Case Studies

At Lenzing OCT uses its Patented Linear Cleaning method as part of a regular maintenance schedule, which has resulted in fewer shutdowns and no unplanned stoppages.

During normal operation the composition of the ash and fouling can differ greatly, as does the degree level of fouling. This requires close and constant monitoring, followed by a flexible cleaning analysis and adaptive cleaning method. Since our services were employed at the plant, it has increased availability and reduced costly unplanned stoppages due to fouling.

During the thermal regeneration process in the fluidised bed boiler of this spent catalyst plant, flue gasses need to be cooled down very quickly or else toxic dioxins will be generated. This cooling is done in a cooling tower with water. Ash in the flue gasses causes contamination in the leading to a build-up of refractory and stones.

This paperboard production company started production in 2013 and OCT was brought on board to clean the plant’s biomass boiler during production and before shutdown prior to safety cleaning. Iggesund utilises our expertise and through close cooperation, we can schedule Linear Cleaning before problems occur.

This energy-from-waste plant in northern Germany has used Online Cleaning Technologies for more than four years. The plant employs a number of our online and offline services including CO2 cleaning, Stick Blasting and Patented Linear Cleaning. Using this combination of techniques, the client has been able to significant extend periods between shutdowns for manual cleaning to only once every year! Silos are cleaned with Stick Blasting, while the superheater is thoroughly cleaned using the Linear Cleaning method. During shutdowns OCT also assists with CO2 cleaning in the boiler and secondary combustion chamber.

This major energy-from-waste plant in Austria has several locations and a total of 9 production lines. Prior to taking on Online Cleaning in 2012, the plant performed traditional manual cleans in the boiler and the superheater and production had to stop every six weeks for manual deslagging. OCT provides regular online cleaning using our Patented Linear Method and water cannon. Both services can be used while the plant remains online and in full operation, improving availability and significantly extending periods between shutdowns.

This traditional energy-from-waste plant operates two separate production lines which process waste to produce electricity. The plant has had a strong operational track record for several decades. In 2004, in a bid to reduce production loss, the company employed an industrial cleaning firm to carry out shockwave cleaning using gas balloons. These results proved disappointing but ignited an interest in shockwave cleaning. This enabled OCT to pilot our Linear Cleaning Method in the boiler, furnace and the slope. The results were perceived so positively by plant management that we were taken on to provide our services regularly, enabling the plant to extend periods between shut downs significantly and increase production. Since taking us on 13 years ago, MVR Rugenberger Damm remains a satisfied OCT customer.

This major energy plant with has six boilers, and generates power using both biomass (70%) and coal (30%). Each unit has a capacity of 660MW, which combines to an overall capacity of 3.3GW. The client faced instable throughput followed by unexpected and costly shutdowns due to non-effective offline cleaning. The client hired us on a trial basis to carry out an online clean of one of its boilers, which we did while the boiler remained in full operation. “Get them back next week to clean all boilers”, was the response we had from the plant manager following our trial run. The job wasn’t without its challenges as the boilers are huge at more than 20 metres wide with temperatures up to 1600°C and direct flame radiation. However Online Cleaning Technologies can rise to almost any challenge.

Using ore this company produces high carbon ferromanganese silicomanganese and sinter, primarily using hydroelectric power. During the smelting process the electrodes lose performance as they’re damaged during the combustion process. Online Cleaning Technologies were able to repair or “reshape” the electrodes to increase output to the desired values.

This plant has been operating since 1975 and holds high environmental and operational standards. Up until 2014, production had to cease every 23-26 weeks for maintenance shutdown lasting 3-4 days for cleaning alone. During this cycle the boiler and furnace were cleaned manually following cooldown of the plant. Since 2014 Online Cleaning Technologies has performed regular Patented Linear Cleans in the boiler and cyclones to deslag the plant during operations. Due to our effective analysis and focused shockwaves, maintenance cycles can be postponed substantially. Intervals between shutdowns have now been extended 32 weeks due to the work carried out by OCT, and periods between shutdowns are expected to be extended further once various mechanical issues are overcome.

When fluidisation in the furnace became unstable or emissions changed, the furnace had to be shut down. The furnace and the boiler then required a rapid safety clean before entering the boiler for the offline clean of the bed.