You are on page 1of 6

See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/289169963

STICKINESS OF FIRESIDE DEPOSITS IN KRAFT RECOVERY UNITS.

Article in Journal of Pulp and Paper Science · May 1986

CITATIONS READS

45 428

4 authors, including:

Honghi Tran Danah Barham


University of Toronto Hamdan Bin Mohammed e-University
241 PUBLICATIONS 3,337 CITATIONS 14 PUBLICATIONS 230 CITATIONS

SEE PROFILE SEE PROFILE

All content following this page was uploaded by Honghi Tran on 07 February 2016.

The user has requested enhancement of the downloaded file.


Stickiness
of FiresideDepositsin Kraft
RecoveryUnits
P . I S A A K ,H . N . T R A N , D . B A R H A Ma n d D . W . R E E V E

Massive fouling in kraft recovery heat transfer, create an environment sodium carbonate, and in some cases
boilers is often attributed to sticky deposits. conducive to corrosion. and force unsche- sodium chloride. Minor. quantities of
The concept of stickinessis familiar to all, duled shutdowns due to plugging of flue sodium hydroxide and potassium com-
but little is known concerning the factors gas passages. pounds are also present. In addition to
that cause fireside deposits to become
Deposit accumulation is related to carryover deposits, vapours formed in the
sticky. Deposit stickiness is usually asso-
many factors. Experience suggests that lower furnace are condensed and depos-
ciated with liquid phase, but the exact
overloading, high excess air, high gas ited in the upper superheater region,
relationship has been unknown.
temperatures, upsets in black liquor generating section, and economizer.
Through this study, two scientific firing, and narrow tube spacing can These condensation deposits tend to be
methods were developed to quantitatively contribute significantly to deposit growth soft, friable, white and powdery. They are
measure deposit stickiness. Effects of composed mainly of sodium sulphate,
tl]. The exact conditions required to
deposit composition, temperature and li- produce sticky deposits are complex and sodium chloride, and a small amount of
quid phase on deposit stickiness were unclear. sodium carbonate. Deposit chemistry,
investigated. morphology, thermal and mechanical
Present efforts at prevention of properties and the mechanism of forma-
The results indicate that the sticki- massive deposit accumulation are based tion have been intensively studied at the
ness of the deposit increases with an on operating experience. Attempts to University of Toronto. The results of
increasein liquid phase, which in Na2SO4- alleviate accumulation include: operating these studies are reported elsewhere
Na2CO j-Na2Cl2 mixtures, is afunction of at lower temperatures; more frequent and
chloride content and temperature. The ll-41.
more severe soot blowing; optimization
liquid phase content of the deposit must of firing conditions; design changes; and This paper describes two laborato-
exceedI 8-20Voforstrong adhesionto occur. use of additives. These have not always ry methods of quantitatively measuring
Solidification of a partially molten deposit been successful.Plugging remains a seri- deposit stickiness developed at the Uni-
on a substrate produces an inseparable ous problem in many mills and often versity of Toronto and the effect of
deposit. determines the ultimate limit of capacity various factors such as temperature,
of a recovery boiler. There is therefore a deposit composition, liquid phase, and
INTRODUCTION
need for a better and more thorough substrate type on deposit stickiness.
The occurrence of fireside deposits understanding of stickiness. EXPERIMENTS
in the superheaterand generating bank of
Deposit composition often varies At the present time, there is little
kraft recovery boilers is inevitable as long
significantly with location in the boiler, published information concerning factors
as black liquor is spray fired. Massive
black liquor composition, boiler operat- affecting kraft recovery boiler fireside
accumulation of deposits can decrease
ing conditions and the mechanism by deposit stickiness, and apparently no
P lsaak,HN Tran,
which the deposit was formed. The quantitative method exists for its meas-
D Barham and D W Reeve impaction of carryover particles on heat urement. During the course of this study,
University of Toronto transfer surfacesis the dominant form of two methods were developed for measur-
D e p t o f C h e m i c a lE n g i n e e r i n g deposition in the lower superheater i.tg deposit stickiness. Both methods
and Applied Chemistry region. Carryover results in thick, hard, employed the same apparatus consisting
Toronto.Ontario and tenacious deposits whose major of a muffle furnace, balance, thermocou-
M55 144 components are sodium sulphate and ple, temperature indicator, substrates,

J O U R N A L O F P U L P A N D P A P E R S C I E N C E :V O L . 1 2 N O . 3 M A Y 1 9 8 6
c.n oNa,SO./Na,co! = 15
o N a , S O . , / N a , C O r= 4 0
E
\/n
o) -v
g
JJU

0)
J

o- 20

10

700 750----800
Temperature
(oC)

Fig. 1. Deposit stickiness apparatus. Fig. 2. Adhesion of alumina powder to synthetic deposits.

