[{"data":1,"prerenderedAt":698},["ShallowReactive",2],{"site-footer-common":3,"glossary:reformer-furnace":45,"glossary-related:reformer-furnace":155},{"id":4,"extension":5,"footer":6,"meta":40,"navbar":41,"stem":43,"__hash__":44},"common\u002Fcommon.yml","yml",{"tagline":7,"links":8,"sections":9},"Acoustic cleaning intelligence for industrial fouling, soot, ash, dust and build-up.",[],[10,19,31],{"title":11,"links":12},"Product",[13,16],{"label":14,"to":15},"How it works","\u002F#product",{"label":17,"to":18},"Cost assessment","\u002F#hero",{"title":20,"links":21},"Company",[22,25,28],{"label":23,"to":24},"What we build","\u002F#about",{"label":26,"to":27},"Careers","\u002F#careers",{"label":29,"to":30},"Contact","\u002F#contact",{"title":32,"links":33},"Resources",[34,37],{"label":35,"to":36},"Blog","\u002Fresources\u002Fblog",{"label":38,"to":39},"Glossary","\u002Fglossary",{},{"links":42},[],"common","YocmZRy1AYfBbpgGVms-zhdiABlF8VTxHx6h4rDmZBA",{"id":46,"title":47,"aliases":48,"body":52,"category":135,"description":136,"extension":137,"meta":138,"navigation":139,"path":140,"relatedTerms":141,"seo":146,"sources":149,"stem":153,"term":47,"__hash__":154},"glossary\u002Fglossary\u002Freformer-furnace.md","Reformer furnace",[49,50,51],"steam methane reformer","SMR","primary reformer",{"type":53,"value":54,"toc":128},"minimark",[55,68,73,76,95,99,106,110],[56,57,58,59,63,64,67],"p",{},"A ",[60,61,62],"strong",{},"reformer furnace"," — almost always a ",[60,65,66],{},"steam methane reformer (SMR)"," in modern refineries and ammonia plants — produces hydrogen by reacting natural gas with steam at ~850 °C over a nickel catalyst inside vertical tubes. The radiant box delivers the reaction heat from burner walls; flue gas leaves to a convection section recovering remaining heat into process steam and feed preheat.",[69,70,72],"h2",{"id":71},"fouling-in-the-convection-bank","Fouling in the convection bank",[56,74,75],{},"The SMR convection bank is particularly fouling-prone because:",[77,78,79,89,92],"ul",{},[80,81,82,83,88],"li",{},"High-temperature flue-gas surfaces sit above the ",[84,85,87],"a",{"href":86},"\u002Fglossary\u002Fammonium-bisulphate","ammonium bisulphate"," dew point but cool sufficiently below it on the cold-end",[80,90,91],{},"SO₃ from any sulphur leaving the desulphurisers reacts with ammonia slip from upstream SCR (if installed) to form ABS",[80,93,94],{},"Deposits consolidate on finned-tube banks reducing heat recovery",[69,96,98],{"id":97},"cleaning","Cleaning",[56,100,101,105],{},[84,102,104],{"href":103},"\u002Fglossary\u002Fsonic-horn","Sonic horns"," on the SMR convection-bank cold end keep ABS deposits from consolidating. Hydrogen-plant reliability is critical to refinery operation (any unit upstream that needs hydrogen will derate without it), so the value of avoided outages is high.",[69,107,109],{"id":108},"related-terms","Related terms",[77,111,112,118,123],{},[80,113,114],{},[84,115,117],{"href":116},"\u002Fglossary\u002Feconomiser","Economiser",[80,119,120],{},[84,121,122],{"href":86},"Ammonium bisulphate",[80,124,125],{},[84,126,127],{"href":103},"Sonic horn",{"title":129,"searchDepth":130,"depth":130,"links":131},"",2,[132,133,134],{"id":71,"depth":130,"text":72},{"id":97,"depth":130,"text":98},{"id":108,"depth":130,"text":109},"steel-refining","A reformer furnace — almost always a steam methane reformer (SMR) in modern refineries and ammonia plants — produces hydrogen by reacting natural gas with steam at ~850 °C over a nickel catalyst inside vertical tubes. The radiant box delivers the reaction heat from burner walls; flue gas leaves to a convection section recovering remaining heat into process steam and feed preheat.","md",{},true,"\u002Fglossary\u002Freformer-furnace",[142,143,144,145],"economiser","ammonium-bisulphate","hydrogen-plant","sonic-horn",{"title":147,"description":148},"Reformer