Fuel Additives – Magcare

MAGCARE BOILER AND GAS TURBINE FUEL OIL ADDITIVES

Introduction :

MagCare specializes in manufacturing and providing a diverse range of Fuel Additives, serving as corrosion inhibitors in residual fuels for Boilers, Gas Turbines, and Coal-powered Boilers. Our primary objective is to enhance the lifespan of combustion equipment while contributing to environmental cleanliness. MagCare upholds the highest standards of quality and safety in the development and production of our products, embodying an innovative specialty chemical company that provides economical and environmentally friendly solutions for clients in the Power, Oil Refinery, and Marine Industries.

Magcare’s fuel oil additives are applied in :

Steam power plants
Gas turbines
Oil refining
Marine boilers

Magcare has complete range of fuel oil additives as described below :

Inorganic MgO or Mg(OH)₂ slurries consist of nano-particles with a large surface area, high reactivity, and reduced consumption. Our Magcare GT30, GT30C and Magcare 60B additives, based on MgO, are highly reactive and efficient, complemented by similarly reactive Mg(OH)₂ additives.
WIO (Water-in-Oil) technology, enhancing combustion through secondary atomization, reducing fouling, and promoting environmental cleanliness by minimizing particulates.
Gas turbine additives, including oil-soluble Organo-Metallic Magnesium and inorganic Mg(OH)₂, effectively inhibiting Vanadic corrosion.
Organo-metallic oxidation catalysts that reduce soot by up to 60% in boilers and down to 50 mg/Nm₃ in turbines.

ADDITIVE REACTIONS:

Hot end neutralization reaction:

MgO + V₂O₅ → 3MgO. V₂O₅

Magnesium reacts with corrosive products formed during combustion, creating Magnesium Ortho Vanadate—high melting and non-corrosive, easily removed by soot-blowers.

Cold end neutralization reaction:

MgO + SO₃ → MgSO₄

MgO + H₂SO₄ → MgSO₄ + H₂O

MgSO₄ is neutral and non-corrosive.

Benefits of employing Magcare range of boiler fuel oil additives:

Prevention of hot-end corrosion due to Vanadium, Sodium, and cold-end corrosion due to Sulphur.
Neutralization of additional SO₃ generated by SCR.
Maintenance of lower boiler conversion rates.
Conversion of tenacious ash deposits to soft and friable.
Elimination of the “White Effect,” preventing an increase in convective section temperature and Eco-out temperature.
Lowering of ADP through neutralization of condensing SO₃ at the cold end, reducing stack temperature and saving fuel.
Protection of Ducts and ESP from corrosion at the back end, including APH.
Elimination of Blue Plume due to SO₃.
Up to 80% reduction in unburned carbon, addressing PM emissions and ash disposal challenges.
Absence of Acid Smut.
Reduced boiler outage frequency and minimized power loss.

Clean Ash

Clean APH Elements

Combustion improvement of heavy fuel oil and vacuum residue burning power plants:

Boilers which require better combustion and substantial particulate reduction have the following treatment options:

Combustion Catalyst
Water-in-Oil Emulsion (WIO)

In the case of WIO Emulsion the secondary atomization facilitates burning of more unburned carbon reducing it up to 60 – 80 %. The NO_x 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.

Dual fuel additive treatment:

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.

Advantages of wio combustion improvement program:

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 NO_X formation.

Less Excess Air Required: Our Emulsified Fuel can be burned cleanly at lower excess air levels, reducing the formation of SO_3, NO_X 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

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)

NB: Treatment with Combustion Catalyst will give up to 40 – 60% reduction in Unburned Carbon and it does not require an Emulsion Skid.

Magcare gas turbine fuel oil additives :

Gas Turbines burn HFO, light crude or heavy fuel oil. Since these fuel oils are not refined, they contain numerous impurities contaminated with vanadium and other metal compounds. Heavy fuel oils contain many metallic contaminants of organic and inorganic compounds, which may include sodium, potassium, vanadium, lead and nickel. These elements interact with oxygen and sulphur during combustion, including oxidation in the combustion plume, to form reaction products, including low melting point oxides. Metal and ash contained in the crude and residual fuels can cause corrosion, erosion and fouling. Sodium and potassium are conventionally removed prior to being injected to the combustion chambers by using an upstream fuel oil treatment system with the aid of electrostatic separators or centrifuges. However, elements such as vanadium and lead are not water soluble and are difficult to remove from the fuel by using any upstream process and corrosion due to these elements treated by applying vanadium inhibitors. Turbines and compressors are frequently 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, causing turbine efficiency to drop due to an increase in surface roughness and a decrease in 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.

Problems due to vanadium corrosion are addressed by applying Magnesium based Organic fuel oil additives. MagCare suppresses hot corrosion in the Gas Turbine and reducing downtime and damage to the plant walls and avoiding corrosion of the flue system enabling a reduction in heat losses.

Vanadium corrosion inhibitor has a large specific surface area making it highly active. MagCare prevents Vanadium Corrosion as it enhances reacting with Vanadium compounds & other impurities to form low melting inorganic salts which deposit as a viscous liquid.
The fire residue is very little. Scale depositsare very easily washed away.
SO₃ content in the smoke reduces drastically! Sulphuric acid dew point corrosion is also reduced in the Boiler part at low temperature

Our MagCare Gas Turbine Oxidation Catalyst can reduce the Particulate Matter to World Bank guidelines of level of 50 mg/Nm₃.

MagCare is an oil soluble liquid and it can easily be metered directly into the fuel handling system. The dosage rate is dependent on content of vanadium, sodium and Sulphur.

MagCare acts as an inhibitor to accomplish the following:

Conversion of corrosive compounds in the hot gas path into high melting point frangible salts that permit higher firing temperatures.
Reduction of the volume of ash generated by using higher valence compounds that form denser reaction products, leading to longer time intervals between water wash cycles.
Driving lead to form lead sulfate instead of a corrosive oxide and
Driving nickel to form nickel sulfates so that nickel constituents in the ash are become water soluble.

Features and Advantages:

Highly reactive sub-micron oil soluble fuel additive.
Eliminate disintegration of organic sludge in fuel tanks of the refinery, the fuel trucks and the tanks in the plants.
Reduce fouling in gas turbine and recovery boiler.
Neutralize vanadium deposits and corresponding corrosion effects.
Reduction of maintenance time.
Improve combustion of the fuel with catalyst action.
Reduce wastewater generation.
Inhibits high-temperature corrosion of furnace, super heater and re-heater tubes.
Modifies Gas Turbine/process heater fly ash
Lower acid dew point of exhaust gases.
Reduces cold-end corrosion in Boiler Plants.
Prevents the formation of low melting deposits of vanadium and sodium.
Neutralises acid-forming SO₂ and So₃.
Maintains the efficiency of Gas Turbines and promotes operational economy through improvement in cleanliness, reduced downtime and reduced thermal losses.
Extends Gas Turbine operation periods and Gas Turbine availability.
Promotes the formation of powdery friable fireside ash.