TABLE I
DEPOSITCOMPOSITION
: 1.5
Mole ratio NaaSQrlNazCOs Figure 2 shows the results of tests
Weight Percent performed with sulphate to carbonate
Moleor6 NAzClz NazSOr NazCOs molar ratios of 1.5 and 4.0. The results
were the same for both compositions.
o 66.8 33.2 o.o
2.5 65.3 32.4 2.3 Thus, the sulphate to carbonate ratio has
5 63.7 31.7 !.6 a negligible effect on the stickiness of the
10 60.6 30.2 9.2 deposit. In all subsequent experiments
15 57.5 28.6 r 3.9 the mole ratio was fixed at 1.5:l. A sharp
increase in the amount of powder picked
up by the Na2SO 4andNa2CO3 syntheric
deposit pellets occurs at temperatures
and molds (Fig. l). The difference pellet from the substrate. above 825'C (the minimum melting point
between the two methods lies in the of the Na2SO4-Na2CO3 system [5]). This
The composition of the synthetic
method of pellet preparation and in the indicates the significant role of the
deposits in this study varied from 0 to 15
type of substrate used. The substrate was melting point temperature in determining
moleVo sodium chloride (expressed as
either a deposit pellet, a metal disk, or whether or not a deposit will be sticky.
Na2Cl2), the remainder being made up of
alumina (Al2O3) powder. The substrate
sodium sulphate (Na2SOa) and sodium Effect of Chloride
was placed in a crucible on the bottom of
carbonate (Na2CO3) in a 1.5:l molar
the muffle furnace. The furnace was The study of the effect of chloride
ratio. Particular emphasis was placed on
heated electrically to the desired temper- was of interest because of the large effect
varying sodium chloride composition due
ature, which lies between 550 and 850oC. of chloride on the thermal properties of
to its significant influence on deposit
A pressed or cast pellet of deposit was the deposit. Sodium chloride lowers the
thermal properties. The effect of varying
suspended 5 mm above the substrate and first melting point of the synthetic deposit
the sulphate to carbonate ratio was also
heated to the same temperature. The by 200"C, from 826 to lessthan 625"C [2,
investigated.
pellet was then contacted with the sub- 4, 51.It is therefore expected to alter the
strate for I min. The force required to Mole ratio or mole percent is used deposit stickiness characteristics.
raise the pellet from the substrate surface throughout the paper. Since weight per-
cent is most commonly used in industry, As shown in Fig. 2, the pressed
was measured to indicate deposit sticki-
Table I has been provided for easy pellets without chloride did not pick up
NESS.
converslon. significant quantities of alumina powder
METHOD I involved contacting a until the temperature of the pellets
pressed pellet to an alumina powder exceeded825oC. With chloride, however,
RESULTS AND DISCUSSION
substrate. Pressed pellets were prepared the pellets became sticky at much lower
by grinding mixtures of synthetic depos- Method 1: Alumina Powder temperatures (Fig. 3). At temperatures
its, adding a small quantity of water to To Deposit Adhesion above 620"C, the deposit first melting
serve as a binder, pressing the powder Method I was developed to simu- point, more alumina powder stuck to the
mixture into pellet form, and then drying late conditions in the upper superheater synthetic deposit pellets with a higher
it at 130"C for 16 h. Alumina powder was where the metal temperature is low. The chloride content. A minimal quantity of
used as a substrate since it is an inert solid formation mechanism is dominated by powder was picked up by pellets contain-
at the temperatures considered in this condensation that produces a thin uni- ing 5 moleVoNa2Cl2 up to temperatures
study. Stickiness was indicated by the form layer of soft white deposit adjacent of 700"C. This is well above the first
weight of alumina powder adhering to the to the metal. Partially molten particles melting point of the synthetic deposit.
pressedpellet. adhere to this white powder surface [3]. The l0 and 15 moleVoNa2Cl2 became
METHOD 2 consistedof contact- The use of the inert alumina powder sticky at approximately 620"C,but the 15
ing a cast pellet to a synthetic deposit or permitted the study of the stickinessof the moleVoNa2Cl2 pellets consistently picked
metal substrate. The pellet was prepared deposit to a powdery material. up the greater amount of powder.
by melting the synthetic deposit mixture These results demonstrate the sub-
and casting it in a mold. This was Effect of Sulphate to Carbonate Ratio
stantial influence of sodium chloride on
developed to simulate the adhesion of The sodium sulphate to sodium synthetic deposit stickiness. A tempera-
deposit to a hard deposit or metal surface. carbonate ratio in carryover deposits ture difference in excessof 200"C exists
In this method, stickinesswas defined as varies significantly [3], and so its effect on between the condition where the l0 and
the force required to separate the cast deposit stickinesswas also studied. 15 moleVoNa2Cl2 and where the chloride

