1 Introduction
Biomass fuels are an important alternative energy for fossil fuels (e.g., coal, oil), which are now attracting increasing attention due to its abundance, carbon-neutral nature, as well as the needs for disposing agricultural residues [
1–
3]. In recent years, China is giving great impetus to use such biomass byproducts/wastes as fuels in power stations for electricity/heat production, which not only helps reduce the CO
2 emission but also facilitates mitigating seasonal PM pollution and heavy haze due to the open-burning of agricultural residues such as rice straw and corn stalk. Up to 2017, over 270 power station units firing agriculture and forestry biomass have been built and put into operation in China, having a total electricity capacity of 7000 MW. However, the ash deposition in boilers is one of those intractable problems troubling the development of biomass firing facilities [
4–
6]. The ash deposition on the heat transfer surfaces would not only reduce heat transfer but also corrode heat transfer surfaces, which would induce unscheduled shutdown and severely affect the operation of biomass-fired power stations [
6–
9]. Thereby, it is of great importance to reveal the physical and chemical properties of the deposits, which determines the harmfulness and clearing difficulty of deposits.
Biomass fuels generally have high contents of troubling mineral matters such as chlorine, potassium and/or calcium while low contents of refractory mineral elements (e.g., Al, etc.), which exhibits a much higher mobility behavior and more severe deposition tendency compared to those in coal [
2,
4,
6,
10]. For example, it is revealed that potassium (K) in the biomass would be released as KCl and KOH, variously affected by the factors such as temperature, acid gases species (e.g., HCl, SO
x, etc.), and other mineral matters (e.g., Si, Ca, etc.) [
10–
16]. Whereafter, the alkali species released would react with silica and form eutectic silicates, which would melt at a quite low temperature (as low as 700°C) and deposit easily on the firesides surface [
17,
18]. The deposition behavior and the controlling mechanism usually vary with the local surroundings (e.g., temperature, atmosphere, flow conditions and concentration, and particle size of fly ash, etc.), which might significantly change with the boiler type [
4,
6,
19,
20]. The ash deposition progress and the property of the deposit in the grate type boiler have been extensively studied [
21–
25]. Hansen et al. [
26] characterized the deposits in a grate type boiler firing rice straw and pointed out that KCl and K
2SO
4 were the main components in the inner layer of the deposits in superheaters. Liu et al. [
24] observed that K
2SO
4 and CaSO
4 behaved as the principal component of the inner layer deposits of the middle superheaters in a 30 MW grate type boiler. Yet, information on the ash deposition progress and the property of deposit in large-scale biomass-firing boilers, especially emerging CFB (circulating fluidized bed) boilers, are still scattered.
The CFB boiler is a rather different boiler type from the grate one, which fires fuel in grains (several centimeters in diameter) and burns the fuel in the hot bed material at a temperature of approximately 800°C [
27,
28]. The release behavior of the mineral matter during the burnout of the biomass in a CFB boiler is reported to be quite different from that in a grate type boiler [
4,
29–
31]. Baxter et al. [
12] characterized the ash deposition on different tube surfaces in the superheaters in a commercial bubbling fluidized bed boiler. The results showed that all of the deposits contained K, Cl, and S as their major composition. However, there were significant changes in their composition and structure along with the position. Valmari et al. [
32] investigated the deposition behavior of the ash particles in a 35 MW CFB boiler firing forest residue, via measuring the concentration and size distribution of the ash particles before and after the heat exchangers. They claimed that almost 70% of the total fly ash particles would deposit on the heat transfer surfaces in the convective back pass, revealing the high deposition rate of the ash particles in the whole back pass. Li et al. [
33] systemically characterized the morphological, compositional, and mineralogical features of the ash deposits on the high temperature superheater of a 12 MW biomass-fired boiler. Stratified structure was observed in the deposits and it was pointed out that the viscous layer would be formed on the tube surface via the condensation of KCl and K
2Ca(SO
4)
2, which further induced the capture and deposition of the ash particles in the flue gas. Sandberg et al. [
34] studied the influence of ash deposits on the heat transfer performance and corrosion of two superheaters installed downstream of the cyclone in a CFB boiler via a seven years field observation. They investigated the thickness growth rates and composition of the deposits, and pointed out that chlorine and zinc accelerated the deposit rate via forming a sticky matter. The harm level such as the thickness and clearing difficulty of the ash deposits depend on the composition and inner structure properties. However, the few existing studies on the ash deposition in CFB boilers are mainly focused on individual devices, and there are still a few studies revealing the evolution of physical and chemical properties of the ash deposits distributed sequentially on the high temperature surfaces to the low temperature surfaces.
