The problem of fireside deposits in boilers is becoming more serious daily due to the inferior quality of fuel used in boilers. Each burner system is designed for a particular type of fuel, and any variation in fuel quality may lead to incomplete combustion. SF-30 is a combustion catalyst designed to prevent fireside deposits on all types of boilers, tubes, heaters, and economizers. It has been formulated to keep the boiler free from honeycomb formation, sulfur formation, and potash formation.
FUNCTION:
Deposition of unburnt carbon, ash, soot, etc., on the fireside of the boiler results in the formation of soot, which acts as an insulator, thereby reducing the boiler heat efficiency. Fireside deposits are generally poor conductors of heat, and their accumulation on metal surfaces reduces the heat conductance of the metal significantly. As little as a 1 mm thick deposit can cause about a 2% loss in efficiency. The presence of corrosive gases like SO2 and SO3 creates severe corrosion problems if unchecked when moisture is present.
PRODUCT BENEFITS:
- Online Cleaning: Clean the boiler/heater while in operation.
- Reduce Fuel Consumption: Lower fuel requirements.
- Reduce Manpower: Decrease the need for manual boiler cleaning.
- Increase Efficiency: Improve boiler efficiency.
- Reduce Cleaning Frequency: Less frequent cleaning needed.
- Prevent Corrosion: Protect against corrosive damage.
- Condition Sludge: Treat sludge in fossil fuel.
APPLICATION:
SF-30 is applied directly to the fire bed utilizing any suitable access point. It is important to ensure the boiler is continuously fired for a minimum period of one hour before and after dosing the chemical. Upon application, SF-30 will produce a gray/white vapor, indicating it is working correctly. This vapor is harmless.
DOSING & FEEDING:
Dosage Based on Fuel Type:
- Solid Fuels: For boilers burning solid fuel like coal, pet coke, wood husk, mustard husk, rice husk, bagasse, lignite, etc.
- Dose: 75-100 grams of SF-30 per ton of solid fuel for optimal results.
- Frequency: Once per shift (every 8 hours).
Important:
- Soot Thickness vs. Thermal Conductivity Loss:
- 0.8 mm ~ 9.5%
- 1.6 mm ~ 26.2%
- 3.2 mm ~ 45.3%
- 4.8 mm ~ 69.8%
HANDLING:
Wear proper personal protective equipment like dust masks, rubber gloves, aprons, safety goggles, rubber boots, etc. Avoid contact with skin, eyes, and clothing. In case of contact, wash thoroughly with water and seek medical advice.
PACKING:
50 kg food-grade virgin HM/HDPE containers.
PROBLEM RELATED WITH SOLID FUEL:
Incomplete combustion of solid fuel can lead to significant energy loss. Partially burnt fuel gets deposited in the boiler in the form of soot, while some of it is expelled through the exhaust, forming soot and clinker. These deposits can cause fouling, which reduces boiler efficiency and necessitates periodic shutdowns for cleaning.
FOULING:
Fouling due to soot, clinker, etc., occurs in all types of combustion equipment and is exacerbated by inferior fuel quality. Fouling deposits reduce boiler efficiency and necessitate frequent cleaning to maintain heat transfer efficiency.
SOOT:
Inferior fuel quality and inefficient combustion lead to fireside fouling. Soot deposits are generally soft but can harden over time, making them difficult to remove. Complex carbon-sulfur ash compounds formed from impurities in the fuel are particularly hard and corrosive.
CLINKER:
Three types of clinker are commonly found in solid fuel-fired boilers:
- Fused Ash: Forms at high temperatures and reduces heat transfer efficiency.
- Sintered Ash: Porous and poor conductors of heat, forming at contact points of particles.
- Matrix Bonded Deposits: Formed from alkalis in the fuel, creating corrosive and obstructive deposits.
CORROSION:
Boiler metal corrosion can occur at high temperatures due to molten ash or at low temperatures due to sulfuric acid precipitation from flue gases. Excess air and high flame temperatures promote sulfur trioxide formation, which reacts with water vapor to precipitate sulfuric acid, causing corrosion in heat recovery units, air pre-heaters, economizers, chimneys, etc.
ADVANTAGE OF ADDITIVES:
SF-30 fireside chemicals enable online boiler cleaning and help maintain peak efficiency by conditioning existing deposits and preventing new ones. They reduce the need for excess air and lower stack temperatures, resulting in fuel savings, reduced air pollution, and improved combustion.
BOILER EFFICIENCY CALCULATIONS (INDIRECT METHOD):
Combustion efficiency = 100 – (10 + T1 – T2) x 0.555 / CO2%
- T1: Stack Temperature
- T2: Ambient Temperature
- CO2% in stack
The above should be determined before additive dosing and during additive usages.