J O U R N A L O F P U L P A N D P A P E R S C I E N C E :V O L . 1 2 N O . 3 M A Y 1 9 8 6
Mole o/oNarCl,
o.15
80

670
o)
E E
q60 o
O)
tr O)
E
xs0
f oo
o

l
o / o .ro
8
I
40 o
I
#so "./z a o

.{ Oo
o
a

dzo t*4 zv
o-a o
10

0
620 640 660
(oC)
Temperature

Fig. 3. Adhesion of alumina powder to synthetic deposits. Fig. 4. Adhesion of alumina powder to synthetic deposits as a
function of liquid phase.

free synthetic deposits begin to pick


;-ZV
up significant quantities of alumina c

powder.
E.
Moleo/o Na,Cl,
Effect of Temperature and c13
o

Liquid Phase 6
c
25
The deposit liquid phase content a
o1n
_c ,v
depends on temperature. The lowest D

temperature at which liquid phase exists 6


a
is approximately 6l5oC [6]for the sodium Pc
o

(sulphate/carbonate/chloride) mixtures
and 826"C for the sodium (sulphate/ 6
o
carbonate/chloride) mixtures [5]. Above
the first melting point, the quantity of
8o
600 650
liquid in the deposit increasesas temper- ("C)
Temperature
ature lncreases.
Fig. 5. Adhesion of cast pellets to synthetic deposit
Sharp increases in deposit sticki-
substrates.
nessoccur at approximately 825'C for the
chloride free deposits (Fig. 2) and 620oC The results also show that the same preted as the weight of deposit that will
for the l0 and l5 mole% Na2Cl2 deposits quantity of alumina powder stuck to just stick to a unit area of deposit or metal
(Fig. 3). These sharp increases in sticki- pellets containing differing quantities of surface.
nesscoincide with the first melting points liquid, thus suggesting that, although
of the deposit. They are due to the sudden Deposit to Deposit Adhesion
liquid phasedominates stickiness,it is not
appearance of large quantities of liquid the sole factor affecting stickiness.These The results of deposit to deposit
phase at the first melting point. From other factors affecting stickiness are adhesion studies illustrate, in Fig. 5, the
Figs. 2 and 3 it is evident that an increase relatively minor and could include sur- dramatic change in stickiness due to a
in the temperature of a deposit above its face tension and viscosity of the liquid slight change in conditions. The 2.5
melting point temperature results in an phase, contact time, surface roughness, mole%oNa2Cl2 deposits are not sticky
increase in the stickiness of the deposit. etc. until the temperature is increased to
Thus temperature affects deposit sticki- 755-765"C. A five-fold increasein deposit
ness indirectly by changing the quantity The stickiness characteristics of a
stickiness occurs as the temperature is
of liquid phase in the deposit. low chloride carryover deposit from a
increased from 755 to 765"C. A similar
recovery superheater were also investi-
It is interesting to note that a increase in the stickiness of the 5 mole%
gated. The results were consistent with
significant increasein the stickinessof the Na2Cl2 deposits occurs at a lower tem-
those obtained from the 5 mole!/oNa2Cl2
5 moleVoNa2Cl2 pellets was not observed perature range, 690 to 700oC. For the l5
synthetic deposits.
at the first melting point. This may moleVo Na2Cl2 deposits, the increase
indicate that the quantity of liquid Method 2: Adhesion of Cast occurs at 615 to 625"C.
present at the first melting point of this Pellets to Deposit or Metal The sharp increase in adhesion of
deposit was insufficient to cause the Substrates the 2.5 and 5 mole% Na2Cl2 deposits
deposit to become sticky and that a Method 2 was developed to inves- occurs at temperatures at which the
minimum quantity of liquid phase is a tigate the role of liquid phase in stickiness amounts of liquid phase are lSVoandAlVo,
prerequisite for stickiness. of carryover deposits. Carryover deposits respectively. For the 15 mole% Na2Cl2
Figure 4 shows stickiness as a can be very hard, smooth, fused, and deposit, the sharp increase occurs at the
function of chloride content and the tenacious. The deposit forms by the deposit first melting point at which more
amount of liquid phase, estimated from impaction of partially molten deposit than 40Vo liquid phase is present. This
phase diagrams. A marked increase in particles on to metal or existing deposit confirms the significant role of liquid
stickiness is observed as liquid phase surfaces.This mechanism was studied by phase in deposit stickiness and indicates
content increases. At high liquid phase contacting a cast pellet to a cast deposit or that a minimum quantity of liquid phase
content a slight increase in liquid phase metal substrate. Stickinessis indicated by is required to causethe deposit to become
results in a large increase in deposit the force required to separate the pellet sticky. This minimum for liquid phase
stickiness. from the substrate. This can be inter- appears to be l8 to 20Vo.At the first

