Device, system and method for on-line explosive deslagging

• US 6,321,690 B1
• Filed: 09/10/1999
• Issued: 11/27/2001
• Est. Priority Date: 01/17/1997
• Status: Expired due to Term

• Current Assignee: Northamerican Industrial Services Incorporated
• Original Assignee: North American Industrial Services, Inc.
• Inventors: Zilka, Timothy, Howard, Donald, Prouty, Kurt, Zilka, Francis, Scaringe, Christopher, Youngs, William
• Primary Examiner(s): Ferensic, Denise L.
• Assistant Examiner(s): Lu, Jiping
• Application Number:
  US09/394,377
• Time in Patent Office: 809 Days
• Field of Search: 122/379, 165/84, 165/95
• US Class Current: 122/379
• CPC Class Codes: B08B 7/0007 by explosions
• CPC Class Codes: B08B 9/08 Cleaning containers, e.g. tanks
• CPC Class Codes: F23J 3/02 Cleaning furnace tubes; Cleaning flues or chimneys
• CPC Class Codes: F23J 3/023 cleaning the fireside of watertubes in boilers
• CPC Class Codes: F27D 1/12 incorporating cooling arrangements constructions of tube assemblies in general F28
• CPC Class Codes: F27D 1/1694 Breaking away the lining or removing parts thereof
• CPC Class Codes: F27D 25/006 using explosives
• CPC Class Codes: F27D 9/00 Cooling of furnaces or of charges therein F27D1/00, F27D3/00 take precedence
• CPC Class Codes: F28G 7/00 Cleaning by vibration or pressure waves
• CPC Class Codes: F28G 7/005 by explosions or detonations; by pressure waves generated by combustion processes

Abstract

A device, system and method permitting on-line explosives-based cleaning and deslagging of a fuel burning facility such as a boiler, furnace, incinerator, or scrubber. A coolant, such as ordinary water, is delivered to the explosives to prevent them from detonating due to the heat of the on-line facility. Thus, controlled, appropriately-timed detonation can be initiated as desired, and boiler scale and slag is removed without the need to shut down or cool down the facility. Alternative preferred embodiments include, but are not limited to: (1) using a non-liquid coolant, such as compressed air or other non-flammable gas, in place of the aforementioned liquid coolant; (2) using one or more highly-heat-resistant insulating materials to insulate the explosive and detonator cap, in place of or in addition to the aforementioned liquid or gaseous coolants; and (3) preparing and using a highly-heat-resistant explosive device, in place of or in addition to the aforementioned liquid or gaseous coolants, and/or the aforementioned highly-heat-resistant insulating materials, in any desired combination.

Claims

1. An explosives-based system for deslagging a hot online heat-exchange device, comprising:

an explosive device;

at least one cooling apparatus cooling said explosive device particularly while said explosive device is at any desired location within said hot online heat exchange device, thereby preventing heat from said hot online heat exchange device from detonating said explosive device prior to a time when it is desired to detonate at will said explosive device;

a cooling apparatus and explosive positioning system with said at least one cooling apparatus and said explosive device cooled thereby affixed thereto, enabling a force applied to said cooling apparatus and explosive positioning system to freely move said at least one cooling apparatus and said explosive device cooled thereby to said any desired location within said hot online heat exchange device and particularly into a proper position for deslagging, while cooling said explosive device; and

detonating means for detonating at will said explosive device.

2. The system of claim 1, said at least one cooling apparatus comprising:

a coolant-delivery apparatus delivering a coolant to said explosive device, said coolant so-cooling said explosive device.

3. The system of claim 2, said coolant comprising a liquid.

4. The system of claim 3, the liquid coolant comprising water.

5. The system of claim 2, said coolant comprising a gas.

6. The system of claim 5, the gaseous coolant comprising air.

7. The system of claim 2, said coolant-delivery apparatus comprising a semipermeable cooling envelope, thereby enabling said coolant to flow continuously into, through, and out of said cooling envelope and so-cool said explosive device.

8. The system of claim 2, said coolant-delivery apparatus comprising a cooling envelope further comprising a release valve, thereby enabling said coolant to flow continuously into, through, and out of said cooling envelope and so-cool said explosive device.

9. The system of claim 2, said at least one cooling apparatus further comprising at least one cooling envelope further comprising an insulating one of said cooling envelopes, said insulating one of said cooling envelopes comprising:

an outer insulating layer comprising at least one layer of at least one heat insulating material insulating said explosive device from said heat from said hot online heat exchange device, and thereby preventing from overheating, and so-cooling, said explosive device.

