Furnace Technology
The reason for excessive clinker formation in gas producers is the

Use of fuel having too low an ash fusion temperature
Development of hot spots in the fuel bed and an abnormally high rate of gasification
Use of coal/coke containing a high % of fines and ash
All of these

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Furnace Technology
In practical operation of any furnace, zero oxygen percentage or theoretical CO₂ percentage in flue gas is rarely achieved, because of

Use of non-preheated combustion air
Imperfect mixing of fuel & air and infiltration of air
Use of excessive positive draft in the furnace
Use of pulverised solid fuels

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