To address these research gaps, typical ash deposits on the tube surfaces in the superheaters situated in different gas locations, economizer, and air preheater of a commercially biomass-firing CFB boiler were purposely collected. The macroscopic appearance features, cross section characteristics, chemical composition, mineralogical composition of these deposit samples were successively determined. Based on these systemic and valuable full-scale data, the spatial distribution of the ash deposits on different superheaters was obtained, and the partitioning behaviors of the primary ash-forming constituents in the deposits on the tube surfaces at different positions were investigated.
2 Experimental
2.1 Boiler and material
This study is focused on the serial superheaters equipped in a 220 t/h biomass-fired circulating fluidized bed boiler (HX220/9.8-IV1, in a commercially operating 50 MW power station unit), located in southern China. As illustrated in Fig. 1, the boiler mainly consists of a membrane-wall, a dry-ash furnace, two cyclone separators, and a vertical heat recovery area (HRA). Fuel is fed into the furnace from the font wall through four feeders. Other key information of the unit is listed in Table S1 in the Electronic Supplementary Material (ESM).
The platen superheaters (marked as PS), the convection superheaters (including the high-temperature superheater (HTS), the low temperature superheater (LTS)), the economizers, and the air preheaters are set sequentially at the furnace outlet, the horizontal flue pass, and the vertical flue pass for heat recovery in the flue gas. Both of the LTSs and the economizers are arranged in three groups, with different tube materials in each part. The tubes in the upper part of the low-temperature superheaters are made of 12Cr1MoVG stainless steel while those in the middle and bottom parts are made of 20 G. The tube materials in the other parts are listed in Table S2 in ESM.
Mixtures of some local biomass fuels are burned in the boiler, including the eucalyptus residues (i.e., bark, branches, and leaves), the sugarcane residues (i.e., bagasse and leaves) and production wastes of furniture. The results of the proximate analysis, the ultimate analysis, and the inorganic element analysis of each biomass are provided in Tables 1 and 2. Briefly, all of the fuels had an ash content of lower than 10% except for fuel B2, which had an ash content of 19.97%. The ash-forming elements in the biomass fuels were determined via ion chromatography (IC, Metrohm 881 Compact IC pro) after microwave digestion. The principle ash-forming elements of the fuels had great disparities. The wood-derived fuels B1, B3, and B4 are high in both K and Ca while the herbaceous fuel B5 had high contents of Si and K with a low content of Al. Based on the fuel properties and the boiler design, the fuels are normally fed at a total rate of approximately 60 t/h. Before being fed into the furnace, fuels were crushed into particles smaller than 150 mm to ensure the fluidized combustion. Local river sand was chosen as the bed material, which has a Si content greater than 96% (see Table S1 in ESM). The data (average value ± standard deviation) in Table 1 are calculated from two parallel determinations while those in Table 2 are calculated from three parallel determinations.
The samples were collected during the maintenance period of the unit (before the ash blowing and washing), and before the samplings the unit has worked for about 100 days. Some key operating parameters (e.g., boiler load rate, flue gas temperature, fuel matching, etc.) (see Figs. S1 and S2 in ESM) during this period were recorded for analysis, which showed that the load of the boiler was rather stable (load rate: 90%–100%).
