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UltraCare® FA Fuel Additives & UltraClean® FC Online Cleaners

Deposits inside the boiler furnace, process furnaces, refineries and incinerators can result in reduced heat transfer, increased fuel consumption, metal corrosion and hence increased plant downtime due to shutdowns, maintenance and cleaning. Consequently, this will mean reduced water and electricity production in both thermal water desalination and power plants.

JAS (formerly SSCI) has developed a range of fuel additives and online cleaners under the brand names of UltraCare® FA and UltraClean® FC explicitly designed to provide maximum protection against corrosion, reduce fuel consumption, reduce emissions and maintain plant efficiency and productivity.

The COAP® Technology

Although UltraClean® FC has some advantages as a corrosion inhibitor in cold and hot zones however it cannot provide maximum protection against corrosion in hot zones when conditions are very corrosive. On the other hand, UltraCare® FA range of magnesium carboxylates, sulfonates and slurries fuel additives provide better protection against corrosion nonetheless have the disadvantage of being unable to provide online cleaning.

COAP® Technology is an innovative and unique approach developed by JAS (formerly SSCI) which combines the advantages of both fuel additives and online cleaners with the flexibility of using either one of them or both depending on the fuel type along with the plant conditions.  COAP® is a comprehensive oil additives package allowing customers to enjoy both online cleaning and maximum corrosion protection in both cold and hot zones. COAP® technology has the following advantages:

  1. Customers run the boilers on timely dosage forUltraClean® FC if continuous dosing is not required.
  2. Combine the advantages of both online cleaners and fuel additives.
  3. Suits all types of solid, liquid and gas fuels.
  4. Contains bi-metallic synergism which increases melting point of ash by 40% more than Mg based additives melting point. It can be efficiently used in super critical boiler as well.
  5. Contains post combustion catalyst (PCC) which enhances the combustion efficiency and minimize the ash production.
  6. Contains “Enhanced Magnesium” which doesn’t form white effect on high temperature zone.
  7. Special ingredient which minimizes solid emission /particulate emission.
  8. Specialized micro and macro emulsion based fuel additives with greater secondary combustion effect, which provide compact, short flame and good temperature distribution and therefore much less in generation of NOx and SOx.
  9. The technology can reduce:
        a) Solid emissions by 80%
        b) NOx by 30%
        c) SOxby 90%
        d) COx between the range of 3 to 7%
  10. After 1100 C of flue gas temperature, the vanadium based deposition is just 4% and anti-deposition property is still 80% active.

PRODUCT

TEMPERATURE

VANADIUM
DEPOSITION RATE

ANTI DEPOSITION
EFFICIENCY
COAP® technology proprietary chemistry 1090 oC 4.2%  80%
 Conventional (Magnesium based products) 1090 oC 21%  0%

 

BUSINESS IMPACT

FUEL SAVINGS CORROSION CONTROL  INCREASED PRODUCTION  LESS MAINTENANCE/INCREASED PLANT AVAILABILITY 

Improved combustion – Improved heat transfer.

Fuel represents the largest expense on any boiler/furnace. Slag deposits interfere with efficient transfer of heat from the radiant section into the tubes.

It is possible to reduce fuel consumption by approx. 5% if slag build-up is a problem.

The flue gas show an increase in carbon dioxide of about 6-10%. Stack temperature is lowered by about10- 12%. There is an economy in fuel consumption to the tune of 4-7%, which recover multiples of additives cost.

When molten vanadium pentoxide deposits on the metal surfaces, it dissolves the oxide layer that all metals form to passivates their surfaces which results in corrosion.

Costs associated to this problem include tube replacement and process debits due to unscheduled downtime.

This is particularly true for plants running at full capacity (olefin plants for example).

A disruption or reduction in plant output will mean less volume for the same amount of plant overhead costs.

The necessity for frequent offline cleaning, maintenance, repair and overhauling are largely reduced, down time is reduced as a result.

 

POTENTIAL PROBLEMS

AIR PREHEATER STEAM FOR HEATER COILS ECONOMIZER FORCE DRAFT FANS STACK COMPONENTS

Function: to heat the incoming air and reduce the amount of heat from the fuel.

As the exhaust gases pass through the air preheater, they are cooled. If SO3 is high enough sulfuric acid can condense causing corrosion. This sticky deposit traps fly ash particles which clogs the air passages and therefore effectiveness and reliability of the air preheater is affected and the need for more soot blowing can be expected.

Cost impact are: Replacement costs, additional fuel and increased electrical cost for the soot blower.

Some plants use steam to ensure that the stack temperature is above the dew point. This steam can account for 10% of the total steam production.

By reducing the dew point temperature, our customer can reduce if not eliminate the need for steam pre-heating.

Deposits on economizer tubes impede the transfer of heat (Ability to scavenge heat from the flue gas to the BFW) thus precious heat energy is lost to the atmosphere.

To prevent condensation of sulphuric acid on the economizer tubes the skin temperature is maintained high by throttling the flow of BFW. This action however results in loss of heat transfer efficiency and require more use of the steam in preheaters.

In cases where dew point condensation occurs additional cost is incurred to replace the tube bundles.

One of the largest users electricity users in the plants.

As the vanes of the fan becomes fouled with deposits of sulphuric acid and fly ash the amperage draw increases the electrical needs even more.

Sulphuric acid condensing on these components can lead to corrosion which results in high replacement cost.

 

COAP® TECHNOLOGY SOLUTIONS

FIRESIDE DEPOSIT PROBLEMS COLD END PROBLEMS  SOOT & ASH DEPOSITS PROBLEMS  CARBON / DUST
EMISSION PROBLEMS

Controls the fireside deposit problems associated with the use of heavy fuel:

Increasing the melting temperature of the slag forming metal through complexing the slag forming Vanadium and making the deposits dry (friable) and don’t stick to the tubes, these deposits can then be easily removed with soot blowing.

By making these deposits dry (friable) we also prevent high temperature corrosion.

These approaches reduce fuel cost for our customers through improved heat transfer, reduce maintenance costs and increase asset life.

Control of cold-end corrosion problems associated with the use of high Sodium, Sulfur and Vanadium fuels by:

Controlling the formation of SO3 which forms sulfuric acid when it condenses with the use of Magnesium to complex the vanadium catalyst and by implementing operational and mechanical adjustment to reduce excess O2.

This will provide value to the customer thru optimized use of heat scavenging equipment such as economizers and air preheaters.

It will also reduce the cost of fuel because the customer does not have to maintain high stack temperatures or excess O2.

On-line removal of soot or ash deposits through the use of our unique COAP® chemistry and application protocol.

This will reduce customer’s costs because they do not have to shut-down their furnace for mechanical cleaning, and thus also improving their throughput.

This will also reduce their soot blowing operations costs because the deposits can now be easily removed.

The unburned carbon is light and will carry other residue from combustion into the atmosphere.

COAP® technology products provide a ʻpost-combustion' catalytic effect and thereby create a reaction with unburned carbon which will be oxidized. Once the unburned carbon has been eliminated by oxidization, the remaining dust particles will have a higher density and will be too heavy to be carried by the flue gas, and accordingly will tend to fall down rather than being emitted into the atmosphere. As a result the effectiveness of electrostatic precipitators and bag-filters will be increased. Emissions will be reduced too.

 

COAP® TREATMENT PERFORMANCE IMPACT

Boilers

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Process Heaters

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Incinerators

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