Professional Documents
Culture Documents
FMDS0621
FMDS0621
Table of Contents
Page
©2013-2024 Factory Mutual Insurance Company. All rights reserved. No part of this document may be reproduced,
stored in a retrieval system, or transmitted, in whole or in part, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without written permission of Factory Mutual Insurance Company.
6-21 Chemical Recovery Boilers
Page 2 FM Global Property Loss Prevention Data Sheets
List of Figures
Fig. 3.3.1-1. Cascade evaporator system ................................................................................................... 14
Fig. 3.3.1-2. Cyclone evaporator system .................................................................................................... 15
Fig. 3.3.2. Tubular cascade evaporator with outer casing removed .......................................................... 16
Fig. 3.3.3-1. Cyclone evaporator ................................................................................................................ 17
Fig. 3.3.3-2. Venturi evaporator-scrubber and cyclone separator .............................................................. 18
Fig. 3.3.3-3 Nozzle location for cascade evaporator and induced draft fan .............................................. 18
List of Tables
Table 3.1.1. Sodahuskommitten Incidents (2004-2006) ............................................................................... 10
Table 3.1.2. Suomen Soodakattilayhdistys Incidents (1990-2006) .............................................................. 10
Table 3.1.3-1. BLRBAC Data on Explosions (1978-2007) ........................................................................... 11
Table 3.1.3-2. BLRBAC Data on Black Liquor Recovery Boiler Critical Exposures (1978–2007) .............. 11
1.0 SCOPE
This data sheet contains recommended practices for the design, operation, and maintenance of black liquor
recovery boilers used in the pulp and paper industry. The primary focus is recovery boilers used in the Kraft
or sulfate recovery process. Recommendations may also be applied to black liquor recovery boilers in the
“soda” or sodium carbonate recovery process. Both boilers are commonly known as black liquor recovery
boilers in North America, and as soda recovery boilers outside North America.
This data sheet is not applicable to red liquor recovery boilers used in the (ammonium or magnesium) recovery
process. See Data Sheet 6-13, Waste Fuel-Fired Facilities, for further guidance.
This is a system-based data sheet covering the feedwater control valve, main header safety shutoff valve
for each auxiliary fuel, firing liquor supply from the final indirect liquor evaporator or concentrator, combustion
air with each forced-draft fan, any direct-contact firing liquor evaporator, electrical power as needed to operate
boiler auxiliary equipment and controls, flue gas equipment (any direct contact evaporator, induced-draft
fans, and electrostatic precipitators, and the steam piping from the boiler, including the two main-steam shutoff
valves.
Guidance is also provided on collection and transport of noxious or flammable pulp mill waste streams for
incineration or firing in the boiler furnace.
1.1 Changes
January 2024. Interim revision. Editorial revision to add clarification, update industry terminology and resolve
conflicts with BLRB Audit Checklist.
2.1 Introduction
Recommendations in the following sections specify a desired level of performance rather than particular
actions. The data sheet user may choose from several written industry practices to achieve the recommended
performance, and clients of FM Global may work with FM Global engineers to develop alternative actions.
Note that some specific practices permitted or recommended by written industry standards are not in
accordance with FM Global guidelines. Currently, written industry standards include the following:
• Those produced by Sodahuskommitten (Swedish-Norwegian Recovery Boiler Committee, SHK)
• Those produced by Suomen Soodakattilayhdistys (Finnish Recovery Boiler Committee, FRBC)
• Those produced by Black Liquor Recovery Boiler Advisory Committee (United States of America,
BLRBAC)
• European Standard EN 12952, Water-Tube Boilers and Auxiliary Installations
When welded repairs are performed on pressure parts in areas where a leak could occur into the furnace,
the integrity of the weld repair should be reevaluated at the next outage.
Qualified welding procedures should be used for all repairs. For tube repairs, the welding technique and
procedure should minimize excessive weld penetration into the tube internal diameter.
2.2.1.2 Specify that all boiler pressure part welds that could admit water to the furnace be examined using
a volumetric method.
2.2.1.3 Specify boiler tube materials having corrosion and erosion resistance appropriate for the boiler’s
operating conditions.
2.2.1.4 Specify construction of the boiler furnace to be gas-tight (fully welded).
2.2.1.5 Specify boiler design to avoid use of a furnace water screen.
2.2.1.6 Specify new or replacement boiler waterwalls to provide explosion relief in one or more corners of
the furnace.
2.2.1.7 Provide boiler water treatment equipment (makeup, condensate, and feedwater) and procedures
appropriate for the boiler operating pressure and sized for the maximum possible steam demand or startup
demand, whichever is greater. See Data Sheet 6-23, Watertube Boilers, for additional guidance.
