SDAF1200b Ash Fusion Tester

The SDAF1200b Ash Fusion Tester is designed for the automated determination of ash fusibility characteristics in coal, coke, biomass and other solid-fuel samples. It supports both oxidizing and weakly reducing atmospheres, with weakly reducing conditions generated through either the carbon-sealed method or a controlled gas-flow method using CO/CO₂ or H₂/CO₂ mixtures.

Featuring an automatic sample loading and unloading mechanism, the analyzer can test up to 10 ash cones in a single batch. An industrial HD camera, real-time monitoring system and advanced image-processing algorithms enable accurate identification of characteristic ash fusion temperatures throughout the heating process. With a maximum furnace temperature of 1600°C, the SDAF1200b is suitable for laboratories in the power generation, coal, metallurgy, petrochemical, cement, environmental monitoring and research sectors.

Key Features

High-Throughput Automated Testing
Tests up to 10 samples per batch, with automatic sample loading and unloading. A complete batch can be finished within three hours, significantly improving laboratory throughput.

Multiple Atmosphere Control Options
Supports oxidizing and weakly reducing atmospheres. Weakly reducing conditions can be established using either the carbon-sealed method or the gas-flow method with CO/CO₂ or H₂/CO₂ mixtures.

Real-Time Image-Based Analysis
An industrial HD camera continuously records the deformation of each ash cone. Advanced image-processing algorithms assist in the rapid and accurate determination of characteristic fusion temperatures.

Clear and Stable Imaging
The heated quartz viewing window minimizes moisture condensation and deposits on the optical surface, helping maintain clear images throughout the high-temperature test.

Stable Furnace Atmosphere
A high-temperature sealing ring at the furnace opening improves gas tightness and helps maintain a stable test atmosphere. The single observation-port design also reduces gas consumption.

Precise High-Temperature Control
Provides a temperature range from ambient to 1600°C, with ±1°C temperature control accuracy and 1°C temperature resolution.

Optimized Sample-Holder Design
The ash-cone support plate incorporates an overflow collection groove that captures molten ash and helps prevent adhesion between the residue and the sample holder.

Durable High-Temperature Construction
The furnace insulation, combustion tube and sample boats are manufactured from high-temperature-resistant materials designed for prolonged operation at temperatures up to 1600°C.

Integrated Safety Protection
Built-in gas-leak detection and alarm functions improve operational safety when combustible or reducing gas mixtures are used.

Applicable International Standards and Methods
StandardStandard TitleApplicable Samples
ISO 540Hard coal — Determination of ash fusibilityCoal and coke
ASTM D1857Standard test method for fusibility of coal and coke ashCoal and coke
ISO 21404Solid biofuels — Determination of ash melting behaviourCoal and coke

Model Selection
ParameterSDAF1200bSDAF1600b
Picture
Maximum Sample Capacity10 samples16 samples
Test AtmosphereOxidizing atmosphere; weakly reducing atmosphere using the carbon-sealed method or gas-flow methodOxidizing atmosphere; weakly reducing atmosphere using the carbon-sealed method or gas-flow method
Sample Loading and UnloadingAutomaticAutomatic
Instrument WeightApprox. 149 kgApprox. 158 kg
Dimensions (L × W × H)642 × 680 × 904 mm642 × 680 × 904 mm
Test Time per Batch≤3 hours≤3 hours
Temperature Resolution1°C1°C
Temperature Control Accuracy±1°C±1°C
Temperature RangeAmbient to 1600°CAmbient to 1600°C
Power SupplyAC 220 V ±10%, 50 Hz ±1 HzAC 220 V ±10%, 50 Hz ±1 Hz
Maximum Power4.2 kW4.2 kW
Application Notes

We are compiling our practical application experience into a growing collection of technical articles that will be published here regularly.

If you have an immediate analytical challenge before then—whether in mining, energy, advanced materials, or PFAS analysis—contact the Sundy Technology Application Laboratory. We provide customized method development, application optimization, and technical support to help you achieve reliable analytical results.

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Customer Testimonials
We have provided a complete set of Sundy testing solutions, including bomb calorimeter, sulfur analyzer, and thermogravimetric analyzer, to the fuel analysis laboratory of Kavçim Cement, a leading integrated cement plant on Turkey’s Black Sea coast. Sundy’s standardized instrument performance bring outstanding practical value to end users. The upgraded solution significantly simplifies daily operations, lowers manual intervention and maintenance costs, and unifies data consistency for routine fuel analysis.We are very satisfied with Sundy’s product quality and technical support, and will continue to promote and recommend Sundy analytical instruments for more industrial laboratory projects in Turkey.
Dr. Karahan, POTANTEK
After more than 10 years of continuous cooperation and market verification, we confirm that Sundy’s products, especially its automatic calorimeters and elemental analyzers, have high precise temperature control, accurate testing results, and ultra-low failure rate. All products are fully compliant with international ISO and ASTM standard, completely meeting the testing demands of coal laboratories, power plants, industrial enterprises, universities and scientific research institutions.We highly recognize Hunan Sundy Science and Technology’s strong production capacity, standardized quality management system, professional technical support team and excellent business credibility. In all our cooperation cases, Sundy has always demonstrated professionalism, reliability and a customer-oriented service attitude.
Dr. Kim, YEONJIN
FAQs

The analyzer determines the characteristic fusion temperatures of an ash cone under a controlled oxidizing or weakly reducing atmosphere. It continuously records the ash-cone profile during heating and automatically identifies the temperatures associated with the principal stages of ash deformation and melting.

