Experimental studies on economizer and air-heater corrosion resulting from the formation of sulfuric acid in residual-oil-fired boilers are described. Factors controlling the oxidation of sulfur dioxide to sulfur trioxide have been investigated in a small experimental boiler. The fuel used was a distillate oil to which synthetic compounds were added to simulate the sulfur and metallic components commonly found in residual oils. The sulfur trioxide content of the flue gases was determined indirectly by measuring the corrosion of and sulfate deposition on a steel specimen maintained at a controlled temperature.

In an initially clean boiler, approximately equal quantities of sulfur trioxide formed in the flame, furnace, and convection sections, while less formed in the economizer-air heater section. Nickel, iron, sodium, and vanadium in the fuel each decreased the corrosion normally experienced by the test specimen, the magnitude of the effect increasing in the order given. Deposits of these metallic fuel-ash components in the boiler had a relatively small effect on the corrosion of the test specimen. Only the iron deposits indicated significant catalytic activity for the oxidation of sulfur dioxide to sulfur trioxide.

Combinations of sodium and vanadium in the fuel were found to decrease corrosion in an initially clean furnace, but boiler deposits from certain combinations of these elements were found to increase corrosion substantially. This catalytic effect is predominant over extended periods of time.

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