J86 JOURNAL OF PULP AND PAPER SCIENCE:VOL. 12 NO. 3 MAY 1986


^zv 850
E
() Mole o/o Na,Cl, Nor Sticky
5
I
a
800 \._
E
-o. - lc
O -\
c -'\.- RadicalDeformation
q)
e- 750 20oloLiquid -zpoint
6 ' /\._
c I rq-Phase -\'\.\
3
c)
ro ?CU 700
c
b Not Sticky Sticky

(E
3 650
c
6q ,o
F 600
First MeltingPoint
6
on 550
600 650 10 15 20
(oC)
Temperature NarCl,moleo/o
Fig. 6. Adhesion of cast pellets to metal substrates. Fig. 7. Stickiness as a function of temperature and composition
for synthetic deposits.
TABLE II
EFFECTOF DEPOSITSOLIDIFICATION
Initial Cooled Adhesion liquid phase, which in turn is affected by
Case Temperature Temperature Strengrth the composition and temperature of the
(oc) (oC) (g/cmJ deposit. Deposit stickiness is minimal at
| 61 O (below M. Pt.) 61 O (no cooling) o.3 temperatures below the first melting
ll 61O (below M.Pt.) 575 (below M.Pt.) 2.4 point. The stickiness increases sharply
lll 62O (above M.Pt.) 62O (no cooling) 6.O
lV 62O (above M.Pt.) (below M.Pt.) lnseparable when the liquid phase content in the
58O
deposit is l8-20Vo,or at the first melting
point if more than 20% liquid is present.
melting point of the 15 mole% Na2Cl2 er particles are in a partially molten form In practical applications, this permits the
synthetic deposit, the percent liquid in the flue gas. If theseparticles strike the determination of the temperature when
phase is already in excess of this mini- superheater tube they will stick to them. stickiness of any deposit will increase
mum. The tube surfaces are at a significantly drastically. Using this information, oper-
lower temperature than the gas, and thus ating conditions can be changed to lower
When this minimum quantity of
the adhering particles cool and solidify. It temperature and thereby decrease liquid
liquid phase is reached, the pellet surface
is expected that this will increase the phase content.
is coated by a thin liquid film. The film
then permits adhesion by surface tension. deposit tenacity, and hence the magni-
Figure 7 shows the temperature
The increasedmobility of the molten salts tude of this effect has been investi-
region in which the synthetic deposit is
increases the interlinking of adjacent gated.
sticky as a function of chloride content.
surface layers and permits mechanical Preliminary tests were performed The lower limit is determined by the
keying to occur. Furthermore, the liquid to study the effect of solidification of the temperature at which the sharp increase
film increases the intimacy of contact of deposit interface on deposit to deposit in deposit stickiness occurred (approxi-
the pellet to the deposit surface and thus stickiness.Deposits containing l5 mole% mately 20Voliquidphase). The upper limit
increases adhesion strength. Na2Cl2 were heated to the desired for stickiness is fixed by the radical
Deposit to Metal Adhesion temperature, contacted to the deposit deformation point (i.e.7O%liquid phase),
substrate, and cooled approximately above which slagging will occur [2]. For
Tests to measure the adhesion of 40'C. The force required to achieve industrial deposits, this sticky tempera-
deposits to metal were performed to separation at the lower temperature was ture region is expected to be 50-100"C
determine the stickiness of deposits on then measured. The results are surrunar- lower due to the presence of potassium,
metal surfaces. Like the adhesion of ized in Table II. sulphides, and other impurities which
deposits to deposit substrates, the lower the melting point of the deposit.
increases in stickiness for the 5 and 15 When the deposit was heated to
temperatures below the first melting The sticky temperature range for furnace
mole%oNa2Cl2 deposits to the metal deposits can be determined experimental-
occurred at about the same temperatures point, cooling increased but did not
significantly alter the deposit stickiness ly using the laboratory apparatus. From
and just as sharply (Fig. 6). This again this information, changes in operating
suggeststhat liquid phase plays a signifi- (cases I & II). When the deposit was