furnace — steam methane reformer for hydrogen production","A reformer furnace produces hydrogen by reacting natural gas with steam over a nickel catalyst at high temperature. Convection-section ammonium-salt fouling is the principal cleaning concern.",[150],{"title":151,"url":152},"Wikipedia — Steam reforming","https:\u002F\u002Fen.wikipedia.org\u002Fwiki\u002FSteam_reforming","glossary\u002Freformer-furnace","Lxt5d6xig_Gcj6inJUsRbXzUeJU_H8nrT3ouWJGaJcc",[156,294,458],{"id":157,"title":117,"aliases":158,"body":161,"category":277,"description":278,"extension":137,"meta":279,"navigation":139,"path":116,"relatedTerms":280,"seo":285,"sources":288,"stem":292,"term":117,"__hash__":293},"glossary\u002Fglossary\u002Feconomiser.md",[159,160],"economizer","feedwater economiser",{"type":53,"value":162,"toc":271},[163,189,193,196,213,216,220,225,229,237,239],[56,164,165,166,168,169,173,174,178,179,183,184,188],{},"An ",[60,167,142],{}," is the tube bank in a boiler's ",[84,170,172],{"href":171},"\u002Fglossary\u002Fconvective-pass-backpass","convective pass"," that recovers residual heat from the flue gas by preheating boiler feedwater. It sits downstream of the ",[84,175,177],{"href":176},"\u002Fglossary\u002Freheater","reheater"," and upstream of the ",[84,180,182],{"href":181},"\u002Fglossary\u002Fair-heater","air heater","; economiser performance directly affects boiler ",[84,185,187],{"href":186},"\u002Fglossary\u002Fheat-rate","heat rate",".",[69,190,192],{"id":191},"fouling","Fouling",[56,194,195],{},"Two failure modes dominate:",[77,197,198,204],{},[80,199,200,203],{},[60,201,202],{},"Ash bridging"," between tubes — gas can no longer pass freely; ΔP across the economiser rises",[80,205,206,212],{},[60,207,208],{},[84,209,211],{"href":210},"\u002Fglossary\u002Flarge-particle-ash","Large-particle ash"," dropping out of the gas stream onto economiser hoppers — bridges and pluggage in the hopper itself",[56,214,215],{},"The first reduces gas-side heat transfer and forces gas channelling around the blocked area; the second causes hopper extraction to fail and back-pressures the gas path.",[69,217,219],{"id":218},"sonic-horn-duty","Sonic-horn duty",[56,221,222,224],{},[84,223,104],{"href":103}," mounted on the economiser shell and hopper are particularly effective because economiser deposits are dry, friable and respond well to acoustic dislodging. Plants commonly report 1–2% boiler-efficiency recovery after horn installation on heavily-fouled economisers.",[69,226,228],{"id":227},"economiser-scr-adjacency","Economiser-SCR adjacency",[56,230,231,232,236],{},"On units with an upstream ",[84,233,235],{"href":234},"\u002Fglossary\u002Fhigh-dust-low-dust-tail-end-scr","high-dust SCR",", the economiser receives the same large-particle ash that the SCR is designed against. LPA screens between SCR and economiser are common; sonic horns help keep both surfaces clean.",[69,238,109],{"id":108},[77,240,241,247,252,258,263,267],{},[80,242,243],{},[84,244,246],{"href":245},"\u002Fglossary\u002Fboiler","Boiler",[80,248,249],{},[84,250,251],{"href":171},"Convective pass \u002F backpass",[80,253,254],{},[84,255,257],{"href":256},"\u002Fglossary\u002Fsuperheater","Superheater",[80,259,260],{},[84,261,262],{"href":181},"Air heater",[80,264,265],{},[84,266,211],{"href":210},[80,268,269],{},[84,270,127],{"href":103},{"title":129,"searchDepth":130,"depth":130,"links":272},[273,274,275,276],{"id":191,"depth":130,"text":192},{"id":218,"depth":130,"text":219},{"id":227,"depth":130,"text":228},{"id":108,"depth":130,"text":109},"boiler","An economiser is the tube bank in a boiler's convective pass that recovers residual heat from the flue gas by preheating boiler feedwater. It sits downstream of the reheater and upstream of the air heater; economiser performance directly affects boiler heat