Early detection of leaks in recovery boilers remains an important priority for pulp and paper manufacturers due to the potentially devastating effects of a smelt-water explosion that can result from a leak.  Developed to help papermakers protect their valuable mill assets, LeakTrac Recovery Boiler Leak Indication System applies simple mass balance concepts around the waterside of the boiler to quickly detect water leaks.  As a reliable leak indication tool, LeakTrac can also provide savings when used to help verify that no leak is present in the boiler and an unnecessary ESP is avoided.  The LeakTrac system uses water mass balance technology and chemical mass balance technology—either separately or combination—to provide reliable and sensitive leak indication under a wide range of conditions.

LeakTrac uses patented mathematical methods that maximize the value that can be extracted from boiler mass balances.  Speed of detection, sensitivity, false alarm minimization, and system availability are all optimized which is critical when a boiler leak occurs or is suspected.  The patented chemical feed and control scheme used for the chemical mass balance portion of the system provides maximum sensitivity while providing excellent boiler chemistry control.  Major system components of LeakTrac are shown in Figure 1.  The LeakTrac system is easily integrated into the Boiler Precision System used to control Congruent Phosphate Treatment boiler programs.

Case History

A northwestern U.S. paper mill installed the LeakTrac Recovery Boiler Leak Indication System.  LeakTrac had only been in place for one week when it alarmed indicating a "Possible Leak Detected."  The boiler had a floor tube leak.  LeakTrac clearly proved to be the early warning indicator of this small, but serious furnace leak that resulted in an ESP of the boiler. 

Further, the LeakTrac data gives the mill a clear picture of when the leak started, it's approximate size and how it grew.  This detailed information on leak profiles is not typically available elsewhere. 

Recorded Benefits

Early indication of water losses in the boiler
Verification of the presence of a boiler leak
Indication of leak location (economizer or superheater versus concentrated boiler water)
Improved chemical control