initially above the first melting point and conditions to attempt to minimize deposit
cant role in stickiness and that the surface accumulation can be implemented. The
type has only a secondary effect on the interface was not cooled, the deposit
could be separated from the substrate operating temperature must allow for the
stickiness. Comparison of Figs. 5 and 6 fact that the in-flight deposit particles are
(caseIII). However, cooling of the deposit
revealsthat, for temperaturesat which the expected to be at a higher temperature
minimum liquid phase requirement is not from a temperature above the first
melting point to a temperature below the (due to in-flight combustion), and there-
reached, the adhesion strength of the fore are stickier and have a higher liquid
deposit to the metal surface is slightly first melting point resulted in an insepar-
able deposit interface (case IV). These phase content than the accumulated
greater than that of the deposit to deposit deposit.
at similar temperatures. This may be due results demonstrate the significant
to the reaction of the liquid in the deposit increasein the strength of the deposit due At the higher temperature condi-
with the surface oxide layer on the metal to solidification and explain the difficul- tions in the lower superheater region of
substrate resulting in stronger bonding at ties in deposit removal, particularly in the the recovery boiler (700-800"C) the
the interface. lower superheater. deposits will be sticky at all times.
However, the temperature may also be
PRACTICAL I M PLICATIONS high enough to cause slagging and so
Effect of Solidification
The results of this study indicate control deposit growth. Due to the wide
In the superheater region, carryov- that stickiness is principally affected by tube spacing, plugging is usually not a

J O U R N A L O F P U L P A N D P A P E R S C I E N C E :V O L . 1 2 N O . 3 M A Y 1 9 8 6 J87
problem in the superheater.The resultsof
this study are more applicable in the R E F E R E N C E : I S A A K , P . , T R A N , H . N . , B A R H A M , D a n d R E E V E , D . W S t i c k i n e s so f
boiler bank region (550-650'C). Many FrresideDeposits in Kraft Recovery Units Journal of Pulp and Paper Science, Vol. 12(3)
mills operate in the l-57osodium chloride J 84-88 May 1986. Paper presented at the 1986 International Chemical Recovery
Conferenceof the TechnicalSection. CanadianPulp and PaperAssociationco-sponsoredwith
with 2Vo being average l2l. At these
TAPPI at New Orleans, LA, April 28-May 3, 1985. Not to be reproduced without permission
chloride concentrations, significant {rom this organization. Manuscript received May 2, 1985; approved by the Review Panel
changes in synthetic deposit stickiness F e b r u a r y3 , 1 9 8 6
occur (Fig. 7) and similar changes are
expected for industrial deposits. An ABSTRACT: Massive fouling in kraft recovery boilers is often attributed to sticky deposits.
increasein local temperature or sodium The concept of stickinessis familiar to all, but little is known concerning the factors that cause
chloride content could shift the deposit fireside deposits to become strcky, Deposit stickinessis usually associatedwith liquid phase,
into the sticky range resulting in rapid but the exact relationship has been unknown.
accumulation.With proper monitoring of Through this study, two scientific methods were developed to quantitativelymeasure
boiler bank conditions, the operator can deposit stickiness Effectsof deposit composition, temperature and liquid phase on deposit
take steps to lower the temperature at this stickinesswere investigated.
location to a value below the sticky The resultsindicatethat the stickinessof the deposit increaseswith an increasein liquid
temperature, thereby preventing sticky phase, which in Na2SO4-Na2CO3-Na2Cl2mixtures, is a function of chloride content and
deposits and avoiding plugging. temperature The liquid phase content of the deposit must exceed 18-2Oo/ofor strong
adhesion to occur. Solidification of a partially molten deposit on a substrate produces an
inseparabledeposit