rate.",{},[277,281,282,283,284,145],"convective-pass-backpass","superheater","air-heater","large-particle-ash",{"title":286,"description":287},"Economiser — final tube bank that preheats feedwater with flue-gas heat","An economiser is the final tube bank in a boiler's convective pass that recovers heat from the flue gas by preheating feedwater. Ash bridging in the economiser is a routine cleaning challenge.",[289],{"title":290,"url":291},"Wikipedia — Economizer","https:\u002F\u002Fen.wikipedia.org\u002Fwiki\u002FEconomizer","glossary\u002Feconomiser","kh4Q3Eo9CNl35_b843VUXSI8fDZuiLZqLyB__NSzVH4",{"id":295,"title":296,"aliases":297,"body":302,"category":442,"description":443,"extension":137,"meta":444,"navigation":139,"path":86,"relatedTerms":445,"seo":449,"sources":452,"stem":456,"term":122,"__hash__":457},"glossary\u002Fglossary\u002Fammonium-bisulphate.md","Ammonium bisulphate (ABS)",[298,299,300,301],"ABS","ammonium bisulfate","ammonium sulphate","NH4HSO4",{"type":53,"value":303,"toc":437},[304,326,330,333,369,373,410,412],[56,305,306,309,310,313,314,318,319,321,322,188],{},[60,307,308],{},"Ammonium bisulphate (NH₄HSO₄, ABS)"," — sometimes written ",[311,312,299],"em",{}," in US technical literature — is a sticky, low-melting deposit formed when ",[84,315,317],{"href":316},"\u002Fglossary\u002Fammonia-slip","slipped ammonia"," reacts with SO₃ in cooling flue gas. ABS condenses between roughly 150 °C and 250 °C, coating the cold end of any ",[84,320,182],{"href":181}," downstream of an ",[84,323,325],{"href":324},"\u002Fglossary\u002Fselective-catalytic-reduction","SCR",[69,327,329],{"id":328},"why-abs-is-the-most-feared-cold-end-deposit","Why ABS is the most-feared cold-end deposit",[56,331,332],{},"ABS is uniquely problematic because it is:",[77,334,335,341,351,357,363],{},[80,336,337,340],{},[60,338,339],{},"Sticky"," — bonds tenaciously to air-heater baskets and economiser tubes",[80,342,343,346,347],{},[60,344,345],{},"Hygroscopic"," — picks up moisture and accelerates ",[84,348,350],{"href":349},"\u002Fglossary\u002Fcold-end-corrosion-dew-point-corrosion","cold-end corrosion",[80,352,353,356],{},[60,354,355],{},"Hard to remove"," — resists steam sootblowing once consolidated",[80,358,359,362],{},[60,360,361],{},"Self-reinforcing"," — coated surfaces trap more ash, accelerating fouling",[80,364,365,368],{},[60,366,367],{},"Concentrated in a narrow temperature band"," — predictably plugs the same air-heater rows",[69,370,372],{"id":371},"mitigation","Mitigation",[77,374,375,384,390,396,404],{},[80,376,377,383],{},[60,378,379,380],{},"Minimise ",[84,381,382],{"href":316},"ammonia slip"," at the SCR (the single biggest lever)",[80,385,386,389],{},[60,387,388],{},"Manage SO₃ formation"," — fuel sulphur control, catalyst formulation",[80,391,392,395],{},[60,393,394],{},"Avoid the dew-point window"," — keep cold-end gas temperature above the formation band",[80,397,398,403],{},[60,399,400,402],{},[84,401,104],{"href":103}," on the cold end"," — continuous cleaning prevents ABS from consolidating before periodic water-washing",[80,405,406,409],{},[60,407,408],{},"Water-washing campaigns"," — periodic offline washes restore air-heater performance",[69,411,109],{"id":108},[77,413,414,419,424,428,433],{},[80,415,416],{},[84,417,418],{"href":316},"Ammonia slip",[80,420,421],{},[84,422,423],{"href":324},"Selective Catalytic Reduction (SCR)",[80,425,426],{},[84,427,262],{"href":181},[80,429,430],{},[84,431,432],{"href":349},"Cold-end corrosion \u002F dew-point corrosion",[80,434,435],{},[84,436,127],{"href":103},{"title":129,"searchDepth":130,"depth":130,"links":438},[439,440,441],{"id":328,"depth":130,"text":329},{"id":371,"depth":130,"text":372},{"id":108,"depth":130,"text":109},"scr-sncr","Ammonium bisulphate (NH₄HSO₄, ABS) — sometimes written ammonium bisulfate in US technical literature — is a sticky, low-melting deposit formed when slipped