The software determines and records four characteristic temperatures:

  • Deformation Temperature (DT)
  • Softening Temperature (ST)
  • Hemispherical Temperature (HT)
  • Fluid Temperature (FT)

The corresponding images are stored together with the temperature results for subsequent review.

A CCD imaging system continuously captures the ash cone during heating. The image-recognition software analyzes changes in the cone’s height, width, tip shape and overall profile to identify DT, ST, HT and FT automatically.

Yes. The software stores the characteristic images and the complete image sequence from the test. Operators can replay the images after the test and manually verify or revise the automatically identified characteristic temperatures, which is particularly useful for ash samples that swell, bubble or deform irregularly.

Depending on the instrument configuration, testing can be performed under:

  • An oxidizing atmosphere
  • A weakly reducing H₂/CO₂ atmosphere
  • A weakly reducing CO/CO₂ atmosphere
  • A weakly reducing atmosphere generated by the sealed-carbon method

The selected atmosphere must correspond to the applicable test standard and laboratory procedure.

The furnace operates from ambient temperature to a maximum of 1600°C, with a displayed temperature resolution of 1°C. The specified temperature-control accuracy is ±1°C under the stated operating conditions.

A complete ash fusion test normally takes no more than approximately 3 hours, depending on the selected standard, heating profile, maximum temperature and fusion behavior of the sample.

The sample capacity depends on the model:

  • SDAF1600: 1–16 samples
  • SDAF1200: 1–10 samples

The automatic sample-handling mechanism introduces, rotates and removes the ash-cone carrier during the test.

The manual states that the heating program, precision and accuracy are designed to meet the requirements of standards including:

  • GB/T 219
  • ISO 540
  • ASTM D1857
  • CEN/TS 15370-1

The correct cone geometry, atmosphere and heating program must be selected for the standard being followed.

The air-dried sample should first be converted to ash using the slow-ashing procedure. The resulting ash should then be ground in an agate mortar to a particle size below 0.1 mm. Certified reference ash should also undergo the specified slow-ashing preparation before testing.

The manual specifies a dextrin solution prepared from approximately 1.0 g of dextrin powder and 10 mL of distilled or purified water. The solution should be clear and transparent. If it becomes cloudy, the manual recommends heating it at approximately 500°C for about five minutes.

A small amount of prepared ash is mixed with dextrin solution until a plastic consistency is obtained. The mixture is pressed into the appropriate GB, ISO or ASTM ash-cone mould. After initial surface drying, the cone is carefully removed and either air-dried or dried at approximately 60°C before use.

A small amount of dextrin solution is applied to the triangular recess in the ash-cone support plate. The cone must be positioned vertically without damaging its tip. Testing should begin only after the mounted cone has dried completely.

The industrial camera should be connected to a USB 3.0 port to ensure adequate image-transfer speed. A USB 2.0 connection may introduce image delay, which can affect real-time monitoring and the correspondence between the recorded cone image and furnace temperature.

Camera position, focus, mirror position and illumination should be adjusted before the test. Minor adjustment may be performed below approximately 800°C when necessary. The manual advises against adjusting the optical system above 800°C because movement of the image may interfere with automatic recognition.

Deposits on the quartz window can reduce contrast, distort the ash-cone outline and cause incorrect image recognition. The window should be inspected before each test and cleaned with lens tissue when necessary. The camera lens and reflector should also be cleaned periodically.

Yes. The high-temperature furnace must be baked or conditioned before the first test and after replacing ceramic components. Previously unused components—including the inner combustion tube, image tube, sample introduction tube and ash-cone support—should be conditioned using the specified slow-heating procedure and allowed to cool with the furnace.

For gas-generated weakly reducing atmospheres, CO₂, CO or H₂ with a purity of at least 99.5% is required. The manual specifies a regulated operating pressure of approximately 0.1 ± 0.01 MPa, with the total cylinder supply pressure not lower than 1 MPa. Dedicated pressure regulators suitable for each gas must be used.

Gas flow must be adjusted according to the selected standard, atmosphere and instrument configuration. It should be verified before starting the test and should not be manually adjusted by opening the gas valves during an active hydrogen-atmosphere test.

The system incorporates hazardous-gas leakage detection, controlled solenoid valves and an automatic exhaust system. The laboratory must also provide effective ventilation and remain free from ignition sources and flammable or explosive materials. Gas connections and exhaust tubing should be checked before every reducing-atmosphere test.

The operator should verify:

  • Whether the selected atmosphere matches the test method
  • Whether gas composition and flow are correct
  • Whether the ash cone was prepared and positioned correctly
  • Whether the inner combustion tube, image tube or related ceramic components are damaged
  • Whether the quartz window and optical path are clean
  • Whether the temperature-correction parameters are valid
  • Whether the correct standard, cone geometry and heating program were selected
  • Whether automatic characteristic temperatures require manual review

Reference ash should be tested periodically to confirm the instrument’s temperature accuracy, atmosphere control and image-recognition performance.

Related Products

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SDAC1200 Bomb Calorimeter

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