ACKNOWLEDGEMENTS
nESUnng: On attribue souvent le colmatageexcessifdes chaudidresde rdcup6rationde kraft
The authors wish to acknowledge
d des d6p6ts collants. Tout le monde connait ce concept, mais on n'en sait gudre sur les
support from the Natural Sciences and facteursqui font que les d6p6ts de combustion deviennentcollants. On attribue g6n6ralement
Engineering ResearchCouncil of Canada cette condition ) la phase liquide, mais la relation exacte reste inconnue.
and the Department of Chemical Engi-
Dans cette 6tude, les auteurs ont mis au point deux m6thodes scientifiques pour
neering and Applied Chemistry, Univer-
mesurer quantitativementles propri6t6sd'adh6sion des d6p6ts. lls ont 6galement 6tudi6 les
sity of Toronto. effets de la composition des d6p6ts, leur temp6rature et la phase liquide'
Les r6sultatsindiquent que les d6p6ts deviennent de plus en plus collants au fur et A
m e s u r eq u ' i l y e n a d a v a n t a g ed a n s l a p h a s el i q u i d e .c e q u i d a n s d e s m 6 l a n g e sd e N a 2 C O 4 -
Na2CO3 - Na2Cl2 est fonction de la teneur en chlore et de la temp6rature. La teneur de
REFERENCES
d6p6ts dans la phase liquide doit d6passer 18 d 2O"/o pour qu'il se produise une forte
l. TRAN, H.N. and REEVE, D.W.. "Kraft adh6sion La solidification d'un d6p6t partiellement fondu sur une strate produit un d6p6t
Recovery Unit Fireside Deposits and ins6parable
Plugging". Pulp Pup. Carr., 85 (10) T266
( l9t{4). KEYWOHDS: RECOVERYFURNACES, DEPOSITION, ADHESION, OUANTITATIVE
) REEVE. D.W., TRAN, H.N. and BAR- A N A L Y S I S , C O R R O S I O NP R E V E N T I O N ,C O M B U S T I O N C O N T R O L , R E A C T I O NM E C H A -
HAM, D., "Chemical and Thermal Prop- N I S M S , T E S T M E T H O D S ,T E S T E O U I P M E N T T, HEORIES
erties of Recovery Boiler Superheater
Fireside Deposits", Pulp Pap. Can.,82 (9)
T 3 r 5( 1 9 8 r ) .
TRAN,H.N..REEVE,D.W.andBAR- its and Corrosion in Kraft Recovery ( | e64).
HAM, D., "Formation of Kraft Recovery B o i l e r s " ,T A P P I 6 4 ( 5 ) 1 0 9 ( 1 9 8 1 ) . 6. BERGMAN, A.G. and SEMENTSOVA,
Boiler Superheater Deposits", Pulp Pap. 5. GITLESEN, G. and MOTZFELDT, K., A.K., "Ternary Systems Na2SO4-
C a n . . 8 4( l ) T 7 ( 1 9 8 3 ) . "Phase Diagrams by the Conductance Na2CO3-N a2Cl2 and K2SOa-K2CO3-
4. REEVE. D.W., TRAN, H.N. and BAR- Method The System Na2SO4- KrClZ", Zhur. Neorg,.Khint. 3 (2). 201
HAM, D., "SuperheaterFireside Depos- NarCO'r", Ac'ra.Chen. Scand.Sl (2), 488 ( | 958).

J88 J O U R N A L O F P U L P A N D P A P E R S C I E N C E :V O L ' 1 2 N O ' 3 M A Y 1 9 8 6

View publication stats

You might also like