2.2 Sampling and analysis method
Both the ash deposits/slags covering heat-exchanging surfaces (namely, the PS, the HTS, the upper LTS, the lower LTS, and the economizer) and cyclone outlet, and the bulk fly ash entrained in the flue gas out of the air preheaters were sampled and analyzed. The ash deposits on some of the superheaters were closely attached to the metal surfaces, so special efforts were made to pry and pick the typical and representative ash deposition blocks at each part, in order to collect integrated and representative samples containing both the outer layer and the inner layer near the tube surface [
24,
35]. Moreover, during sampling, photos of the deposits at each part were taken to show their general appearances (e.g., shape, porosity, and texture) and the occurrence degree of the ash deposition. Bulk fly ash samples were collected in the horizontal flue gas duct between the air preheater and the ESPs.
The samples of the ash deposition/slag blocks were subjected to comprehensive chemical and physical examinations from four aspects (Fig. 1(b)). First of all, deposition blocks were cut along the radial direction to expose a smooth observing cross section from the outer layer to the inner one (namely the radial direction of the tube in Fig. 1(b)). Subsequently, an X-ray fluorescence probe (XRF, EAGLE III, EDAX Inc.) was used to determine the composition distribution in different layers of the deposits [
36,
37]. Next, the section-cross of the deposition samples was characterized under an electron probe microanalyzer (EPMA, EPMA-8050G, Shimadzu Corp.) with the scanning electron microscope (SEM). The detailed micromorphology and micro-area composition of the inner layer of the ash/deposition block were obtained via high-resolution mapping analysis (a maximum spatial resolution of 3 nm) on the EPMA. It is worth noting that prior to the cutting and polishing procedures, the sample blocks were purposely inlayed in the epoxy resin to improve their mechanical strength. Besides, EPO-KWICK epoxy and hardener were used as the resin and curing agent respectively. An additional platinum (Pt) layer was also sprayed onto the cross section in order to improve the conductivity under EPMA detection [
36]. After that, the ash deposition/slag blocks were pulverized in a mortar mill (RM200, Retsch GmbH) and powders smaller than 45
mm were subjected to X-ray diffraction (XRD, Empyrean, Malvern Panalytical Ltd.) detection to identify the crystal mineral species [
36,
38]. Finally, the inorganic elemental composition of the pulverized deposition samples was measured via the XRF to obtain bulk compositional characteristics of deposits formed at different heat transfer surfaces. This helped investigate the partitioning behaviors of the ash forming constituents along with the position of heat transfer surfaces.
3 Results and discussion
3.1 Appearance features of ash deposits at different positions
Photos of the ash deposits/slags in different superheaters (i.e., the PS, the HTS, the upper LTS, and the lower LTS), the cyclone outlet, and the economizer are orderly presented in Fig. 2, which directly showed the appearance features from the aspects of the geometrical shape, amount and deposition severity, porosity and so on. Purposely, the deposits in the PSs and the HTSs were partially scraped to probe into their inner structure. It is observed that the deposits on different surfaces had significantly different appearances which can be broadly classified into four categories depending on their geometrical shapes and textures.
First, as displayed in Fig. 2, the deposits in the PSs and the HTSs are thin (several millimeters) and compact, consisting of a yellow outer layer and snow-white inner layer near the tube surface. The white layer of both samples is made of fine crystal powder. Comparing these two samples, it can be seen that the outer layer of the deposits in the PSs is sintered and voidless while the inner layer is closely adhered to the tube surface and fused together with the metal surface. There are visible cracks spreading over the outer layer of the deposits in the HTSs whereas the inner layer is not sintered as tightly as that in the PSs.
Second, the deposits on the tubes at the cyclone outlet were observed to be the thickest and the most severe in all of the surveyed positions. The deposition was up to tens of centimeters thick with a loose and fragile outer layer cover but a tough inner core.
Third, the deposits on both of the upper LTS and the lower LTS were particularly studied (Fig. 2). Interestingly, although these two groups of LTSs were installed close to each other in the vertical heat recovery area, the deposits in them dramatically differed in both shape and texture. The deposits on the upper LTS appeared to be ceramic, which was toughly sintered and hard to break. Moreover, the deposits formed a ridge-shaped protrusion along the axial direction of the tube and had clearly ravine-liked pleats. In comparison, the deposits on the lower LTSs were composed of the dispersive coarse ash particles and/or sintered deposition grains, and had a relatively rough and unsintered surface which was distinctively different from all the deposits in the upstream positions.
