The acoustic horn system is designed to remove contaminants from the boiler’s heating surfaces using a powerful sound wave generated by an acoustic horn installed in a selected location within the boiler.
The acoustic transducer, built into the acoustic horn, periodically generates high-pressure, low-frequency sound waves. The source of vibration is a titanium diaphragm in the acoustic transducer, which generates a series of sound waves propagating through a voice tube sized and shaped to suit the operating conditions.
The system is powered by compressed air from the existing power plant service air network.
The system is controlled by a dedicated system that automatically monitors power supply conditions and controls the frequency at which the system is activated.
Schedule of activities
Project Timeline
The installation of acoustic horn for the OP-650 boilers was preceded by a site visit to Units 7 and 8, during which the technical conditions were verified and the potential installation locations were determined.
Based on an analysis of the OP-650 boiler’s technical documentation, the feasibility of safe and effective acoustic horn use was assessed and assumptions for further design work were prepared.
A team of specialists from Prague urgently arrived at the facility to conduct detailed frequency response measurements and perform the necessary acoustic calculations to optimize the equipment’s operating parameters.
Simultaneously, the necessary measurement equipment was delivered and installed at the facility, allowing for precise adjustment of the acoustic horn to the boiler’s conditions and preparing the facility for further implementation.
Client’s Problems
The current lack of effective and non-invasive methods for removing deposits in the OP-650 boiler resulted in the accumulation of contaminants on the heat exchange surfaces, leading to poor boiler performance and reduced efficiency. The accumulating deposits restricted exhaust gas flow and disrupted heat exchange, negatively impacting the stability of the combustion process.
The lack of an effective boiler cleaning system made it difficult to maintain optimal operating conditions, leading to increased fuel consumption, increased emissions, and more frequent maintenance downtime
Installation Challenges
The acoustic horn system was designed to safely and effectively remove deposits resulting from fuel combustion in the OP-650 boiler at the Rybnik Power Plant. Its purpose is to improve heat transfer efficiency by keeping the heating surfaces clean without interrupting boiler operation.
The OP-650 boiler operates at high temperatures and steam pressures (up to 540°C and 13.65 MPa downstream of the boiler). However, these parameters are not constant and vary depending on the type and calorific value of the fuel used. Varying fuel quality affects combustion characteristics, which in turn modifies the propagation of acoustic waves within the boiler. This requires individual adjustment of the acoustic horn frequency and power to actual operating conditions.
The acoustic horn must operate reliably in environments with high dust levels, fluctuating temperatures, and dynamic thermal loads. Thanks to its cyclical and non-contact operation, the device eliminates deposits without the risk of damaging boiler components, which is particularly important in hard-to-reach areas of inter-superheaters and convection surfaces, where traditional cleaning methods are ineffective or invasive.
- Acoustic horn
- A special mounting element fits into the boiler hatch
- Control cabinet with a Sielems LOGO controller
What We Delivered as Part of the Project?
- Operational Analysis and Site Inspection – We analyzed the operation of the OP-650 boiler, identifying areas with the highest ash deposition rates. Intervention points and equipment operating parameters were determined.
- System Technical Design – Based on operational data, an acoustic horn system was designed, taking into account the boiler geometry, thermal conditions, and compressed air availability.
- Component Delivery – A complete set of equipment was delivered:
- High-temperature and dust-resistant acoustic horn
- Solenoid valves, air manifolds, piping, and installation accessories.
- Assembly and Integration – Within the designated downtime window, the equipment was installed, piping was routed, and connection to the existing compressed air system was completed.
- Commissioning and Testing – The system was commissioned, tightness and performance tests were conducted under load. Sound pulse parameters were configured.
- Staff Training and Documentation – The operations team was trained in system operation. Full technical documentation and operating recommendations were provided.