How it Works

DS-600i is considered a multi-functional burn rate modifier because the technology is affecting the combustion environment on two fronts.

First, the technology has a chemically engineered affect on the rate determining steps in the combustion process. Essentially, the rate of combustion is normalized, which creates a more efficient and complete release of available energy. More complete combustion with less temperature spikes will directly reduce harmful emissions (NOx, SOx, THC, PM, CO).

Second, it works as a carbon-deposit-surface modifier which essentially helps to modify the types of slag deposits that contribute to hot and cold-end corrosion. It also helps to burn off existing carbon deposits through a process called decarboxylation. Removal of carbon deposits will release stored energy into the combustion environment and improve or help to maintain optimal thermal transfer for steam production.

The process of deposit removal by DS-600i begins immediately after treating the fuel, but the time required for the full benefits of DS-600i to be realized depends on the operation, history, and age of the equipment.

The formation of NOx appears to take place late in the combustion process during the exhaust phase or in the stack. Its creation is influenced by three primary factors: (1) available oxygen, (2) high temperatures, and (3) time. There is a limited amount of energy in the fuel that is released through the production of CO2. DS-600i promotes the formation of CO2 in the early stages of combustion or in the chamber. The creation of the additional CO2 in the chamber results in using up much of the excess oxygen in the chamber, thus reducing the amount available in the exhaust. Increasing the energy output in the chamber thus reducing the temperature of the exhaust, and reduces the high heat duration by utilizing the additional available energy through the heat transfer process within the chamber not allowing it to get to exhaust. All these factors lead to the reduction of NOx formation.

To fully understand how DS-600i effects NOx, it is important to note that when monitoring the effects of DS-600i on general emissions wide fluctuations were noted in the amount of NOx produced. Although over time the NOx emissions trended downward, they correlated with the removal of deposits. The low production of NOx in a clean combustion unit running on DS-600i treated fuel further supports the direct connection between the removal of deposits and the reduction of NOx emissions.

Therefore, the process by which DS-600i inhibits the formation of NOx is a direct result of the process by which it destroys and inhibits the formation of deposits, namely through the promotion of CO2 production.

Heavy fuel oils are generally considered to be dirty, environmentally polluting fuels. Most of the environmental objections relate to the high sulfur content (up to 5%) and the concentrated mineral content, which is responsible for particulate emissions, acid corrosion, and slag formation. The principle metal contaminants are sodium, potassium, vanadium (up to 200 ppm), and sometimes aluminum, silicon, copper, and nickel. The metals, particularly vanadium, are usually present, as nitrogen-containing fuel-soluble heterocyclic porphyrin chelates which cannot be economically removed from the fuel.

The combination of vanadium and sodium (Na) will typically create a situation where less energy is required to create higher oxidation states of vanadium i.e., V+4 and V+5. These higher oxidation states of vanadium and sodium are what form the sticky slag deposits. When these deposits come in contact with the steam tubes and other areas of the boiler, it will promote corrosion by reacting with the metal surfaces to create scaling.

In the same regard, sulfur (S) will be present in different oxidation states in the fuel and on the fire-side during combustion. Sulfur will oxidize to SO2 during the combustion process, but requires the catalytic function of vanadium pentoxide to convert to SO3. This can lead to the formation of sulfuric acid H2SO4 in the presence of water vapor, which is primarily responsible for corrosion problems in combustion equipment.

DS-600i does not react with sulfur in the fuel, nor will it have any effect on the sulfur content in the fuel. However, DS-600i will affect where sulfur ends up and its chemical state after combustion.

The use of DS-600i inhibits the formation and reversible dissociation of V5+, which occurs during the exhaust phase of the combustion process at temperatures between 700-1125 C. This is achieved by increasing the energy release in the combustion chamber by allowing the fuel to burn more completely reducing the available O2, high temperatures, and time periods needed for the reactions to occur. This greatly reduces the catalytic effect that V5+ has on the formation of sulfur trioxide (SO3) and thus the formation of sulfuric acid. By reducing the catalytic effect of V5+, DS-600i promotes the combination of SOx compounds with other minerals in the fuel such as Na and Ni. This leads to the formation of stable mineral salts and low valence sulfur compounds, which show up in the clinker or fly ash thereby shifting the gaseous sulfur emissions to the particulate portion of the combustion byproducts.

In a similar manner DS-600i has been engineered to leverage a chemical attraction to the different valence and oxidation levels of the vanadium/sodium slag and carbon deposits that will interfere with their formation by breaking down the oxidation levels of the slag/carbon deposits and removing them over time.

More complete combustion will translate into lower carbon content of the ash and an overall reduction in deposit formation inside the boiler and exhaust systems. As a result, greater thermal efficiency will be maintained.

Chemicals like magnesium and calcium oxide, which are commonly used to disrupt the oxidation states of vanadium and sodium slag, will result in a greater volume of bottom and fly ash. The increased volume of ash will still have an impact on the thermal efficiency of the boiler and can require more frequent maintenance and cleaning.

Combustion Deposits are mostly carbon and aromatic compounds in a highly combustion resistant state. These deposits are the source of many engine problems, such as higher than normal fuel consumption, excessive harmful exhaust, and costly maintenance. Fuel problems and incomplete combustion ultimately cause complete engine failure.

Deposit formation begins with spherical molecules called primary particles and branched aromatic chains, both of which are produced in the early stages of combustion. The chain branches consist of alkyl, alcohol, carbonyl, and carboxyl compounds. The alkyls oxidize to alcohol, oxidizing to carbonyl, oxidizing to carboxyl. The oxidation process stops with the carboxyl compounds, which are acidic and highly combustion resistant with a high energy of activation.

The various branch compounds are attracted to the primary particles, which spin at extremely high velocities. When a branch becomes attached to a primary particle, the entire chain structure is quickly wrapped around the primary particle forming a secondary particle. These secondary particles agglomerate and form a tertiary particles. This can happen when several primary particles become attached to the same chain on different branches, and then simultaneously become secondary and tertiary particle, as they wrap up the chain.

Tertiary particles agglomerating on a surface will become further coated to form quaternary particles. The coated quaternary particles make up deposits. The chain structures coating the surface of deposits leave exposed branches. It is at these branches where Rennsli technology begins to break down and destroy the deposits as it modifies the surfaces.

The carboxyl branches are acidic, and attract the catalyst oxide which is basic. When the two combine, a process called dehydration occurs, and a water molecule is produced. What remains is a compound with a low energy of activation, which readily breaks down at high temperatures, releasing a CO2 molecule and the catalyst oxide.

Upon releasing the CO2 and the catalyst oxide, the end of the chain re-oxidizes to an alkyl, alcohol, or carbonyl compound, and finally to a carboxyl compound. When the end of the chain reaches this state, the catalyst oxide once again combines with the carboxyl and starts the break down cycle again. Over time, the deposits are removed by being converted to CO2 and water.

DS-600i inhibits the formation of new deposits in much the same way as it destroys existing deposits. It interacts with the ends of the aromatic chains and the attachment sites on the primary particles. This interaction keeps the primary particles from wrapping up full chains by blocking or destroying the attachment sites and breaking the chains.

This interference stops the deposit agglomeration process at the primary and secondary particle agglomeration stage. This results in much lighter and smaller particles that don’t stick together and are more easily oxidized. The result of this interference is a lower mass of particulate emissions, and instead, an increased energy output and increased production of CO2 and water, which are the desirable end products of the combustion cycle.