Ash Adhesion Prediction Using Ratra Tester Sticking Degree
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Solution Overview
Problem
Existing methods for predicting ash adhesion in coal-fired boilers are unreliable for low-grade coals like subbituminous coal, as they fail to consistently correlate ash composition indices with adhesion behaviors, leading to potential ash damage and operational disruptions.
Innovation Solution
A method and device that generate sintered ash at various temperatures, calculate sticking degrees using a ratra tester, and determine correlations between sticking degrees and exhaust gas temperatures to predict ash adhesion, allowing for the effective use of low-grade coals by adjusting combustion conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional ash composition indices are used to predict ash adhesion, then the prediction method is simple, but the prediction reliability is low for low-grade coals
Solution Approach 1:
The invention changes the prediction parameters from conventional ash composition indices to sticking degree measured by a ratra tester. This parameter transformation enables accurate prediction of ash adhesion for low-grade coals including subbituminous coal, high-silica coal, high-sulfur coal, high-calcium coal, and high-ash coal, while maintaining operational simplicity through standardized testing procedures
Solution Approach 2:
The invention replaces conventional chemical analysis methods with a mechanical testing approach using a ratra tester. The tester mechanically separates sintered ash particles and measures sticking degree through weight ratio, providing reliable predictions without complex chemical composition analysis
2Loss of energy
If low-grade coal is used to reduce fuel cost, then economic advantage is improved, but ash adhesion damage increases
Solution Approach 1:
The invention performs preliminary testing of coal sticking degree using a ratra tester before actual boiler operation. By measuring the sticking degree of sintered ash at combustion temperatures, operators can predict potential ash adhesion problems and take preventive actions such as adjusting combustion conditions or selecting alternative fuels, thereby avoiding costly operational disruptions
Solution Approach 2:
The invention establishes a feedback mechanism where sticking degree measurement results directly inform fuel selection and combustion operation decisions. The correlation between sticking degree and ash adhesion behavior provides continuous feedback for optimizing fuel usage and preventing ash damage in coal-fired boilers
3Measurement precision
If sticking degree measurement is performed to accurately predict ash adhesion, then prediction precision is improved, but measurement complexity increases
Solution Approach 1:
The invention extracts the essential measurement function from complex chemical analysis and isolates it into a dedicated ratra tester device. The tester specifically measures sticking degree by mechanically separating sintered ash particles and calculating weight ratios, providing precise measurements without the complexity of full chemical composition analysis
Solution Approach 2:
The invention uses disposable or easily replaceable sintered ash samples in the ratra tester. The testing process involves heating coal ash to form sintered particles, which are then mechanically separated and measured. The simplicity of the testing cycle allows for rapid, repeated measurements without requiring complex calibration or maintenance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables precise prediction and prevention of ash adhesion, enhancing the operational availability of coal-fired boilers and enabling the economical use of low-grade coals by correlating sticking degrees with exhaust gas temperatures, thus reducing the risk of ash damage and maintaining stable boiler operation.
Implementation Method 1
a sintered-ash generating step for heating the coal ash generated in said coal-ash generating step at a plurality of temperatures within a combustion temperature range of the coal-fired boiler to generate sintered ash
Implementation Method 2
a sticking-degree calculating step for rotatively separating each sintered ash generated in said sintered-ash generating step by a ratra tester to calculate a sticking degree from a weight ratio
Implementation Method 3
a correlation determining step for burning each coal having a corresponding sticking degree calculated in said sticking-degree calculating step in the coal-fired boiler to measure an exhaust gas temperature
Data Source
AI summary
Conducted are coal-ash generating step for generating coal ash, sintered-ash generating step for heating the coal ash at temperatures within combustion temperature range of coal-fired boiler to generate sintered ash at each heating temperature, sticking-degree calculating step for rotatively separating each sintered ash by ratra tester to calculate sticking degree from weight ratio of each sintered ash after and before the rotary separation of the sintered ash, correlation determining step for burning each coal having corresponding sticking degree calculated to measure exhaust gas temperature and obtain correlation between sticking degrees and exhaust gas temperatures, exhaust-gas-temperature predicting step for predicting exhaust gas temperature from sticking degree of coal to be employed as fuel based on the correlation between the sticking degrees and the exhaust gas temperatures and adhesion predicting step for predicting ash adhesion in the coal-fired boiler based on the exhaust gas temperature predicted.