10. The system of claim 9, said insulating one of said cooling envelopes further comprising:

an inner insulating layer comprising at least one heat-reflective material further insulating said explosive device from said heat from said hot online heat exchange device, and thereby further preventing from overheating, and so-cooling, said explosive device, by reflecting any heat penetrating said outer insulating layer away from said explosive device.

11. The system of claim 10, further comprising:

non-flammable bulk fiber insulation within said insulating one of said cooling envelopes further insulating said explosive device from said heat from said hot online heat exchange device, and thereby further preventing from overheating, and so-cooling, said explosive device.

12. The system of claim 11, said at least one cooling envelope comprising a casing one of said cooling envelopes, said explosive device further comprising:

a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and further comprising a detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing to provide suitable heat insulation to a detonator cap placed within said detonator well; and

explosive material encased within, and thereby insulated and prevented from overheating by said heat-resistant explosive casing.

13. The system of claim 10, said at least one cooling envelope comprising a casing one of said cooling envelopes, said explosive device further comprising:

a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and further comprising a detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing to provide suitable heat insulation to a detonator cap placed within said detonator well; and

explosive material encased within, and thereby insulated and prevented from overheating by said heat-resistant explosive casing.

14. The system of claim 9, further comprising:

non-flammable bulk fiber insulation within said insulating one of said cooling envelopes further insulating said explosive device from said heat from said hot online heat exchange device, and thereby further preventing from overheating, and so-cooling, said explosive device.

15. The system of claim 14, said at least one cooling envelope comprising a casing one of said cooling envelopes, said explosive device further comprising:

a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and further comprising a detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing to provide suitable heat insulation to a detonator cap placed within said detonator well; and

explosive material encased within, and thereby insulated and prevented from overheating by said heat-resistant explosive casing.

16. The system of claim 9, said at least one cooling envelope comprising a casing one of said cooling envelopes, said explosive device further comprising:

a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and further comprising a detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing to provide suitable heat insulation to a detonator cap placed within said detonator well; and

explosive material encased within, and thereby insulated and prevented from overheating by said heat-resistant explosive casing.

17. The system of claim 2, wherein said explosive device is substantially fixed relative to said cooling apparatus.

18. The system of claim 2, wherein said any desired location within said hot online heat exchange device comprises a furnace region of said hot online heat exchange device.

19. The system of claim 1, said at least one cooling apparatus comprising at least one cooling envelope in turn comprising an insulating one of said cooling envelopes comprising:

an outer insulating layer comprising at least one layer of at least one heat insulating material insulating said explosive device from said heat from said hot online heat exchange device, and thereby preventing from overheating, and so-cooling, said explosive device.

20. The system of claim 19, said insulating one of said cooling envelopes further comprising:

an inner insulating layer comprising at least one heat-reflective material further insulating said explosive device from said heat from said hot online heat exchange device, and thereby further preventing from overheating, and so-cooling, said explosive device, by reflecting any heat penetrating said outer insulating layer away from said explosive device.

21. The system of claim 20, further comprising:

non-flammable bulk fiber insulation within said insulating one of said cooling envelopes further insulating said explosive device from said heat from said hot online heat exchange device, and thereby further preventing from overheating, and so-cooling, said explosive device.

22. The system of claim 21, said at least one cooling envelope comprising a casing one of said cooling envelopes, said explosive device further comprising:

a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and further comprising a detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing to provide suitable heat insulation to a detonator cap placed within said detonator well; and

explosive material encased within, and thereby insulated and prevented from overheating by said heat-resistant explosive casing.

23. The system of claim 20, said at least one heat-reflective material selected from the heat-reflective material group consisting of:

treated and untreated;

aluminized cloth;

silica cloth;

fiberglass cloth;

ceramic cloth; and

stainless steel cloth.

24. The system of claim 20, said at least one cooling envelope comprising a casing one of said cooling envelopes, said explosive device further comprising:

a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and further comprising a detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing to provide suitable heat insulation to a detonator cap placed within said detonator well; and

explosive material encased within, and thereby insulated and prevented from overheating by said heat-resistant explosive casing.

25. The system of claim 19, further comprising:

non-flammable bulk fiber insulation within said insulating one of said cooling envelopes, further insulating said explosive device from said heat from said hot online heat exchange device, and thereby further preventing from overheating, and so-cooling, said explosive device.

