Steam Boiler and Process Heater Fuel Treatment

There are three distinct problems in steam boilers and process heaters from the use of fuels containing high levels of contaminants and sulfur. These are

• Superheater and Water Wall Deposits and Corrosion
• Cold-end Corrosion from Sulfuric Acid
• Sulfuric Acid in Exhausts - Acid Rain
• Emissions.

SFA International has a comprehensive program for treating these problems.

A modern field-erected steam boiler with primary and reheat super heaters, economizer and air heater. This type of boiler powering a steam turbine for electricity generation can operate at greater than 50% efficiency.

Combustion Catalysts

Combustion catalysts are used to reduce smoke and carbon particles in the exhaust. A number of metals are known to have combustion catalyst characteristics. The best that is reported in the literature is 50% reduction in particulate matter.

We have seen a 90% reduction in particulate matter in steam boilers and process heaters with our FuelSpec® 116 and 118 Series catalysts. We recommend our FuelSpec® 118-1502 colloidal iron-magnesium patented catalyst for use in large steam boilers. For examples of application of our patented catalyst technology in steam and process heaters, go to our Experience List.

For more information on the mechanism of this process, go to the SFA Technical Article & Paper Library.

High Temperature Deposits and Corrosion

Deposits on the superheater tubes and water walls are derived from vanadium, lead, sodium and calcium in the fuel. These deposits can be modified and/or eliminated by treatment with our FuelSpec® 140 Series over-based magnesium compounds containing up to 30% magnesium by weight of metal.

Package steam boiler with superheater drums and economizer. Process heaters frequently have a similar design.

Cold End Corrosion

Cold end corrosion is caused by formation of sulfuric acid from sulfur in the fuel. Sulfuric acid condenses below 175o C. on air preheaters leading to severe deposits and corrosion. This problem can be reduced or eliminated with ultra small particle size slurries combined with oil soluble magnesium. This treatment reduces sulfuric acid in the emissions as well. We recommend our FuelSpec® 140 Series magnesium for this application.

Technical Service

SFA Engineers provide technical service to aid customers in achieving optimum results from use of boiler fuel additives. Before a recommendation is made, a survey of the plant is made. From this information, a proposal is prepared outlining the additive application, dosage rate, function and expected benefits.

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