ammonia reacts with SO₃ in cooling flue gas. ABS condenses between roughly 150 °C and 250 °C, coating the cold end of any air heater downstream of an SCR.",{},[446,447,283,448,145],"ammonia-slip","selective-catalytic-reduction","cold-end-corrosion-dew-point-corrosion",{"title":450,"description":451},"Ammonium bisulphate (ABS) — sticky deposit from SCR slip plus SO3","Ammonium bisulphate is a sticky low-melting deposit formed when slipped ammonia reacts with SO3 in cooling flue gas. The dominant cold-end fouling species on SCR-equipped boilers.",[453],{"title":454,"url":455},"POWER Magazine — SO3's impacts on plant O&M","https:\u002F\u002Fwww.powermag.com\u002Fso3s-impacts-on-plant-om-part-ii\u002F","glossary\u002Fammonium-bisulphate","eVfkw0arMYLXvUn7Eb2ZquRKgct13PXCySe8Iclt3GY",{"id":459,"title":127,"aliases":460,"body":464,"category":673,"description":674,"extension":137,"meta":675,"navigation":139,"path":103,"relatedTerms":676,"seo":683,"sources":686,"stem":696,"term":127,"__hash__":697},"glossary\u002Fglossary\u002Fsonic-horn.md",[461,462,463],"sonic horns","sonic cleaning horn","industrial sonic horn",{"type":53,"value":465,"toc":666},[466,497,501,509,513,581,585,622,626,634,636],[56,467,58,468,471,472,476,477,481,482,481,486,481,489,492,493,188],{},[60,469,470],{},"sonic horn"," is a pneumatically-driven sound emitter that produces high-intensity, low-frequency sound waves — typically between 60 and 400 Hz at sound pressure levels of 140 to 180 dB — used to dislodge particulate fouling from inside industrial process equipment. Sonic horns are the most common form of ",[84,473,475],{"href":474},"\u002Fglossary\u002Facoustic-cleaner","acoustic cleaner"," and the default specification for cleaning ",[84,478,480],{"href":479},"\u002Fglossary\u002Felectrostatic-precipitator","ESPs",", ",[84,483,485],{"href":484},"\u002Fglossary\u002Ffabric-filter","baghouses",[84,487,488],{"href":324},"SCR catalysts",[84,490,491],{"href":256},"boiler heat-transfer surfaces"," and ",[84,494,496],{"href":495},"\u002Fglossary\u002Fhopper","hoppers and silos",[69,498,500],{"id":499},"how-a-sonic-horn-works","How a sonic horn works",[56,502,503,504,508],{},"Compressed plant air admitted through a ",[84,505,507],{"href":506},"\u002Fglossary\u002Fsolenoid-valve","solenoid valve"," drives a metal diaphragm — typically titanium or 316 stainless — into resonant oscillation at the horn's fundamental frequency. The oscillating pressure field is amplified by an exponential bell horn and projected into the vessel as a near-spherical sound wave. Particulate already deposited on internal surfaces receives an oscillating acceleration that overcomes adhesion; loosened material is then carried out with the gas flow before it can sinter, bridge or bond. Because the cleaning is acoustic and non-contact, the horn can fire while the plant is online without tube erosion, refractory damage or thermal shock.",[69,510,512],{"id":511},"key-parameters","Key parameters",[514,515,516,529],"table",{},[517,518,519],"thead",{},[520,521,522,526],"tr",{},[523,524,525],"th",{},"Parameter",[523,527,528],{},"Typical range",[530,531,532,541,549,557,565,573],"tbody",{},[520,533,534,538],{},[535,536,537],"td",{},"Fundamental frequency",[535,539,540],{},"60–400 Hz",[520,542,543,546],{},[535,544,545],{},"Sound pressure level",[535,547,548],{},"140–180 dB",[520,550,551,554],{},[535,552,553],{},"Compressed-air consumption",[535,555,556],{},"8–14 Nm³\u002Fmin at 4–7 bar",[520,558,559,562],{},[535,560,561],{},"Operating temperature (with appropriate materials)",[535,563,564],{},"−40 °C to +500 °C",[520,566,567,570],{},[535,568,569],{},"Firing cycle",[535,571,572],{},"5–15 s burst, repeated every 3–15 minutes",[520,574,575,578],{},[535,576,577],{},"Mass",[535,579,580],{},"15–60 kg depending on horn size",[69,582,584],{"id":583},"frequency-selection","Frequency