26. The system of claim 25, said non-flammable bulk fiber insulation comprising at least one heat insulating material selected from the heat insulator group consisting of:

treated and untreated;

amorphous silica fiber;

silica cloth;

aluminized silica cloth;

silicone coated silica cloth;

fiberglass cloth;

silicone impregnated fiberglass fabric;

vermiculite coated fiberglass;

neoprene coated fiberglass;

ceramic cloth; and

knitted silica glass.

27. The system of claim 25, said at least one cooling envelope comprising a casing one of said cooling envelopes, said explosive device further comprising:

a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and further comprising a detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing to provide suitable heat insulation to a detonator cap placed within said detonator well; and

explosive material encased within, and thereby insulated and prevented from overheating by said heat-resistant explosive casing.

28. The system of claim 19, said at least one layer of said at least one heat insulating material selected from the heat insulator group consisting of:

treated and untreated;

silica cloth;

aluminized silica cloth;

silicone coated silica cloth;

fiberglass cloth;

silicone impregnated fiberglass fabric;

vermiculite coated fiberglass;

neoprene coated fiberglass;

ceramic cloth; and

knitted silica glass.

29. The system of claim 19, said at least one cooling envelope comprising a casing one of said cooling envelopes, said explosive device further comprising:

a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and further comprising a detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing to provide suitable heat insulation to a detonator cap placed within said detonator well; and

explosive material encased within, and thereby insulated and prevented from overheating by said heat-resistant explosive casing.

30. The system of claim 1, said at least one cooling apparatus comprising at least one cooling envelope in turn comprising a casing one of said cooling envelopes, said explosive device further comprising:

a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and further comprising a detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing to provide suitable heat insulation to a detonator cap placed within said detonator well; and

explosive material encased within, and thereby insulated and prevented from overheating by said heat-resistant explosive casing.

31. The system of claim 30, further comprising a non-heat-resistant explosive casing encasing said explosive material, wherein said non-heat-resistant explosive casing and said explosive material therein is encased within said heat-resistant explosive casing.

32. The system of claim 30, said heat-resistant explosive casing comprising at least one layer of at least one heat insulating material selected from the heat insulator group consisting of:

treated and untreated;

silica cloth;

aluminized silica cloth;

silicone coated silica cloth;

fiberglass cloth;

silicone impregnated fiberglass fabric;

vermiculite coated fiberglass;

neoprene coated fiberglass;

ceramic cloth; and

knitted silica glass.

33. The system of claim 2, said at least one cooling apparatus further comprising at least one cooling envelope in turn comprising a casing one of said cooling envelopes, said explosive device further comprising:

a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and further comprising a detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing to provide suitable heat insulation to a detonator cap placed within said detonator well; and

explosive material encased within, and thereby insulated and prevented from overheating by said heat-resistant explosive casing.

34. The system of claim 1, wherein said explosive device is substantially fixed relative to said cooling apparatus.

35. The system of claim 1, wherein said any desired location within said hot online heat exchange device comprises a furnace region of said hot online heat exchange device.

36. A method for deslagging a hot, online heat-exchange device, comprising the steps of:

cooling an explosive device particularly while said explosive device is at any desired location within said hot online heat exchange device, thereby preventing heat from said hot online heat exchange device from detonating said explosive device prior to a time when it is desired to detonate at will said explosive device;

affixing said at least one cooling apparatus and said explosive device cooled thereby to a cooling apparatus and explosive positioning system;

applying a force to said cooling apparatus and explosive positioning system and thereby freely moving said at least one cooling apparatus and said explosive device cooled thereby to said any desired location within said hot online heat exchange device and particularly into a proper position for deslagging, while cooling said explosive device; and

detonating at will said explosive device.

37. The method of claim 36, further comprising the step of:

delivering a coolant to said explosive device, said coolant so-cooling said explosive device, using a coolant-delivery apparatus.

38. The method of claim 37, said coolant comprising a liquid.

39. The method of claim 38, the liquid coolant comprising water.

40. The method of claim 37, said coolant comprising a gas.

41. The method of claim 40, the gaseous coolant comprising air.

42. The method of claim 37, said coolant-delivery apparatus comprising a semipermeable cooling envelope, further comprising the step of:

flowing said coolant continuously into, through, and out of said cooling envelope and so-cooling said explosive device.

