introduction

Clinker formation is a serious problem in the boilers of thermal power plants which results in forced outage
for very long duration and generation loss. The removal of clinkers from the water wall and hopper of
boilers is very difficult because clinkers are very hard lumps due to presence of metals in them. Removal
of clinkers from boiler is very difficult procedure which takes a long time and the cost involved is also
very high. Pneumatic hammering is done manually to dislodge clinkers from boilers, and clinker
grinders can be used in grind large pieces of clinkers into small ones.

Causes of Clinker Formation

The causes of clinker formation are low quality coal having low gross calorific value, more ash content, high
mineral content, low fusion temperature of ash below 1500 C, and over-firing of the molten slag.

In India the coal used for thermal power plants is often of low quality with low gross calorific value, high ash
and minerals content, so the problems of clinker formation and deposition are evident in many plants.
The best solution is to avoid the deposition of clinker is precaution.

Blaming poor quality coal may prove harmful for the boiler. Instead of very poor quality coal having high ash
and mineral content, clinker formation may be avoided by a sincere attitude of power plant engineers.

Typical Clinker

Dealing with Clinker Removal

If great care is not taken for poking, then deposition may start, and its sudden collapse may cause injury and
burns to workers. A sufficient quantity of water must be provided in the hoppers to flush molten slag
and ash so they will not deposit. For flushing of molten ash, water is sprayed into the hopper by the flush
pump. Soot blowing must be regularly done to avoid deposition of soot in the water wall by injecting
steam at sufficient pressure and temperature to dislodge soot from the water walls tubes.
Clinker grinders are provided in boilers to grind large pieces of clinkers into small ones so that choking of the
exhaust hole may be avoided, but it is observed in many thermal power plants that clinker grinders are
out of service due to negligence or being considered a redundant feature. Due to this negligence large
pieces of clinkers can choke the exhaust hole of the hopper and accumulation of small pieces of clinkers
and water starts above it. Clinker grinders must be made operational.

Summary

The major cause of clinker formation in a boiler is over-firing due to which ash fuses, hence firing must be
properly adjusted by using the right quantity of primary and secondary air ratio in the boiler. Good
quality coal having more gross calorific value, less ash content, less mineral content in the coal, and ash
fusion temperature above 1500 C must be used to avoid clinker formation. Regular watch must be done
on poking. Precautions may avoid clinker formation and its deposition in boilers.

Precaution is the best solution.

Clinkers have been a recurring problem in all coal-fired boilers for as

long as humans have operated coal boilers. Clinkers occur in small
stoves used for heating a home and in giant commercial/industrial
boilers. Clinkers, also known as slag, consist of the noncombustible
elements and minerals found in coal that melt and fuse together as
lumpy ashes from coal combustion. Boiler operators consider
clinkers to be miserable stuff.

Clinker Problem

Clinkers resemble volcanic ash and lava. They occur in the high-
temperature furnace area of the boiler. Clinkers form as a result of
interaction among coal quality, boiler design and boiler operation.
Coal boilers draw their combustion air from the bottom, up
through the combustion grate. Lots of large clinkers on the
combustion grate can hinder air passage, increase operation and
maintenance costs and even force shutdowns of the boiler for
cleaning out the clinkers.

How They Form

Coal clinkers form when noncombustible elements contained in coal
such as iron, calcium, silicon, aluminum and sodium interact with
sulfur and carbon at high temperatures. These elements melt
together with clays and alkalis to form a glassy slag that eventually
hardens into clinkers. Clinker formation is a complex series of
mineralogical transformations and phase changes that occur as
coal burns. Small clinkers can fuse together to form large ones that
can physically damage boilers.

Contributing Factors

Bituminous coal that’s rich in sulfur, iron compounds and clay

minerals tends to produce the most clinkers. Boiler operating
practices that reduce emissions of oxides of nitrogen tend to
increase formation of clinkers. Other contributors to clinker
formation include failure to remove soot and other deposits,
poorly pulverized coal, and improper burner adjustments that
result in inefficient mixtures of air and fuel. A firebox that’s too
small for the type of coal being burned coupled with infrequent
ash removal also encourages clinker formation. The problem is
compounded if there’s no way to observe clinker buildup in the
boiler.

Chemical Cure

Some companies are offering chemical combustion enhancers to be

added to coal that they claim will virtually eliminate clinker
formation from burning lower-quality coal. These compounds act
as a chemical catalyst that uses the moisture inherent in solid fuels
to increase the temperature of combustion and thereby greatly
reduce the amount of unburnt matter that otherwise would just
melt to form clinkers.