Ash Fusion Tester

A laboratory instrument used to determine the characteristic temperatures at which coal ash softens, deforms, and eventually flows into a liquid, which is crucial for predicting slagging and fouling behavior in combustion systems.

Types of Ash Fusion Tester

Manual/Visual Ash Fusion Testers: 

Operator observes the ash cone through a viewport as it's heated.

Automated Ash Fusion Testers:

Use image analysis software to automatically detect and record the characteristic temperatures, offering higher precision and repeatability.

Applications in Various Industries:

Coal-Fired Power Plants: Critical for selecting suitable coals, optimizing combustion, and preventing operational issues (slagging, fouling) in boilers.

Cement Industry: Analyzing ash from fuels used in kilns.

Steel Industry: Analyzing ash from coking coal.

Research & Development: Studying ash behavior of various solid fuels (biomass, waste-to-energy).

Coal Trading & Quality Control: Assessing coal quality for contractual purposes.

Technology:

High-Temperature Furnaces: Capable of reaching temperatures up to 1600°C or more.

Precise Temperature Control: PID controllers and high-accuracy thermocouples.

Controlled Atmospheres: Ability to introduce oxidizing, reducing, or inert atmospheres (e.g., air, CO/CO2, N2) to simulate different combustion conditions.

Image Capture & Analysis: High-resolution cameras and software for automatic detection of deformation, softening, hemispherical, and fluid temperatures.

Data Logging & Reporting: Automated generation of test reports.

Material Selection Considerations

• Furnace Lining: High-purity refractory materials (e.g., alumina, zirconia, mullite) that can withstand extreme temperatures and resist chemical attack from ash.
• Heating Elements: Molybdenum disilicide (MoSi2) or silicon carbide (SiC) heating elements for high temperatures and long life.
• Thermocouples: Platinum-Rhodium (Type B, S, R) for accurate high-temperature measurement.
• Ash Cones/Sample Holders: High-purity alumina or porcelain crucibles/cones that are inert at high temperatures.
• Atmosphere Control System: Stainless steel tubing, precise flow controllers for gases.