What is a common consequence of incomplete combustion in a boiler?

Incomplete combustion in a boiler occurs when there is not enough oxygen to fully oxidize the fuel, leading to the production of various undesired byproducts. Soot accumulation is indeed one of the most common consequences of this process. When combustion is incomplete, the carbon in the fuel does not fully convert to carbon dioxide, and instead, it forms fine particulate matter known as soot, which can settle on boiler surfaces and other components.

Soot not only reduces the efficiency of the boiler by acting as an insulator and thereby increasing heat transfer resistance but can also lead to overheating and potential damage to boiler tubes. Because soot can restrict airflow and gas flow, it further exacerbates the problem, leading to a cycle of reduced efficiency and increased emissions.

In a properly functioning boiler, complete combustion would occur, which minimizes the formation of soot and ensures that the fuel is used effectively. The presence of soot indicates that the combustion process needs to be adjusted to optimize performance and reduce harmful emissions.