Understanding The Science of Soot Buildup and Fires in Exhaust Gas Boilers

Exhaust gas fires, soot deposits, and boiler efficiency issues hold a more prevalent presence in maritime operations than initial assumptions might suggest. Within the maritime industry, marine engineers, superintendents, and ship owners frequently find themselves entangled in critical situations that, with proper foresight, could have been entirely averted.

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Humble request: For all the mariners(especially management levels) who think that after all the licences and reaching at the top, learning ends. sorry to that, sea is a grea leveller of all our rowdiness, it just a matter of seconds a one wrong move and a life is lost at sea, so do try to finish reading this, we belive one day it might save someone's life on board, so think family, safety first, keep learning keep upgrading your self, lifelong.

For those among you who possess extensive experience with Exhaust Gas Boilers (EGBs), you can advised and requested to give a quiz promptly by clicking the quiz con on the right or utilising the button provided below.

EGB Fire Quiz

A short little story, to set the context of this very long blog

Overcoming an EGB Challenge: A Real-Life Triumph by Alex and Solanki(Click here)

Aboard the cargo ship "The Endeavor" a critical situation was unfolding. Alex, a seasoned superintendent, faced a significant challenge in the engine room. The ship's Exhaust Gas Boiler (EGB) was malfunctioning, posing a potential threat to the entire crew's safety.

As the moon cast its gentle glow on the calm waters, Alex received a message from Chief Engineer Solanki, who was new to the role. The ship's ongoing issue with soot deposits in the EGB had escalated, requiring immediate attention.

"I can't ignore soot blow; that'd lead to deposits," Alex murmured as he reviewed the messages. He pondered the complexities, including the risk of a hydrogen fire during steam blow and the operating temperature limits.

Recognizing the urgency, Alex suggested meeting in person. In the control room, they analyzed the gauges and data, assessing the EGB's status. Solanki expressed concern about the soot blow's hydrogen fire risk and the inlet temperature's impact on operation.

Alex devised a plan: they would analyze current conditions, evaluate hydrogen fire risks, and proceed with caution if safe. With meticulous review, they deemed the hydrogen fire risk to be low and successfully conducted the steam soot blow.

Encouraged by the outcome, they addressed running the EGB under 425°C. After thorough research, they verified its feasibility within specified limits. They set the EGB in motion, maintaining safe parameters.

Their collaborative efforts proved fruitful, showing the power of teamwork and diligent analysis. Alex and Solanki's united front resolved a complex problem, underscoring that safety and solutions could prevail through knowledge and coordination.

These challenges extend beyond mere safety concerns; they also cast an impact on operational efficiency and the overall performance of vessels. In this comprehensive blog, we endeavour to provide readers with an extensive understanding of exhaust gas fires, soot accumulation, and boiler efficiency concerns that mariners frequently encounter. By delving into the root causes and offering preventive measures, we aim to empower maritime professionals with the necessary knowledge to adeptly navigate such situations. Ultimately, our goal is to enhance operational seamlessness and safety at sea.

We would be covering following topics in this blog

The pursuit of optimal fuel efficiency in the maritime propulsion sector has driven developments in the market for ocean-going vessels. Presently, this sector is largely dominated by highly efficient two-stroke, low-speed diesel engines that run on lower-grade fuels. These engines make use of exhaust gas boilers or economizers to recover and utilize exhaust gas heat.

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Special mention to MAN Diesel and Turbo research, which has inspired our team to take this challenge of writing this blog

The advancements in high-efficiency engines have led to reduced specific fuel oil consumption, resulting in increased thermal efficiency of diesel engines and subsequently lower exhaust gas temperatures.

Under ISO standard conditions (25°C air and 25°C cooling water), and considering the current nominal ratings of engines such as MC/MC-C and ME/ME-C/ME-B, the exhaust gas temperature after the turbocharger for standard engines without waste heat recovery systems is approximately 240-270°C. However, this temperature may be even lower for derated engines(Engine derating is the reduction of an engine's output due to less-than-ideal operating conditions)

The term "exhaust gas economizer" is often used for an exhaust gas boiler that cannot function independently, without its own steam drum. In this paper, we will use the term "exhaust gas boiler" in a general sense, even in instances where "exhaust gas economizer" would be more appropriate.

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