2.2.5.4 Train operators in appropriate methods for manual removal of salt cake or ash accumulations from
pressure parts (salt cake on superheaters or upper furnace, generation bank, economizer, and water screens,
salt cake in burner or air port openings, and solidified smelt in smelt spout openings).
2.4.1.3 Design ductwork for high-volume low-concentration gas (HVLC, also known as dilute noncondensible
gases or DNCG) as recommended in Data Sheet 7-78, Industrial Exhaust Systems.
2.6.1.4 If the control or equipment rooms are located near a potential source of substantial release of corrosive
gases, maintain the rooms under a positive air pressure of at least 0.1 in. of water (25 Pa). Supply fresh
air from a contaminant-free location.
2.6.1.5 If it is determined the control area cannot be attended as recommended during emergency conditions,
provide an alternate, remote control interface so all recommended emergency actions, including boiler
monitoring, can be accomplished.
2.7.2 Sparing
Sparing can be a mitigation strategy to reduce the downtime caused by a chemical recovery boiler breakdown
depending on the type, compatibility, availability, fitness for the intended service, and viability of the sparing.
For general sparing guidance, see Data Sheet 9-0, Asset Integrity.
There are 30 recovery boilers in Sweden and two in Norway, with the average boiler having been in service
about 30 years and having a capacity of 3,031,500 lb/day (1378 mt/day).
SHK compiles boiler incident data volunteered by member operators. Table 3.1.1 lists incidents resulting in
tube leaks reported to the Committee from 2004 through 2006.
Fuel Explosions
1. Pyrolysis gas 3 1
2. Fuel rich mixture 3 1
Subtotal 6 1 1
Table 3.1.3-2. BLRBAC Data on Black Liquor Recovery Boiler Critical Exposures (1978–2007)
BLRBAC Critical Exposures
Water Source: Number
1978-1987 1988-1997 1998-2007
1. Floor tube leaks 13 16 11
2. Wall tube leaks 82 148 94
3. Screen tube leaks 16 8 19
4. Roof tube leaks 2 2 2
5. Generating bank tube leaks 27 63 46
6. Weak liquor 1
7. Water entered through liquor guns 1 2 1
8. Water entered through oil guns 2
9. Wash water 2 1
10. Smelt spout leaks 10 10 7
11. Economizer Tubes 4 6 37
12. Other Water Sources 3 5 5
TOTAL 161 262 223
3.1.5.2 Failure to Remove Black Liquor Guns after Terminating Firing Results in Explosion
This BLRB is rated for 3,000,000 lb/day (13.6 x 105 kg/day) dry solids recovery and 769,400 lb/hr (3.5 x
105 kg/hr) steam at 890 psi (61 bar). Black liquor gun position switches were removed six months after the
BLRB was commissioned. A “no divert” bypass of the automatic divert control was installed about six months
before this incident in.
The BLRB was operating normally when the forced draft fans, black liquor pumps and the precipitator level
tank pump tripped off. The black liquor automatically diverted and the induced draft fan continued operating.
The firemen shut off the individual liquor guns and opened the steam out connections, but left the guns in
place. Condensate is not manually drained from the steam out lines.
Two hours were spent locating the reason for the trip and preparing the BLRB for re-firing. Preparation
included making a steam out connection between the green liquor piping and the steam ring header for the
black liquor guns. It was subsequently discovered the steam pressure can drop to 30 psi (2 bar) and the
green liquor pump can develop up to 60 psi (4 bar) at gun level.
At two hours and 20 minutes, the black liquor pump control was bypassed and control logic modified to start
the precipitator level tank pumps. These pumps were started and the ‘‘no divert’’ was activated on the black
liquor control to permit recirculation of liquor. Subsequent investigation revealed the total reduced sulfur
(TRS) recorder indicated a rapid increase in TRS at this time. This would indicate black liquor was entering
the furnace. At two hours and 25 minutes an explosion occurred followed by a second explosion. The
feedwater valve was closed, water was observed on the boiler exterior, and the ESP was initiated at two hours
and 40 minutes.
Following the recommended practice of removing the black liquor guns from the furnace prior to reopening
the black liquor header valve could have prevented this incident.
3.1.5.3 Excessive Smelt Flow upon Start-up After an Unplanned Outage Results in Dissolving Tank
Explosion
An electric power interruption stopped firing of this BLRB. The following day the BLRB was re-fired. Green
liquor and steam shatter sprays were turned on and the dissolving tank was being filled while an operator tried
to clear one spout. Tank level was above normal and a large pool of molten smelt had accumulated when
one spout was opened. The flow exceeded shatter spray capacity and a solid stream of smelt entered the
dissolving tank.
