Shock Pulse Generator
The Shock Pulse Generator (SPG) is an online boiler-cleaning device developed in 2009 by the Swiss company Explosion Power GmbH, which produces automated shock pulses through the combustion of gas pressurised mixtures produced upstream. The technology has been applied within more than 700 installations in over 20 countries.
Plant operators have confirmed extended boiler operation periods and increased efficiency, thereby giving more sustainable and economic operation.
How it works
Shock Pulse Generators clean steam generators using shock waves which are triggered by the explosive combustion of a mixture of a combustible gas (natural gas or methane) and air.
Manual explosive cleaning processes also use shock waves for their cleaning effect. In contrast to the manual processes, with Shock Pulse Generators, the automatically triggered isochoric combustions take place outside the boiler in a sturdy pressure-proof vessel.
The shock wave induces a structure-borne vibration, produces a brief localised vacuum and causes a short-term vibration of the fouled tubes and boiler walls. These three effects cause the deposits to be loosened, cleaning the boiler.
The shock pulses are injected into the boiler interior via a discharge nozzle, with a control cabinet controlling the sequence of the shock pulses and being connected to a distributed control system (DCS).
The combustion air is supplied via an air compressor unit, while natural gas (or methane) and nitrogen are usually supplied in bottles. The pressure regulating units reduce the pressure to 40 bar line pressure.
Structure of the SPG system
Schematic of the Shock Pulse Generator system
Components
The Shock Pulse Generator system consists of the following components:
- Shock Pulse Generator: installed on a boiler connection flange. The shock pulses are guided into the interior of the boiler using a discharge nozzle. The flange can also be positioned on a manhole.
- Control cabinet: controls the shock pulses, connected with the distributed control system (DCS).
- Pressure regulating units: reduce to 40 bar line pressures.
- Valve panel: Assembly of valves and pressure transmitters
- Air compressor unit: supplies combustion air
Automated control
Every Shock Pulse Generator has its own PLC control with touchscreen panel which monitors all important processes. Various versions of data exchange with the distributed control system are possible as well as with the manufacturer and/or maintenance provider.
The SPGLogView software developed by Explosion Power GmbH and the associated hardware enable secure transmission of the operating data from the Shock Pulse Generators as well as automatic evaluation, for example for maintenance planning.
Materials
The Shock Pulse generators are manufactured and assembled from materials that are particularly resistant to pressure and heat.
Installation
The Shock Pulse Generator is mounted on a boiler flange, whereby the flange can also be placed on a manhole. The SPG is installed on the outside of the boiler wall. The SPG is held in position on a rail by means of a spring-loaded attachment to the customer-side flange, which compensates for the expansion of the boiler. Shock Pulse Generators from Explosion Power GmbH can be mounted horizontally on the boiler wall or vertically on the boiler ceiling.
Operating media
The fuel supply of the Shock Pulse Generators can be easily implemented using single bottles or small bundles. A small compressor can also be used for natural gas if a mains supply is available. An air compressor unit is used for the air supply. In addition, a single nitrogen bottle is required for the gas spring of the piston in the Shock Pulse Generator.
Application areas
The SPG cleaning technology is already used in many different industrial boiler plant applications.
Depending on the size and complexity of the boiler, a different number of Shock Pulse Generators are used:
- Waste incineration plants
- Biomass power plants
- Hazardous waste incineration plants
- Coal-fired power stations
- Industrial boilers for various fuels
- Waste heat boilers for coke plants, metallurgy
- Sewage sludge incinerators
History of the Shock Pulse Generator technology
The Shock Pulse Generator technology was developed and patented by Explosion Power GmbH in 2009. From 2009 to 2020, it spread to industrial plants in more than 20 countries. Two new models called SPGr10 and SPGr16 were launched in 2020. Compared to the previous devices, the new SPGr series devices differ in the use of air instead of oxygen, a more compact design and an extended performance range.
Known models
Higher efficiency, lower consumption and easier cleaning
Users reportedly state that regular and automated application in the correspondingly cleaned area of the boiler has achieved lower flue gas temperatures, which also increases the boiler efficiency. It was also noted as beneficial that the process does not consume any steam and causes little wear or depletion of the boiler tubes. Longer operating periods and a lower cleaning effort during boiler shutdowns resulted in higher overall plant availability.
Web links
- Articles from "Gases for Life" magazine about SPG technology
- Article from POWER Magazine about SPG technology
- Article from Waste Management World Magazine about the new introduction of the TwinL Shock Pulse Generator at the time
References
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