Globally coal, crude oil, residual oil, gas etc., are fired as fuel in power plants. Combustion of these fossil fuels release SOx, NOx, CO2, CO, PM, Hg etc., and they need to be addressed.
The residual oil has Vanadium, Sodium and Sulphur and on burning it causes corrosion in boilers, turbines and associated ancillary equipment.
To combat the corrosion and to protect the environment from emissions fuel oil additives are used.
MagCare manufactures and offers a wide range of Fuel Additives used as corrosion inhibitors in residual fuels for applications in Boilers, Gas Turbines and Coal powered Boilers to improve the life of the combustion equipment and to keep the environment clean.
MagCare products are developed and manufactured using the highest quality and safety standards. Ours is an innovative specialty chemical company providing more economical and environmental friendly products for the customers in the Power, Oil Refinery and Marine Industries.
Magnesium in Fuel oil additives combats corrosion. Iron derivatives accelerates combustion. The alternate technology for improving combustion is to fire Water-in-Oil (WIO) emulsion.
MgO + V2O5 → 3MgO· V2O5
V2O5 and the reactions products of Na with V formed during the combustion are low melting and highly corrosive. Magesium reacts with these corrosive products and form Magnesium Ortho Vanadate which is high melting and non-corrosive. This is soft and friable and can be removed by soot-blowers.
MgO + SO3 → MgSO4
MgO + H2SO4 → MgSO4 + H2O
MgSO4 is a neutral and non-corrosive product.
Boilers which require better combustion and substantial particulate reduction have the following treatment options:
In the case of WIO Emulsion the secondary atomization facilitates burning of more unburned carbon reducing it up to 60 – 80 %. The NOx reduction achieved can be up to 15%.
This application solves to greater extent ash disposal problems which has no commercial value. This satisfies the local environmental agency norms in solid waste disposal and Particulate Matter reductions from the stack emissions.
In the case application of CC or WIO Emulsion, the Vanadium, Sodium and Sulphur present in the oil are to be additionally treated with Magnesium based additive to fight the hot and cold end corrosions.
STACK 2: BEFORE WIO TREATMENT
STACK1 & 3: AFTER WIO TREATMENT
(Similar results can be achieved with Combustion Catalyst)
WIO EMULSION FIRED ASH (NO BLACK PARTICLES)
(Similar results can be achieved with Combustion Catalyst)
Our WIO Emulsion Additive combustion Improvement Program uses stable, water-in-oil emulsified fuel which provides improved combustion, cleaner operation, and higher efficiency than conventional No. 6 fuel oil and the vacuum residue.
Secondary Atomization:Emulsified water droplets contained in every atomized fuel droplet rapidly vaporize and expand in the combustion chamber, shattering the oil into many smaller droplets for faster, more complete combustion.
Better Carbon Burnout: Smaller fuel droplet size means more complete carbon burnout and lower particulate emissions.
Lower Peak Flame Temperature: OurEmulsified Fuel lowers the peak flame temperature which in turn reduces NOX formation.
Less Excess Air Required: Our Emulsified Fuel can be burned cleanly at lower excess air levels, reducing the formation of SO3, NOX and low melting point vanadium oxides.
More Compact Flame.A more compact flame increases the gap between the flame envelope and boiler walls, which in combination with high melting point ashes, allows molten ash to solidify before reaching the boiler tubes.
Reduced Slag Deposits: The more complete combustion provided by our Emulsified Fuel keeps boiler surfaces clean longer, allowing better heat transfer and less maintenance.
The emulsions achieve smaller droplet size by a phenomenon known as “secondary atomization.” When this fuel enters the combustion chamber, it is atomized to approximately 100 micron sized droplets. However, the emulsified water within each drop of oil flashes into steam, exploding the fuel into thousands of smaller droplets. Photomicrograph of dispersed 5-20 um water droplets in fuel oil
NB:Treatment with Combustion Catalyst will give up to 40 – 60% reduction in Unburned Carbon and it does not require an Emulsion Skid.
Gas Turbines burn natural gas, light crude or heavy crude. Metal and ash contained in the crude and residual fuel can cause corrosion, erosion and fouling. Corrosion due to Vanadium is fixed by applying Vanadium inhibitor. Frequently the turbines and compressors are washed offline to remove the ash deposits. This washing is done when rated output and heat rate degradation happens due to fouling.
Ash deposits build-up on the hot gas path airfoils for gas turbines operating with HFO, the turbine efficiency drops due to increase in surface roughness and decreasing nozzle throat areas. This loss of turbine efficiency results in a gradual drop in firing temperature, effectively magnifying the performance loss due to fouling. This necessitates maintaining the control of firing temperature.
Problem due to Vanadium corrosion is fixed by applying Magnesium based Organic fuel oil additives mostly Sulphonates and Carboxylates. Country like Iraq is applying Magnesium Hydroxide successfully. Sulphonates and Carboxylates are expensive and the Hydroxide is competitive in terms of performance and price. Saudi Arabia and other countries use either or both the Sulphonates and the Carboxylates as their preferred additives.
Gas Turbines use oxidation catalyst to reduce Particulate Matter.
As explained, Magcare has all the capabilities to supply and monitor the gas turbine fuel treatment with the following metal additives according to the customer preference.
Our Magcare Gas Turbine Oxidation Catalyst can reduce the Particulate Matter to the World Bank guide line of level of 50 mg/Nm3.
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Magcare has started manufacturing boiler fuel oil additives for oil fired boilers in the year. It has a world class manufacturing facility in Mumbai, India and a blending facility in Dubai.
Address : 1st Floor, Warden House, Sir P M Road, Fort, Mumbai – 400001, India.
Tel : +91 2243112700
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