Finally, the tubes in the economizer was freed from the ash deposition. The surfaces of the tubes were smooth with only few fine ash particles being observed on them. These ash particles were dispersive and not sticky, which made them easy to be blown off. The distinct appearances observed in the PSs, the HTSs, and the upper LTSs intuitively stressed the importance and necessity to control the high temperature deposition.
3.2 Cross-section analysis of ash deposits in PSs and HTSs
The detailed cross-section analysis results, connecting the chemical composition and appearance features, were depicted in Figs. 3(a) and 3(b). The XRD patterns of the deposition powders were also provided in Fig. 4 to show their components of the mineral in the crystalline phase. In addition, the distributions of the key elements across the initial layer were detected and displayed in Fig. 5. At least, four major findings were obtained.
The results in Fig. 3(a) demonstrated that the deposits in the PSs had a multi-layer structure, with brown ash layers spaced clearly with white ash layers. The dominating compositions in both the brown (e.g., spots 1 and 2) and white ash layers (e.g., spots 3 and 4) were Cl and K (50%–70%), which was consistent well with the ash compositions of biomass fuels. The white ash layers also had certain contents of Si as well as Ca and S, which were higher than those in the brown layers. The XRD identification results in Fig. 4 suggested that they were formed by crystal minerals such as SiO2 and CaSO4. Besides, it was observed that there was an increasing tendency in the contents of Ca and S crossing from the inner ash layers to the outer ones.
In addition, the ash deposits in the HTSs were also mixtures of ash matters of different colors (dark brown, light brown, and white) and mainly composed of Cl and K (40%–60%). However, there were no such organized layered structure as that in PS. The composition analysis results revealed that the dark brown matter (spots #1 and 3) had a higher content of Ca than the other two. Similarly, the higher Si content in the white colored matter also indicated the existence of SiO2, which is supposed to come from the abrasion of the bed material (namely, sand).
Moreover, as is well known, the initial layer closely next to the tube surfaces plays a key role in the formation of ash deposits. The micro morphology and element distribution in the approximately 3 mm ash layers on the tube surface of the deposits in the PSs and the HTSs were depicted in Figs. 5(a) and 5(b), which help probe into the characteristics of the initial layer in the deposits. As shown in Fig. 5(a), there were four typical class zones in the deposits in the PSs from the inside to the outside. Zone I had both Fe and Cr, confirming that it was part of the stainless tube. Zone II also had a relative content of Fe but no Cr, which suggested that it was the rust layer (Fe
2O
3, approximately 0.1 mm) covering the metal tubes [
39]. Zone III was a layer (approximately 1.4 mm) of KCl with a few SiO
2 particles and CaSO
4. Zone IV was composed of the alternant CaO or CaCO
3 layer (approximately 0.1 mm) and KCl layer (0.05–2 mm). Zone V was composed of SiO
2, KCl, and CaO/CaCO
3. The above results agreed well with the appearance observance and revealed that the snow-white layer was made of KCl and SiO
2 while the brown-cover layer was made of CaO/CaCO
3/CaSO
4, KCl, and SiO
2. It was supposed that because of the thermal resistance of the ash layer, the substance at the outer layer suffered a high temperature from the flue gas and thereby produced eutectic material, which melt and formed the sintered voidless surface (shown in Fig. 2) [
4].