The subsequent smelt-water explosion damaged the dissolving tank, shatter piping and BLRB casing. Greater
care in re-melting the smelt bed, maximizing the shatter sprays, and in re-opening the smelt spouts could
have minimized this incident.
3.1.5.4 Why Actuation of the ESP Upon Pressure Containing Part Failure within the Furnace is
Recommended
This BLRB is rated for 328,000 lb/hr (1.56 × 105 kg/hr) steam at 400 psi (26 bar) and 1,900,000 lb/day
(9.1 × 105 kg/day) dry solids. Operator training is rated excellent. A complete ESP system and written
procedure are provided.
The BLRB was operating normally although water chemistry analysis indicated a major change from readings
of eight hours earlier. After eight more hours the chemical feed rate remained excessive. At 11 hours, a sound
similar to a soot blower was noted at one liquor gun port. At 11-1⁄2 hours, it was decided a leak existed in
the furnace, but there was no evidence of water entering the furnace. Control room instrumentation did not
indicate any leakage.
Liquor guns were removed from service and auxiliary burners were started. With auxiliary burners in service
at 13 hours, 20 minutes, a low water alarm followed by a low water trip occurred. At this time, water was
observed spraying into the furnace and the ESP was initiated.
Subsequent investigation revealed the entrance to one waterwall tube was more than 80% obstructed by a
foreign object. This obstruction led to short term overheating and tube rupture. Due to the obstruction, initial
discharge from the rupture was steam, followed by water as boiler pressure was reduced.
E. Correct liquid level within the cascade evaporator was not maintained, particularly during startup,
shutdown and auxiliary fuel firing.
F. Auxiliary fuel oil atomized improperly, allowing oil droplets to carry over.
G. The boiler was not in a fire-free condition which should have been checked as part of the shutdown
procedures.
H. Boiler operation resulted in poor liquor combustion.
I. Unburned fuel accumulations in the electrostatic precipitator were susceptible to ignition through
electrical short-circuiting or excessive arcing.
J. Air leaked through open seams, loose doors, corrosion holes, etc., into ductwork and hoppers
contributed to fire intensity.
Electrostatic Recovery
Precipitator Boiler
To Stack
I.D. Fan
Cascade Liquor In
Wheel
Concentrated
Liquor Out
I.D. Fan
Liquor In Recovery
Boiler
Electrostatic
Precipitator
To Stack
Cyclone
Venturi
Concentrated
Liquor Out
The interior of a DCE and ductwork can accumulate combustible, organic deposits commonly called char.
Deposits occur because the hot flue gas directly contacts the weak liquor. The flue gas is cooled and the liquor
is concentrated. Liquid droplets and solids from the liquor are deposited in the DCE and on surfaces and
ledges in the ductwork. Over time, layers of char deposits build up, creating a concealed, generally
inaccessible fire hazard.
Fire in the char deposits can occur due to process upsets. During normal conditions, flue gas flow through
the ductwork is oxygen deficient due to high carbon dioxide component. Even though char is constantly
exposed to temperatures well above its autoignition temperature, it normally will not ignite because of limited
oxygen. However, during process upsets, oxygen can increase in the flue gas stream, creating optimum
conditions for the preheated char to auto ignite. In addition, loss of power to the cascade evaporator wheel
drive can allow liquor to dry out and auto ignite on the wheel. Increased liquor viscosity may cause high torque,
which in turn trips the cascade drive, also resulting in autoignition of the char.
Fires in char deposits display surface-burning characteristics rather than deep-seated burning characteristics
and can be extinguished by a quickly actuated steam suppression system.
Because the fire is in a concealed space and provision for access for manual suppression is not provided
nor practical during normal operation, lack of a fixed automatic suppression system can lead to an
uncontrolled fire within the DCE, ductwork and downstream equipment. Damage to the equipment and
extended business interruption can result.
During complete shutdown, when ductwork is open for maintenance or inspection, char deposits have been
ignited by hot work and electrical appliances. Manual response with fire water hoses or extinguishers can
be effective during shutdown when steam might not be available or is undesirable.
DCE is not typically installed on a new BLRB and many DCE have been removed from existing BLRB due
to air quality requirements. In the “low odor” design the DCE is replaced by another evaporator, known as
a “concentrator”. To maintain boiler efficiency, the low odor boiler will have extended economizer surface and
may have feedwater-to-combustion-air heat exchangers.