43. The method of claim 37, said coolant-delivery apparatus comprising a cooling envelope, further comprising the step of:

flowing said coolant continuously into, through, and out of said cooling envelope and so-cooling said explosive device, using a release valve of said cooling envelope.

44. The method of claim 37, said at least one cooling apparatus further comprising at least one cooling envelope in turn comprising an insulating one of said cooling envelopes, further comprising the step of:

insulating said explosive device from said heat from said hot online heat exchange device, and thereby preventing from overheating, and so-cooling, said explosive device, using an outer insulating layer of said insulating one of said cooling envelopes comprising at least one layer of at least one heat insulating material.

45. The method of claim 44, further comprising the step of:

further insulating said explosive device from said heat from said hot online heat exchange device, and thereby further preventing from overheating, and so-cooling, said explosive device, by reflecting any heat penetrating said outer insulating layer away from said explosive device, using an inner insulating layer of said insulating one of said cooling envelopes comprising at least one heat-reflective material.

46. The method of claim 45, further comprising the step of:

further insulating said explosive device from said heat from said hot online heat exchange device, and thereby further preventing from overheating, and so-cooling, said explosive device, using non-flammable bulk fiber insulation within said insulating one of said cooling envelopes.

47. The method of claim 46, said at least one cooling envelope comprising a casing one of said cooling envelopes, comprising the further steps of providing said explosive device by:

encasing an explosive material within a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and thereby insulating and preventing from overheating, said explosive material; and

placing a detonator cap within a detonator well of said heat-resistant explosive casing, said detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing, thereby suitably insulating and preventing from overheating, said detonator cap.

48. The method of claim 45, said at least one cooling envelope comprising a casing one of said cooling envelopes, comprising the further steps of providing said explosive device by:

encasing an explosive material within a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and thereby insulating and preventing from overheating, said explosive material; and

placing a detonator cap within a detonator well of said heat-resistant explosive casing, said detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing, thereby suitably insulating and preventing from overheating, said detonator cap.

49. The method of claim 44, further comprising the step of:

further insulating said explosive device from said heat from said hot online heat exchange device, and thereby further preventing from overheating, and so-cooling, said explosive device, using non-flammable bulk fiber insulation within said insulating one of said cooling envelopes.

50. The method of claim 49, said at least one cooling envelope comprising a casing one of said cooling envelopes, comprising the further steps of providing said explosive device by:

encasing an explosive material within a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and thereby insulating and preventing from overheating, said explosive material; and

placing a detonator cap within a detonator well of said heat-resistant explosive casing, said detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing, thereby suitably insulating and preventing from overheating, said detonator cap.

51. The method of claim 44, said at least one cooling envelope comprising a casing one of said cooling envelopes, comprising the further steps of providing said explosive device by:

encasing an explosive material within a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and thereby insulating and preventing from overheating, said explosive material; and

placing a detonator cap within a detonator well of said heat-resistant explosive casing, said detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing, thereby suitably insulating and preventing from overheating, said detonator cap.

52. The method of claim 37, said at least one cooling apparatus further comprising at least one cooling envelope in turn comprising a casing one of said cooling envelopes, comprising the further steps of providing said explosive device by:

encasing an explosive material within a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and thereby insulating and preventing from overheating, said explosive material; and

placing a detonator cap within a detonator well of said heat-resistant explosive casing, said detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing, thereby suitably insulating and preventing from overheating, said detonator cap.

53. The method of claim 37, wherein said explosive device is substantially fixed relative to said cooling apparatus.

54. The method of claim 37, wherein said any desired location within said hot online heat exchange device comprises a furnace region of said hot online heat exchange device.

55. The method of claim 36, said at least one cooling apparatus comprising at least one cooling envelope in turn comprising an insulating one of said cooling envelopes, further comprising the step of:

insulating, said explosive device from said heat from said hot online heat exchange device, and thereby preventing from overheating, and so-cooling, said explosive device, using an outer insulating layer of said insulating one of said cooling envelopes comprising at least one layer of at least one heat insulating material.

56. The method of claim 55, further comprising the step of:

further insulating said explosive device from said heat from said hot online heat exchange device, and thereby further preventing from overheating, and so-cooling, said explosive device, by reflecting any heat penetrating said outer insulating layer away from said explosive device, using an inner insulating layer of said insulating one of said cooling envelopes comprising at least one heat-reflective material.

57. The method of claim 56, further comprising the step of:

further insulating said explosive device from said heat from said hot online heat exchange device, and thereby further preventing from overheating, and so-cooling, said explosive device, using non-flammable bulk fiber insulation within said insulating one of said cooling envelopes.