Furthermore, the deposits in the HTSs could also be divided into four zones (displayed in Fig. 5(b)). Zone I (approximately 0.4 mm) had a high content of Fe and some Cr, suggesting that it was the tube surface. Zone II (approximately 0.2 mm) had a high content of Si, which was most likely resulted from the ceramic anti-corrosion layer covering the tube. Zone III (approximately 1 mm) was a layer composed of K and Cl, with some Si, Ca, and Fe. It should be noted that although the contents of K and Cl fluctuated at different positions, the molar ratio of K/Cl in this zone remained at approximately 1 mm, which confirmed that they existed as KCl. Moreover, Ca and Si as well as Ca and Fe also exhibited a steady molar ratio at approximately 1 mm, suggesting that some substances in the forms of CaSiOx and CaFeOy existed in this zone. Zone III was composed of Ca, K, and Cl. As observed above, K and Cl existed as KCl while Ca was most possibly presented as CaO and/or CaCO3 as there were no commensurable S with Ca. Additionally, high contents of ash constituents rather than Fe were observed in the initial part of the results (e.g., 0–200 mm). The reason for this is that a few of the deposit powders might inevitably entrain into the liquid epoxy during the inlay of the sample, which finally distributed at the junction just between the sample and the epoxy due to the surface tension.
3.3 Cross-section analysis of ash deposits in low-temperature superheaters
The cross-section analysis results (i.e., morphology and elemental composition) of the ash deposits in the upper and lower LTSs were exhibited in Figs. 6 and 7 respectively. Distributions of the key elements across the 3 mm inner ash layer of the deposits in the upper LTSs were also determined and displayed in Fig. 8. The cross-section of the deposits of the upper LTSs (see Fig. 6) was about three centimeters in height. Besides, what is interesting is that it had a unique lamellar structure with each sheet of the thickness of hundreds of micro meters. The cross-section was triangle in shape with the center line positioned at the positive direction of incoming flue gas flow. The composition analysis results of the typical ash sheets in the cross section indicated that the major composition in them were Ca and S with certain contents of Si, P, and Cl, which was significantly different from that in the PSs and the HTSs. Comparatively speaking, the inner ash sheets closely next to the tube surface (denoted as #1–3) had a relatively high content of S than the outer ash sheets.
The deposits in the lower LTSs (see Fig. 7), as expected, were composed of large dark-brown ash/slag grains glued together by some yellow matter. Ash grains in the cross section were irregularly dispersed and this unordered structure was different from those in the upper LTSs, the HTSs, and the PSs. The composition analysis results revealed that the these deposits were mainly composed of Si and Ca with some contents of S, Cl, and K.
As shown in Fig. 8, the cross section of the deposits in the upper LTSs could also be divided into four zones. Similar to those in the deposits in the PSs, Zones I and II were also the tube surface and the rust layer (0.7 mm) based on their compositions while Zone III (>2 mm) was mainly composed of Ca, K, Cl, and S. Based on their molar ratios, these elements most possibly existed as KCl, CaO, CaCO3, and CaSO4. Compared to the observations in the PSs and HTSs, there were two major differences. On the one hand, there were no notable KCl-enriched layer between Zone II and Zone III. On the other hand, there were increased content of S in Zone III. Besides, the improved content of S inclined an increased deposition tendency of acid species, which was responsible for the aggravated corrosion.
The above cross-section analysis of the ash deposits in the PSs (Fig. 5(a)), the HTSs (Fig. 5(b)) and the low-temperature super heaters (Fig. 8) also partially uncover the deposition process on different heat transfer surfaces. On the surfaces of the PSs, the HTSs, and the upper LTSs, gaseous and/or molten KCl first condensed and adhered to the surfaces. Under the action of local high temperature, the initially deposited KCl layers melt. Then, Si-/Ca-contained ash particles were adhered onto the initial layer when colliding with it. When the sticky molten surfaces were covered by the solid ash particles, the deposition of solid particles was reduced while the deposition of the molten particles continued and became dominant again. This process repeated and finally resulted in the observed layered structure (Figs. 5(a) and 5(b), and 8). The surface temperature of the lower LTSs was lower and little KCl melt. Thereby, the deposition occurred in a lower level and no layered structure was formed.
3.4 Partitioning behavior of key mineral elements onto different surfaces
The chemical composition and mineral components of the bulk deposits sampled from the PS, the HTS, the cyclone outlet, the upper LTS, the lower LTS, and the economizer as well as the fly ash were depicted in Fig. 9, to show the partitioning behavior of harmful mineral elements onto the surfaces in different positions. The elements K, Cl, Ca, Si, S, and Fe were found to be the principal constituents involved in the ash deposits. Moreover, their contents differ a lot in the deposits formed at different locations. The aforementioned clear spatial dependencies of the inorganic elements on the heat surfaces reflected the deposition characteristics and their growth mechanism.