Fig. 3.3.3-3 Nozzle location for cascade evaporator and induced draft fan
4.0 REFERENCES
4.1 FM Global
Data Sheet 1-44, Damage-Limiting Construction
Data Sheet 5-32, Data Centers and Related Facilities
Data Sheet 6-5, Oil- or Gas-Fired Multiple Burner Boilers
Data Sheet 6-11, Thermal and Regenerative Catalytic Oxidizers
Data Sheet 6-12, Low-Water Protection for Boilers
Data Sheet 6-13, Waste Fuel-Fired Facilities
Data Sheet 6-23, Watertube Boilers
Data Sheet 7-32, Ignitable Liquid Operations
Data Sheet 7-78, Industrial Exhaust Systems
Data Sheet 9-0, Asset Integrity
Data Sheet 10-8, Operators
Data Sheet 12-43, Pressure Relief Devices
4.2 Others
See Appendix C, Bibliography.
A.2 Terms
Continuous Gas or Light Oil Fueled Igniter: A spark ignited, supervised pilot supplying sufficient energy
to ignite and maintain ignition of an associated fuel burner under all light off and firing conditions. Location and
capacity of the igniter ensures minimum ignition temperature for any ignitable combination of burner fuel
and air inputs.
Interrupted Gas or Light Oil Fueled Igniter: A spark ignited, supervised pilot used to ignite an associated
fuel burner under prescribed light-off conditions. Interrupted igniters may be shutdown at the end of the main
burner trial for ignition period or may be left in service to support combustion of the main burner fuel under
controlled firing conditions. When left in service beyond the main burner trial for ignition, interrupted igniters
are either sized as continuous igniters or are provided with flame supervision independent of that provided
for the fuel burner. When not sized as a continuous igniter, loss of main burner flame after the trial for ignition
period, causes the shutdown of both the burner and igniter fuels.
Interrupted Direct Electric Igniter - A retractable igniter providing a high energy electrical spark discharge
or high energy electric arc capable of directly igniting the auxiliary fuel burner. (Interrupted service only.)
Supervision of main burner flame is required.
Supervise: Monitor conditions and automatically initiate corrective action upon detection of condition beyond
prescribed limits (unsafe condition).
Minimum Furnace Purge Airflow: Purge air flow of sufficient volume and duration to ensure removal of
flammable gases from the furnace prior to initiating any fuel firing.
Trial for Ignition: Time interval during which the burner flame safeguard system permits the BSSV to be
open without proof of burner flame.
Vent Valve: Automatic valve on fuel gas vent line located between two fuel safety shutoff valves. Vent valve
is interlocked to open when safety shutoff valves close. This reduces chance of gas leakage into the recovery
furnace when the safety shutoff valves are closed.
Firing Liquor Divert System or Valve: An automatic system that prevents flow to the liquor sprayers.
Firing Liquor Diversion: The automated process of preventing flow to the liquor sprayers.
Firing Liquor Heaters:
Direct Steam Heater: Firing liquor is heated by steam injected into the firing liquor flow.
Indirect Steam Heater: Firing liquor is heated in a shell-and-tube heat exchanger.
Firing Liquor Pump: Any pump that delivers firing liquor to the liquor header.
Furnace-Pressure (high or low) Interlock: A furnace pressure sensing system providing protection from
predetermined high or low furnace gas pressures.
Hot Restart: Re-establishing liquor firing after a flame out, partial black out or furnace trip (no auxiliary fuel
burner in service) with a hot smelt bed.
Liquor Purge Credit: A system that proves that the firing liquor header(s) contains only firing liquor.
Lower Furnace Wash System: A system of interlocks and a multiple position switch that bypasses the firing
liquor refractometers to permit washing of the lower furnace once the operator has verified furnace conditions
are appropriate for entry of wash water.
Managed System: A system using jumper tags and logs to track temporary system changes.
Moisture Balance: An analytical instrument used to determine the total solids content of black liquor.
Monitor: To sense and alarm a condition requiring attention, without initiating corrective action.
Non-Operating Water Source: Any water or weak black liquor that is not part of the process cycle (i.e.,
wash water, cascade fire protection water, etc.).
Operating Water Source: Any water or weak black liquor that is part of the process cycle (i.e., direct contact
evaporator dilution water, gland seal water, steam for heaters, and steam out connections, etc.).
Precipitator Outlet Temperature: Temperature of the flue gases leaving an electrostatic precipitator of a
recovery boiler system.
Prove: To establish, by measurement or test, the existence of a specified condition such as flame, level,
flow, pressure, temperature, or position.
Recirculation Valve: A valve on the black liquor header that when open allows the black liquor to flow through
the header(s) and recirculate back to the final evaporator or storage. The recirculation valve can also be a
valve that allows black liquor to constantly recirculate from the black liquor firing header back to a pressurized
black liquor storage on high solids fired recovery boilers. These recirculation valves shall be interlocked in
the safe firing of black liquor firing and tripping logic.
Recovery Superintendent: Person having direct operational responsibility for the recovery boiler.
