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Unlocking Efficiency Across Industries

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20 September 2018 | Media

Unlocking Efficiency Across Industries with Bang & Clean PressureWave+™ Technology

Despite the global push toward renewable energy, fossil fuel power plants —particularly coal- and gas-fired utilities—continue to play a vital role in providing stable, large-scale electricity supply. However, these plants face continuous challenges related to operational efficiency, emissions control, and equipment reliability. One of the most persistent issues in such environments is fouling—the buildup of ash, slag, and other combustion by-products on boiler tubes and heat exchanger surfaces.

Bang&Clean Technologies AG offers a powerful solution to this challenge through its PressureWave+™ system —a patented cleaning technology that uses controlled pressure waves to remove deposits without damaging equipment or requiring a shutdown. For fossil fuel utilities, this innovation has proven to be a game-changer in maintaining high performance while minimizing maintenance disruptions.

A Persistent Challenge: Ash and Slag Buildup

In coal-fired power plants, especially those burning high-ash or low-grade fuels, ash particles tend to accumulate on heat surfaces such as superheaters, economizers, and air preheaters. These deposits reduce heat transfer, increase fuel consumption, and lead to overheating or even tube failure. Similarly, in gas-fired combined cycle plants, heat recovery steam generators (HRSGs) can experience fouling from particulate matter in the flue gas, particularly when burning heavier or variable fuels.
Traditional cleaning methods—such as sootblowers, high-pressure water lances, or manual deslagging—have limitations. They often require downtime, expose maintenance crews to safety risks, and may not reach all areas effectively. Additionally, water-based cleaning can introduce corrosion and wastewater management issues.

PressureWave+™: A Non-Invasive, Online Cleaning Solution

PressureWave+™ addresses these issues by offering a dry, shockwave-based cleaning method that can be applied during plant operation. The system works by inserting a lance into the flue gas path and igniting a controlled gas mixture, which generates a high-energy pressure wave. This wave travels through the ducting or boiler passes, dislodging deposits from heat surfaces without physical contact or water use.
In coal-fired boilers, PressureWave+™ is typically used to clean the convective passes, including high-temperature and low-temperature superheaters. It effectively removes slag bridges and stubborn deposits that sootblowers struggle to reach. In gas-fired HRSGs, the technology is employed to maintain clean fins and tubes in the economizer and evaporator sections, supporting continuous and efficient heat recovery.

Operational Gains for Fossil Utilities

For fossil fuel utility operators, the benefits of implementing PressureWave+™ are significant:
  • Reduced Forced Outages : By maintaining cleaner surfaces, the risk of overheating, pressure drop, and component failure is reduced.
  • Improved Thermal Efficiency : Clean surfaces enable better heat transfer, directly improving boiler and plant efficiency.
  • Extended Maintenance Intervals : Online cleaning reduces the need for frequent shutdowns or manual cleaning.
  • Lower Fuel and Emissions Costs
    : Increased efficiency leads to reduced fuel consumption and lower emissions per MWh.
  • Enhanced Safety and Compliance : The dry, remote-operated system minimizes personnel exposure and eliminates the need for hazardous cleaning methods.

Supporting Reliable Power Generation

In an industry where uptime, efficiency, and cost control are critical, Bang&Clean’s PressureWave+™ technology offers fossil fuel power plants a strategic tool for performance optimization. Whether deployed as a standalone cleaning solution or integrated into a broader maintenance program, it enables operators to meet performance targets while maintaining compliance and extending equipment life.
As fossil power plants evolve to meet new challenges—from flexible load operation to emissions reduction— advanced, non-disruptive technologies like PressureWave+™ will play a central role in keeping these assets reliable and competitive.
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