selection",[56,586,587,588,481,592,596,597,481,601,605,606,481,609,613,614,492,618,188],{},"Lower frequencies (60–125 Hz) project longer wavelengths and penetrate further into large open vessels — ",[84,589,591],{"href":590},"\u002Fglossary\u002Fpreheater-cyclone","preheater cyclones",[84,593,595],{"href":594},"\u002Fglossary\u002Frecovery-boiler","recovery-boiler superheaters",", large ",[84,598,600],{"href":599},"\u002Fglossary\u002Fesp-field-bus-section","ESP fields",[84,602,604],{"href":603},"\u002Fglossary\u002Fsilo","silos",". Higher frequencies (230–400 Hz) carry more energy per unit volume and suit finer dust loads in ",[84,607,608],{"href":484},"fabric-filter compartments",[84,610,612],{"href":611},"\u002Fglossary\u002Fhoneycomb-catalyst","catalyst layers"," and smaller hopper geometries. See ",[84,615,617],{"href":616},"\u002Fglossary\u002Flow-frequency-acoustic-cleaner","low-frequency acoustic cleaner",[84,619,621],{"href":620},"\u002Fglossary\u002Fhigh-frequency-acoustic-cleaner","high-frequency acoustic cleaner",[69,623,625],{"id":624},"sonic-horn-vs-steam-sootblower","Sonic horn vs steam sootblower",[56,627,628,629,633],{},"Sonic horns are increasingly specified alongside or in place of ",[84,630,632],{"href":631},"\u002Fglossary\u002Fsteam-sootblower","steam sootblowers"," because they consume no boiler-grade steam, cause no tube erosion, require almost no moving parts and can fire every few minutes without operator intervention. They are less effective on hard, fused slag than retractable steam lances, so on furnace waterwalls and high-temperature superheaters they typically complement rather than replace mechanical cleaning.",[69,635,109],{"id":108},[77,637,638,643,649,655,661],{},[80,639,640],{},[84,641,642],{"href":474},"Acoustic cleaner",[80,644,645],{},[84,646,648],{"href":647},"\u002Fglossary\u002Fsonic-sootblower","Sonic sootblower",[80,650,651],{},[84,652,654],{"href":653},"\u002Fglossary\u002Fbell-horn","Bell horn",[80,656,657],{},[84,658,660],{"href":659},"\u002Fglossary\u002Fdiaphragm-horn","Diaphragm horn",[80,662,663],{},[84,664,665],{"href":616},"Low-frequency acoustic cleaner",{"title":129,"searchDepth":130,"depth":130,"links":667},[668,669,670,671,672],{"id":499,"depth":130,"text":500},{"id":511,"depth":130,"text":512},{"id":583,"depth":130,"text":584},{"id":624,"depth":130,"text":625},{"id":108,"depth":130,"text":109},"core-technology","A sonic horn is a pneumatically-driven sound emitter that produces high-intensity, low-frequency sound waves — typically between 60 and 400 Hz at sound pressure levels of 140 to 180 dB — used to dislodge particulate fouling from inside industrial process equipment. Sonic horns are the most common form of acoustic cleaner and the default specification for cleaning ESPs, baghouses, SCR catalysts, boiler heat-transfer surfaces and hoppers and silos.",{},[677,678,679,680,681,682],"acoustic-cleaner","acoustic-cleaning-system","sonic-sootblower","bell-horn","diaphragm-horn","low-frequency-acoustic-cleaner",{"title":684,"description":685},"Sonic horn — definition, frequency, SPL and industrial applications","A sonic horn is a pneumatically-driven low-frequency sound emitter (typically 60–400 Hz at 140–180 dB SPL) used to dislodge particulate fouling from boilers, ESPs, baghouses and process vessels.",[687,690,693],{"title":688,"url":689},"Power Engineering — Sonic Horns: A User's Introduction","https:\u002F\u002Fwww.power-eng.com\u002Fcoal\u002Fsonic-horns-a-userrsquos-introduction\u002F",{"title":691,"url":692},"Power Engineering — Tuning in to Acoustic Cleaning","https:\u002F\u002Fwww.power-eng.com\u002Fcoal\u002Ftuning-in-to-acoustic-cleaning\u002F",{"title":694,"url":695},"Wikipedia — Sonic soot blowers","https:\u002F\u002Fen.wikipedia.org\u002Fwiki\u002FSonic_soot_blowers","glossary\u002Fsonic-horn","YzrhN0kKzqSaQo0wfn0rueNZ-V43mcg5zahqeWi3lnU",1782613756983]