Refractometer: An optical instrument that measures the dissolved solids in black liquor; it will not measure
suspended solids.
Supervise: To sense and alarm a condition requiring attention, and automatically initiate corrective action.
Total Solids: All non-water constituents of the black liquor which is the sum of dissolved and suspended
material in the liquor.
CNCG collection system: the gas collection and transport system used to convey gases from the CNCG
sources to the recovery boiler, or other combustion device.
CNCG system: the collection of equipment including the digester, turpentine recovery, evaporator, and steam
stripper systems.
Dilute noncondensible gas (DNCG): gas containing a concentration of sulfur compounds that is below
the lower explosion limit (LEL), frequently referred to as High Volume, Low Concentration Gases (HVLC).
The DNCG definition is exclusive of volume.
DNCG collection system: the gas collection and transport system used to convey gases from the DNCG
system to the recovery boiler, or other combustion device.
DNCG system: the collection of equipment including the pulp washing, knotter, screen, decker, and oxygen
delignification systems, black liquor storage tanks, and boiler house chemical ash mix tank.
EPA: Environmental Protection Agency.
ESP: emergency shutdown procedure (ESP) M the steps taken to shutdown a recovery boiler in a very rapid,
crash method. This procedure is used to reduce the possibility of an unsafe condition, such when water is
entering the furnace from a leaking water wall tube, causing a smelt-water explosion. Operating devices, such
as valves and dampers are automatically taken to a safe position and liquor burning is discontinued. (See
the Safe Guidelines for Black Liquor Burning.)
Firm power: Two independently supplied AC sources not susceptible to the same interruption. Uninterruptible
power supply or emergency generator power, sufficient duration of the power is available to permit a safe
and controlled shutdown upon loss of the primary power supply.
Flammability limits: a fuel is flammable within two limits referred to as the UEL and LEL. Between these
percentages of a fuel-air mixture, the gas once ignited propagates a self-sustaining flame.
Hazardous air pollutants (HAP): Phase I of the EPA Cluster Rule sets standards for these emissions at
all pulping and bleaching facilities in the USA.
High Volume, Low Concentration (HVLC): generally those gases that represent high volume streams with
a concentration of sulfur compounds that is below the lower explosion limit (LEL). The term does not reflect
all of the low concentration streams in a mill, as some are low volume.
Lower Explosion Limit (LEL): a fuel-air mixture below this limit does not have enough fuel to support a
flame. The LEL is fuel dependent. (See flammability limits.)
Low volume, high concentration (LVHC): generally those gases that represent low volume streams with
a concentration of sulfur compounds that is above the upper explosion limit (UEL). The term does not reflect
all of the high concentration streams in a mill, as some are high volume. (See concentrated noncondensible
gas.)
Maximum flame propagation (MFP): the fastest velocity at which a flame will travel through a flammable
vapor.
Methanol (CH30H): an alcohol by-product created during the pulping and bleaching process by the derogation
of the methoxy groups on lignin. Methanol is flammable and provides positive net Btu value. Methanol is
water soluble and may be found in solution or as a vapor.
Noncondensible gas (NCG): refers to the gases containing sulfur and/or organic compounds, i.e., CNCG,
DCNG, and SOG. Some mills refer to NCG as TRS gases.
Other waste streams: refers to any other waste stream that may be identified in the future for collection
and treatment similar to the NCG.
Oven-dried pulp (ODP): a pulp sample at zero percent (0.0%) moisture content by weight.
Recovery boiler building (or area): this referring to the recovery boiler building, battery limit or whatever
boundary is used within a mill to identify the areas around a recovery boiler that are affected by an ESP.
Personnel are not to enter these areas until after an ESP is completed and entry is permitted.
Red oil: mixture of turpenes and TRS compounds.
Soap: a by-product formed during the pulping process by the reaction of alkali and fatty wood acids.
Interlock - A device that senses a limit or off- limit condition or an improper sequence of events. It causes
shutdown of the offending or related piece of equipment, or it prevents proceeding in an improper sequence,
to prevent a hazardous condition. Direct signals rather than transmitted signals shall be used wherever
possible to actuate interlocks.
Monitor - To sense and alarm a condition requiring attention, without initiating corrective action.
Precipitator -A means (usually electrostatic) of collecting dust in the flue gases just before they go up the
stack. The flue gases pass through a high- voltage electric field and dust particles take on an electrostatic
charge. The charged dust particles are then attracted to oppositely charged plates or wire in the chamber.
The dust particles attach themselves to the plate or the wire and accumulate into clumps that are too heavy
to be carried in the flue gas stream. These clumps fall into a hopper and are carried away.
Precipitator Outlet Temperature - Temperature of the flue gases leaving an electrostatic precipitator of a
recovery boiler system.
