The Role of Atomizing Medium in the Effectiveness of Water-Oil Emulsions to Reduce Unburned Carbon Particles

Two older boilers were burning low grade heavy fuel oil (number 6) and emitting large amounts of unburned carbon particles. Owing to the short life remaining of the units and economic constrains, it was not possible to change to a better fuel or install new burners. To contribute to the solution of this problem, an experimental program was carried out by emulsifying water in the fuel oil. Tests were performed in a scale furnace (0.35MWth) and the emulsions that produced the best results were assessed in the two boilers, 28 and 34 MWe capacity with Y-jet atomizer type. The system to prepare the emulsion was very simple: water was added into the oil before the fuel oil pump, no chemical products were added and a static mixed was used to improve the water size distribution, which 90% ranged from 1 to 9 micron. In the pilot furnace the emulsions were prepared with 5 and 10% water and atomized with compressed air. Particle reductions of 43 and 67% were obtained compared with the net heavy fuel oil. In the boilers, the emulsions were prepared with the same amount of water, and were atomized with saturated steam. In the 28 MWe boiler, a similar particle reduction was obtained to that of the scale furnace. However, in the 34 MWe boiler there was no particle abatement. By using a commercial fluid dynamic computer code, it was found that the combustion air transferred heat to the steam raising its temperature. Thus, in the mixing chamber of the Y-jet atomizers, the steam was superheated and destroyed the water droplets of the emulsion. Compressed air and saturated steam as atomizing medium of the emulsions had similar effect on the unburned particle reduction. However, the effectiveness of the emulsions may be affected by the steam. Care should be taken to avoid the use of steam with a temperature higher than the saturated water temperature.