As apparently shown, K and Cl were the major compositions (approximately 70% in total) in the deposits on the high temperature surfaces, and their contents were approximately equal to each other. The K and Cl contents in the deposits in the economizer and fly ash were similar but much lower than those in the PSs and the HTSs (approximately 15% in total). It was clearly shown that the contents of K and Cl decreased dramatically in the deposits from the HTSs to the economizer, which indicated that the deposition of K and Cl occurred significantly in the LTSs [
40,
41]. The XRD results further revealed that they were deposited in the form of KCl. The contents of Ca and Si increased from approximately 10% to approximately 60% in the compositions from the high temperature surfaces to the low temperature ones. In comparison, Ca-contained species showed similar partitioning behaviors in the LTSs, the economizer, and the fly ash while Si had a more obvious partitioning tendency in the economizer and the fly ash than in the LTSs. The partitioning behavior of S and Fe appeared to be correlated, both of which showed an obvious deposition in the LTSs. This phenomenon indicated that the acid gas species (e.g., SO
3, H
2SO
4) preferred to deposition in the LTS area.
The contents of the crystal phase mineral in the deposits agreed well with the above chemical composition results. Amounts of KCl occurred in the deposits in the PSs and HTSs and a great amount of CaSO4 occurred in the deposits in the LTSs. It was interesting to observe that the Ca contained in the deposits in the superheaters was in the form of CaSO4 while that in the fly ash was in the form of CaCO3. This disparity was supposed to be resulted from the sufficient sulfuration of the Ca-contained minerals (CaO, CaCO3) in the deposits due to the high reaction temperature. Moreover, the high SOx content and continuous exposure/interaction facilitated the formation of CaSO4 in this process.
Another interesting observation was the partitioning behavior of Si. Certain content of Si was detected in the deposits, especially in the fly ash. The Si in the deposits most possibly came from the coalescence of the Si in the biomass particle and the abrasion of the bed material. In addition, the interaction of the K in the fuel with the bed material would generate some low-melting-point silicates (e.g., K-silicates) [
18], which enhanced the abrasion process and formation of fine ash particle. In the low temperature regions such as the LTSs, although the condensation of KCl also happened, the deposition of sulfates, carbonates, and silicates appeared to play a more important role, forming the initial layer (see Fig. 10). Besides, the ash particles (e.g., limestone, gypsum, quartz, etc.) further deposited on the initial layer [
42,
43].
4 Conclusions
In this work, typical ash deposits on the tube surfaces in the superheaters situated in different gas locations, economizer, and preheater in a commercially biomass firing CFB boiler were purposely collected. The macroscopic appearance features, cross section characteristics, chemical composition, mineralogical composition of these deposit samples were successively determined. Based on the analyses, the following conclusions were obtained.
The deposits in the PSs and the HTSs were thin (several millimeters) and compact, and deposits in the upper LTSs appeared to be ceramic, which was toughly sintered. In comparison, the deposits in the lower LTSs were composed of the dispersive coarse ash particles and had a relatively rough and unsintered surface. The distinct appearances observed in the PSs, the HTSs, and the upper LTSs intuitively stressed the importance and necessity to control the high temperature deposition.
The dominating compositions in both the PSs and HTSs were Cl and K (approximately 70%) in the form of potassium chloride. The major compositions in the cross-section of the deposits in the upper LTSs were Ca and S with certain contents of Si, P, and Cl. Moreover, the inner ash sheets closely next to the tube surface had a relatively high contents of S than the outer ash sheets. The different element distribution characteristics in the cross section help reveal the depositing process on different heat transfer surfaces.
The vaporized mineral matter such as KCl played the most important role in the deposits progress in the PSs and HTSs. Besides, the deposition of the ash particles (e.g., limestone, gypsum, quartz, etc.) in the low temperature regions such as LTSs played a more important role in the formation and growth of the ash deposits.