Supervise - To sense and alarm a condition requiring attention. This may also automatically initiate corrective
action.
Total Solids - All non-water constituents of the black liquor, which is the sum of dissolved and suspended
material in the liquor.
Evaporator, Cyclone: An evaporator in the shape of a cylinder in which the flue gases enter tangentially
near the bottom and exit at the center of the top. The black liquor is sprayed into the flue gases at the tangential
entrance and around the top of the cylinder. The concentrated black liquor flows down the sides of the cyclone
cylinder into a funnel and out the bottom. The evaporated moisture is carried out the top with the flue gases.
A cyclone evaporator is a direct contact evaporator.
Evaporator, Direct Contact: A heat exchanger (Cascade or Cyclone Evaporators) in which hot flue gases
are in direct contact with the black liquor. As the flue gases heat the liquor, water is evaporated. This is used
to concentrate the black liquor up to a minimum of 58 percent total solids for firing.
Functional Test: A method of proving all elements of a system operate as designed.
Micro Processor: An intelligent piece of hardware, usually capable of executing only pre-defined programs.
It usually cannot store or retrieve data from bulk storage devices.
Modification: A change or alteration that results in a deviation from the original design specifications or
criteria.
Monitor: A means of showing (or reminding) the operator of conditions as they occur. A monitor displays a
condition or measurement.
Noxious Stack Gas Analyzers: A group of gas analyzers which measure the presence and concentration
of objectionable gases which are contained in the flue gases of a recovery boiler. Examples are: TRS (totally
reduced sulfur), SO2 (sulfur dioxide), NOX (Nitrogen Oxides), etc.
Opacity (Smoke, Particulate): The measurement of light transmittance through a duct or stack. By proper
calibration methods an opacity meter can measure particulate matter solids suspended in a gas stream,
i.e., flue gases. An opacity meter can also measure smoke density, turbidity in liquids, etc. It is basically a
means of measuring the loss of light between a light source and a light receiver.
Percent Total Solids in Black Liquor: The percentage of solids by weight in black liquor fluid in the recovery
system. For example, if the black liquor is 70% solids, then 30% is water.
Powered Relief Valve: An electrically or pneumatically operated quick opening valve which relieves excess
steam pressure. It is generally set at a lower pressure than mechanically (spring) operated relief valves.
Precipitator: A means (usually electrostatic) for collecting dust in the flue gases just before they go up the
stack. The flue gases pass through a high voltage electric field and dust particles take on an electrostatic
charge. The charged dust particles are then attracted to oppositely charged plates or wire in the chamber.
The dust particles attached themselves to the wire where they precipitate into large groups or clumps which
are too heavy to be carried by the flue gas stream. These clumps fall into a hopper where they are removed.
Primary Black Liquor Heater: Usually a direct contact heater which injects steam directly into the low
temperature black liquor. This heater is normally located on the suction side of the black liquor nozzle pump.
Indirect heaters may be used to avoid dilution of the black liquor.
PC: This abbreviation may represent programmable controller, or personal computer, depending on the
context of its use. Throughout these recommendations, PC is used to represent programmable controller.
Programmable Logic Controller (PLC): A digital first level control device utilized for sequencing operations
which are configured using ladder logic and may have limited analog or continuous control capability.
Record: A measurement that is continuously collected over a given time sample, using a chart recorder or
trend log in a DCS system. NOTE: The time sample rate selected represents the most accurate record.
Safety Instrumented System (SIS): (ISA-S84.01 P.3.1.53) System composed of sensors, logic solvers, and
final control elements for the purpose of taking the process to a safe state when predetermined conditions
are violated. Other terms commonly used include Emergency Shutdown Procedure/System (ESP), Safety
Shutdown System (SSD), Safety Interlock System and Flame Safety Supervisory System (FSSS).
SAMA Logic: Represents the total control loop philosophy with symbols and a diagramming format. (SAMA-
Scientific Apparatus Manufacturers Association).
Secondary Black Liquor Heater: Usually a direct contact heater which injects steam directly into the warm
black liquor. This heater is between the discharge of the black liquor nozzle pump and the black liquor spray
nozzles in the furnace. Indirect heaters may be used to avoid dilution of the black liquor.
Smelt Bed Camera: A video camera to observe smelt bed and combustion conditions.
Smelt Spout: A trough which drains the molten smelt from the furnace into the dissolving tank. It is cooled
to retard spout wastage by molten smelt. Water is commonly used as the cooling medium.
Soot Blower: A device using steam or compressed air for blowing dust, soot and ash from the fire side of
the boiler tubes. Most soot blowing systems operate automatically and usually have a sequence control to
blow in a specific pattern or arrangement.