58. The method of claim 57, said at least one cooling envelope comprising a casing one of said cooling envelopes, comprising the further steps of providing said explosive device by:

encasing an explosive material within a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and thereby insulating and preventing from overheating, said explosive material; and

placing a detonator cap within a detonator well of said heat-resistant explosive casing, said detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing, thereby suitably insulating and preventing from overheating, said detonator cap.

59. The method of claim 56, further comprising the step of selecting said at least one heat-reflective material from the heat-reflective material group consisting of:

treated and untreated;

aluminized cloth;

silica cloth;

fiberglass cloth;

ceramic cloth; and

stainless steel cloth.

60. The method of claim 56, said at least one cooling envelope comprising a casing one of said cooling envelopes, comprising the further steps of providing said explosive device by:

encasing an explosive material within a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and thereby insulating and preventing from overheating, said explosive material; and

placing a detonator cap within a detonator well of said heat-resistant explosive casing, said detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing, thereby suitably insulating and preventing from overheating, said detonator cap.

61. The method of claim 55, further comprising the step of:

further insulating said explosive device from said heat from said hot online heat exchange device, and thereby further preventing from overheating, and so-cooling, said explosive device, using non-flammable bulk fiber insulation within said insulating one of said cooling envelopes.

62. The method of claim 61, said non-flammable bulk fiber insulation comprising at least one heat insulating material, further comprising the step of selecting said at least one heat insulating material from the heat insulator group consisting of:

treated and untreated;

amorphous silica fiber;

silica cloth;

aluminized silica cloth;

silicone coated silica cloth;

fiberglass cloth;

silicone impregnated fiberglass fabric;

vermiculite coated fiberglass;

neoprene coated fiberglass;

ceramic cloth; and

knitted silica glass.

63. The method of claim 61, said at least one cooling envelope comprising a casing one of said cooling envelopes, comprising the further steps of providing said explosive device by:

encasing an explosive material within a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and thereby insulating and preventing from overheating, said explosive material; and

placing a detonator cap within a detonator well of said heat-resistant explosive casing, said detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing, thereby suitably insulating and preventing from overheating, said detonator cap.

64. The method of claim 55, further comprising the step of selecting said at least one layer of said at least one heat insulating material from the heat insulator group consisting of:

treated and untreated;

silica cloth;

aluminized silica cloth;

silicone coated silica cloth;

fiberglass cloth;

silicone impregnated fiberglass fabric;

vermiculite coated fiberglass;

neoprene coated fiberglass;

ceramic cloth; and

knitted silica glass.

65. The method of claim 55, said at least one cooling envelope comprising a casing one of said cooling envelopes, comprising the further steps of providing said explosive device by:

encasing an explosive material within a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and thereby insulating and preventing from overheating, said explosive material; and

placing a detonator cap within a detonator well of said heat-resistant explosive casing, said detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing, thereby suitably insulating and preventing from overheating, said detonator cap.

66. The method of claim 36, said at least one cooling apparatus comprising at least one cooling envelope in turn comprising a casing one of said cooling envelopes, comprising the further steps of providing said explosive device by:

encasing an explosive material within a heat-resistant explosive casing comprising said casing one of said cooling envelopes, and thereby insulating and preventing from overheating, said explosive material; and

placing a detonator cap within a detonator well of said heat-resistant explosive casing, said detonator well sufficiently removed from an outside surface of said explosive device and said explosive casing, thereby suitably insulating and preventing from overheating, said detonator cap.

67. The method of claim 66, comprising the further steps of:

encasing said explosive material in a non-heat-resistant explosive casing; and

encasing said non-heat-resistant explosive casing and said explosive material therein within said heat-resistant explosive casing.

68. The method of claim 66, comprising the further step of selecting at least one layer of at least one heat insulating material of said heat-resistant explosive casing from the heat insulator group consisting of:

treated and untreated;

silica cloth;

aluminized silica cloth;

silicone coated silica cloth;

fiberglass cloth;

silicone impregnated fiberglass fabric;

vermiculite coated fiberglass;

neoprene coated fiberglass;

ceramic cloth; and

knitted silica glass.

69. The method of claim 36, wherein said explosive device is substantially fixed relative to said cooling apparatus.

70. The method of claim 36, wherein said any desired location within said hot online heat exchange device comprises a furnace region of said hot online heat exchange device.