified The latest process recovery (PR) boiler design from of the furnace cavity with steam expensive rigging beams or sleds. multi -lead ribbed tubes are key fl owing parallel to the fl ue gas, the components that add safety margin. Babcock & Wilcox Power Generation Group, Inc. • Tapered fi n design signifi cantly coolest available steam will be exposed reduces tube stresses and tube B&W is routi nely called upon by (B&W PGG), a subsidiary of The Babcock & Wilcox to the hott est gas and radiant heat leaks, compared with the experience both industrial and uti lity customers Company, is the leading-edge technology in the industry. from the furnace. This arrangement of other angled fi nned designs. to analyze and fix issues on non- provides eff ecti ve heat transfer and B&W boilers. With the largest installed base in the world of more minimizes tube metal temperatures, Longfl ow generati ng bank thereby reducing tube metal corrosion • Shop-assembled tube secti ons are Modern, Single-Drum Design than 350 recovery boilers, B&W PGG is committed to and improving reliability and safety. modularized to minimize Drum internals provide high steam the pulp and paper industry by helping today’s energy- constructi on ti me and expenses. purity to meet today’s steam turbine intensive mills become more competitive and profitable. Modularized Longflow Economizers • Full-length access cavity accommodates requirements, with a low pressure drop and Generati ng Bank retractable sootblowers for opti mal for additi onal circulati on safety B&W’s longflow economizers and margin. B&W’s welded, single-drum Our recovery boiler customers benefit from B&W PGG’s cleaning and maintenance. generati ng bank secti ons are shop- design addresses the need for high industry leadership in utility boiler design. We can apply modularized for lower installati on cost. Advanced Circulati on Design pressure and temperature steam utility boiler technology advancements such as high- They incorporate the latest design and For personnel safety, one of the most cycles with a large, conservatively sized temperature/pressure designs, advanced materials, technological improvements available criti cal recovery boiler component furnace. The location in front of the and reheat steam cycles to PR boilers whenever it is for recovery boilers. B&W’s robust designs is the natural circulati on furnace provides other benefits such design features have been selected appropriate, assuring you of the most up-to-date system. Due to the potenti al for smelt as extended drum length and simpler as the basis for current industry water reacti ons and the corrosive erection. design for your plant. standards. lower furnace environment, recovery boilers require ample 3 Other Multi -Level B&W’s QuantumAirTM Air Equipment System ISO-Surfaces of Gas Speed (70 ft /s) Twin Terti ary Air Emissions Lower NOX CO Carryover Liquor Air B&W’s QuantumAir system outperforms Liquor Gun other multi -level air systems in reducing NOX, CO and carryover. Generous Furnace Plan Area Secondary Air and Volume The QuantumAir system was developed by Primary Air uti lizing &B W’s COMO fl uid dynamic modeling program that enabled designers to opti mize the quanti ty and locati on of air levels for the most effi cient combusti on. Leading the industry with technology innovati ons COMO Modeling Program B&W’s industry-leading combusti on modeling (COMO) program for black liquor combusti on has led to numerous air system enhancements and modifi cati ons for improved boiler effi ciency and emissions. B&W leads the industry with state-of-the-art designs, equipment opti ons and opti mized operati ng conditi ons for your recovery boiler. Our proprietary COMO system has become the benchmark for other industry models. QuantumAir™ System B&W’s QuantumAir system can be upsets and auxiliary natural gas fuel B&W’s QuantumAir system – developed adapted for firing up to 85% black consumpti on. based on our industry experience and liquor solids. • Liquor air level reduces fi ne parti cle combustion modeling program for carryover above the liquor guns. black liquor combustion – sufficiently QuantumAir system benefi ts include: • Twin terti ary air level ports aligned lowers nitrogen oxides (NO ), carbon x • Increased staging reduces NOx with the liquor level ports further monoxide (CO) and carryover to help emissions. reduce parti cle carryover, improve reduce boiler emissions. The multi - • Reverse interlaced secondary air mixing and reduce emissions, level air system uses levels of primary ports minimize gas plume along the enabling you to extend the run ti me and secondary air in conjuncti on with furnace rear wall providing lower CO between water washes. close-coupled liquor air and twin terti- emissions and reduced maintenance. ary air. The system provides reduced • Single-level secondary air provides Improved Boiler Effi ciency emissions through increased staging excellent control of char bed com- Many features and capabiliti es of and higher air level elevations. busti on for both low and high solids our process recovery boilers provide fi ring, which minimizes operati onal 4 Tight Roof Casing Steam Drum Safety Reliability Lower Emissions Longfl ow Generati ng Bank and Economizer 100% Cooled Surface Maintenance Beams Conti nuous Trough Ash Removal High Solids Liquor Generous Delivery System and Furnace Plan Area QuantumAirTM System and Volume Twin Terti ary Air Lower Furnace Liquor Air Tube Protecti on Liquor Gun Secondary Air Rearwall Smelt Primary Air Spout Locati on PROCESS RECOVERY (PR) BOILER Liquor processing capacity up to or greater than 10,000,000 lb/day (4500 t/day) dry solids Steam pressure to 1850 psi (12.6 MPa) Steam temperature to 950F (510C) Fuel pulp mill liquor, soda, Kraft and other fuels Dual Sloped Floor Auxiliary fuels natural gas and/or oil Solids fi ring Up to 85% black liquor solids improved boiler effi ciency: B&W designs and manufactures an priority. Specifi c examples include: • Lower exit gas temperatures array of recovery boiler lower furnaces • Explosion relief point is located in • Increased air temperatures with metallurgy that includes: upper furnace, away from • Higher steam temperatures • composite tubes operati ng fl oors and personnel and pressures • weld overlay tubes for improved safety. • Reheat steam cycles • chromized and carbon steel pin studs • Increased number of fl oor beams • High solids fi ring provides greater support. High alloy composite furnace • Flexible seals and att achments Customized Liquor Delivery System panels are manufactured in B&W’s minimize stress-assisted corrosion For opti mal combusti on, reduced nuclear-grade manufacturing plant to and reduce maintenance. emissions and improved long-term provide a high-quality product for this maintenance, B&W offers a criti cal component. Our automated Auxiliary Fuel System – LM2100™ customized liquor delivery system pin studding machine provides a high- Retractable Burner that opti mizes liquor spray patt erns, quality, consistent pin stud patt ern B&W’s innovative LM2100 auxiliary droplet size and distributi on into the reducing plant maintenance, forced burner is designed for improved furnace.