APPENDIX C BIBLIOGRAPHY
Adams, T. N. and W. J. Frederick. Kraft Recovery Boiler Physical and Chemical Processes. The American
Paper Institute. 1988.
Adams, Terry N. Kraft Recovery Boilers. TAPPI Press. 1997.
American Forest & Paper Association (AF&PA) Recovery Boiler Committee. Guidelines and Checklist for
Specification and Construction of Black Liquor Recovery Boilers. www.afandpa.org
American Forest & Paper Association (AF&PA) Recovery Boiler Committee, Operations and Maintenance
Subcommittee. Recovery Boiler Safety Audit Guidelines. www.afandpa.org
American Forest & Paper Association (AF&PA) Recovery Boiler Committee. Operations and Maintenance
Subcommittee. The Recovery Boiler Reference Manual for Owners and Operators of Kraft Recovery Boilers,
Volumes I, II, and III. www.afandpa.org
American Society for Nondestructive Testing. Nondestructive Testing. Recommended Practice SNT-TC-1A.
www.asnt.org.
American Society of Mechanical Engineers (ASME). Boiler and Pressure Vessel Code. Section I: Power
Boilers; Section VII: Recommended Rules for Care of Power Boilers. www.asme.org.
Barna, J. L. and E. F. Radke. “Comparative study of membrane temperatures and stresses in composite
tube recovery boilers.” Presented at TAPPI Engineering September 1988.
Barna, J. L. and R. J. Mattie, et. al. “Corrosion Experience in Black Liquor Recovery Boilers.” Presented at
the TAPPI Kraft Recovery Operations Seminar, January 1989.
Black Liquor Recovery Boiler Advisory Committee (BLRBAC). Materials and Welding Guidelines for Black
Liquor Recovery Boilers (DRAFT). www.blrbac.net.
Black Liquor Recovery Boiler Advisory Committee (BLRBAC). Recommended Good Practice: Emergency
Shutdown Procedure (ESP) and Procedure for Testing ESP System for Black Liquor Recovery Boilers, and
Recommended Good Practice: Guidelines for Post-ESP Procedures for Black Liquor Recovery Boilers.
www.blrbac.net
Black Liquor Recovery Boiler Advisory Committee (BLRBAC). Recommended Good Practice: Fire Protection
In Direct Contact Evaporators and Associated Equipment. www.blrbac.net
Black Liquor Recovery Boiler Advisory Committee (BLRBAC). Recommended Good Practice: Installation
Checklist and Classification Guide for Instruments and Control Systems Used in Operation of Black Liquor
Recovery Boilers. www.blrbac.net
Black Liquor Recovery Boiler Advisory Committee (BLRBAC). Recommended Good Practice: Safe Firing
of Auxiliary Fuel in Black Liquor Recovery Boilers. www.blrbac.net
Black Liquor Recovery Boiler Advisory Committee (BLRBAC). Recommended Good Practice: Safe Firing
of Black Liquor in Black Liquor Recovery Boilers. www.blrbac.net
Black Liquor Recovery Boiler Advisory Committee (BLRBAC). Recommended Good Practice: Thermal
Oxidation of Waste Streams in Black Liquor Recovery Boilers Recovery Boilers. www.blrbac.net
Black Liquor Recovery Boiler Advisory Committee (BLRBAC). Recommended Rules for Personnel Safety
for Black Liquor Recovery Boilers. www.blrbac.net
European Committee for Standardization (CEN). Water-Tube Boilers and Auxiliary Installations. Standard
EN 12952.
Fapet OY. Papermaking Science and Technology. Book 6B: Chemical Pulping. TAPPI Press. 1999.
Feedwater Quality Task Group for the Industrial Boiler Subcommittee of the ASME Research Committee
on Water in Thermal Power Systems. Consensus of Operating Practices for the Control of Feedwater and
Boiler Water Quality in Modern Industrial Boilers. 1979.
Hough, G. Chemical Recovery in the Alkaline Pulping Processes. Third Edition. TAPPI Press. 1992.
Joint Textbook Committee of the Paper Industry. Pulp and Paper Manufacture. Third Edition. Volume 5,
Alkaline Pulping. 1989. www.tappi.org
Joint Textbook Committee of the Paper Industry. Pulp and Paper Manufacture. Third Edition. Volume 4, Sulfite
Science and Technology. 1985. www.tappi.org
Keiser, J. R., et. al. “Why Do Kraft Recovery Boiler Composite Floor Tubes Crack?” TAPPI Journal,
Vol.-84:No.8. TAPPI Press. 2001.
Keiser, J. R., et. al. “Recent Observations of Recovery Boiler Primary Air Port Cracking and Characterizations
of Environmental Conditions.” Presented at the 2002 TAPPI Fall Technical Conference. TAPPI Press. 2002.
Mimms, A. Kraft Pulping, A Compilation of Notes. TAPPI Press. 1989.
National Board of Boiler and Pressure Vessel Inspectors. National Board Inspection Code. ANSI / NB-23.
www.nationalboard.org
Power Specialists Associates. AF&PA CBT-Based Recovery Boiler Training Program.
www.psa-engineering.com
Singer, Joseph G. Combustion Fossil Power. 4th Edition. Combustion Engineering, Inc. 1991.
Sodahuskommitten (Swedish-Norwegian Recovery Boiler Committee). Bulletins A, B, C, D, E, and F.
www.sodahuskommitten.se
Smook, G. A. Handbook for Pulp and Paper Technologists. Joint Textbook Committee of the Paper Industry.
1986.
Suomen Soodakattilayhdistys (Finnish Recovery Boiler Committee). Recommended Procedure for
Incineration of Noncondensible Gases. www.soodakattilayhdistys.fi
Stultz, S. C. and J. B. Kitto.-Steam: Its Generation and Use. 41rst Edition. The Babcock and Wilcox Company,
2005.
TAPPI. Chloride and potassium measurement and control in the pulping and chemical recovery cycle.
Technical Information Paper TIP 0416-15 2005. www.tappi.org
TAPPI. Collection and burning of concentrated noncondensible gases: regulations, design, and operation.
Technical Information Paper TIP 0416-09 2008. www.tappi.org
TAPPI. Design engineer decisions tree: paper mill boiler feedwater. Technical Information Paper TIP 0416-04
2005. www.tappi.org
TAPPI. Estimating the first melting temperature of fireside deposits in recovery boilers. Technical Information
Paper TIP 0416-12 2004. www.tappi.org
TAPPI. Evaluating reverse osmosis for treating makeup to the boiler feedwater in a pulp and paper mill.
Technical Information Paper TIP 0416-07 2006. www.tappi.org
TAPPI. Guidelines for evaluating quality of boiler tube butt welds with ultrasonic testing. Technical Information
Paper TIP 0402-31 2006. www.tappi.org
TAPPI. Guidelines for obtaining high quality radiographic testing of butt welds in boiler tubes. Technical
Information Paper TIP 0402-33 2006. www.tappi.org
TAPPI. Guidelines for replacement of generating bank tubes with expanded joints in two-drum boilers.
Technical Information Paper TIP 0416-08 2002. www.tappi.org
TAPPI. Guidelines for specification and inspection of electric resistance welded (ERW) and seamless boiler
tube for critical and non-critical service. Technical Information Paper TIP 0402-13 2005.www.tappi.org
TAPPI. Inspection for cracking of composite tubes in black liquor recovery boilers. Technical Information Paper
TIP 0402-30 2001. www.tappi.org
TAPPI. Installation and repair of pin studs in black liquor recovery boilers. Technical Information Paper TIP
0402-15 2002. www.tappi.org
TAPPI. Keys to successful chemical cleaning of boilers. Technical Information Paper TIP 0416-06 2004.
www.tappi.org
TAPPI. Recovery boiler energy efficiency improvements. Technical Information Paper TIP 0416-16 2008.
www.tappi.org
TAPPI. Recovery boiler performance calculation M short form. Technical Information Paper TIP 0416-01 2007.
www.tappi.org
TAPPI. Response to contamination of high purity boiler feedwater. Technical Information Paper TIP 0416-05
2005. www.tappi.org
TAPPI. Solids Content of Black Liquor. Test Method T 650 om-05. www.tappi.org
TAPPI. Stripping of kraft pulping process condensates: regulations, design and operation. Technical
Information Paper TIP 0416-10 2008. www.tappi.org
TAPPI. Ultrasonic testing (UT) for tube thickness in black liquor recovery boilers. Part I: Guidelines for accurate
tube thickness testing. Part II: Default layouts for tube thickness surveys in various boiler zones. Technical
Information Paper TIP 0402-18 2001. www.tappi.org
TAPPI. Ultrasonic technician performance test for boiler tube inspection. Technical Information Paper TIP
0402-21 2008. www.tappi.org
TAPPI. Water quality and monitoring requirements for paper mill boilers operating on high purity feedwater.
Technical Information Paper TIP 0416-03 2005. www.tappi.org
TAPPI. Water quality guidelines and monitoring requirements for paper mill boilers operating with softened
makeup water. Technical Information Paper TIP 0416-14 2005. www.tappi.org
Tran, H., et. al. “Removal of Recovery Boiler Fireside Deposits By Thermal Shedding.” Presented at the 1992
International Chemical Recovery Conference. TAPPI Press. 1992.