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H.F.O. Emulsification : A SINGLE SOLUTION TO MYRIAD PROBLEMS :

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There is a lot of disinformation, inflated promises and junk science associated with Fuel Emulsification Technology, Various companies who have poor understanding of the subject, no actual experience or clients, proliferate the internet with loud claims of outlandish fuel economy. Here we try to explain in a concise way how Fuel Emulsion work across different sectors and is needed to make them work. RADE Initiative had been a pioneer in this field in India and has over a decade of practical experience in this field,

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H.F.O. Emulsification : A SINGLE SOLUTION TO MYRIAD PROBLEMS :

  1. 1. R.A.D.E 2015|www.rade.co.in A SINGLE SOLUTION TO MYRIAD PROBLEMS : - POLLUTION - HIGH COST OF FUEL - SHUTDOWN - BREAKDOWNS EMULSIFIED HEAVY FUEL OIL
  2. 2. R.A.D.E 2015|www.rade.co.in Problems Of Furnace Oil • Comprise of Residual & Waste Oils from the Petroleum refining process. • Suffers from Incomplete Combustion due to Poor Atomization. • Burner, Strainer Blockages due to Asphaltenes & Sludge. • Very Hydroscopic, which also helps forms Tank Sludge. • Black Smoke and Sulfur smell, Pollutants like NOx & SOx in Flue Gas. • No Uniform Quality Standards even by Manufacturers. • Very Often Adulterated by Dealers and Transporters. • Vague Metering Practices.
  3. 3. R.A.D.E 2015|www.rade.co.in One Solution: Emulsified Heavy Fuel Oil • Additional Fuel Economy by 3-10 % over Normal F.O . • Doesn’t require any Major Equipment changes. • Completely Homogenized. • Zero Sludge, Free Water & Impurities. • Reduced Un-burnt Carbon, Smoke and Particulate Matter . • Total Fuel Utilization & Complete Combustion. • Clean & Economical Alternative to normal F.O. & Diesel.
  4. 4. R.A.D.E 2015|www.rade.co.in Emulsified F.O. : Characteristics • Emulsions are stable blends of immiscible liquids like Oil & Water. • Fuel Emulsions contain suspended micron sized water droplets. • The water droplets are inserted by a special High Shear process. • Special additives and Surfactants stabilize the Fuel Emulsion. • The Emulsifying process can also reduce the Sulfur in F.O. • Can be used in Boilers, Furnaces, IC Engines and even Gas Turbines.
  5. 5. R.A.D.E 2015|www.rade.co.in Furnace Oil vs. Emulsified F.O. Normal F.O. Emulsified F.O. Under Microscope 100x Magnification
  6. 6. R.A.D.E 2015|www.rade.co.in How It Works • Fuel Emulsion’s water droplets bursts into steam during combustion in a series of micro-explosions called Secondary Atomization. • This shatters the atomized fuel drops into a nano-fuel-mist, with 100 times more surface area causing instant Gasification and Complete Combustion. • Increased combustion efficiency reduces Auxiliary and Excess Air requirement. • Reduction of Excess Air improves Thermal efficiency and reduces Waste-heat. • The free carbon strips hydrogen from the steam, forming traces of SynGas.
  7. 7. R.A.D.E 2015|www.rade.co.in Emulsified F. O.: Flame Diagram
  8. 8. R.A.D.E 2015|www.rade.co.in Secondary Atomization in Flames
  9. 9. R.A.D.E 2015|www.rade.co.in Emulsified F.O. Essentials • Water Droplets must be 2-5 microns and never exceed 10 microns. • Water Droplets should be uniformly sized & dispersed. • Fuel Emulsion should be Thermo-dynamically stable. • The Burners should have separate controls for Auxiliary air. • Excess Air levels must be reduced. • Fuel Emulsion shouldn’t be pre-heated above prescribed levels.
  10. 10. R.A.D.E 2015|www.rade.co.in Good Emulsion Vs. Bad Emulsion Under 100x Magnification Our FO Emulsion 100% Homogenised Uniform Dispersal Uniform Droplet Size Droplets < 5 microns Poor FO Emulsion Un-homogenized Uneven Dispersal Uneven Droplet Size Droplets 5 - 50 microns
  11. 11. R.A.D.E 2015|www.rade.co.in The Kilocalorie Question • Theoretically the GCV of Emulsions is lower due to the water content. • Bomb Calorimeters cannot be used for measuring Fuel emulsions. • However the NCV of the Emulsions can be measured in actual use. • Low Excess Air levels possible only in Fuel Emulsions, reduces Waste Heat. • Improved Combustion Efficiency + Less Excess Air offset the effects of water. • Steam released during combustion helps transfer the heat better. • Fuel Emulsions actually release more usable energy then stock F.O.
  12. 12. R.A.D.E 2015|www.rade.co.in Benefits: Boilers • Complete Combustion: Fuel economy of 5-10%. • No Equipment changes needed. • Clean burners and Strainers : Reduced maintenance. • Requires Less Excess Air : Reduced Waste Heat Loss. • Low Carbon and Soot deposits on Tubes: Reduced downtime. • Enhanced Thermal efficiency. • Cleaner Emissions.
  13. 13. R.A.D.E 2015|www.rade.co.in Benefits: Furnaces • Complete Combustion: Fuel economy 3 - 7 %. • Drastic Reduction of Metal Oxide Losses like Dross & Furnace Scale. • Increased Refractory / Reccuperator / Stack Lifespan. • Clean burners and Strainers : Reduced maintenance. • No major Equipment changes needed. • Requires Less Excess Air : Reduced Waste Heat losses. • Enhanced Thermal Transfer. • Cleaner Emissions.
  14. 14. R.A.D.E 2015|www.rade.co.in Benefits: IC (Generator) Engines • Can be used in most H.F.O. Generator engines without any changes. • Low Carbon and Soot deposits on Pistons: Reduced maintenance. • No Wastage of Fuel in Filters and Centrifuges. • Lean-Burn due to reduced Hydrocarbon content in Fuel: Economy. • Peak Temperature Reduction: Longer Engine Life. • Very Clean Emissions.
  15. 15. R.A.D.E 2015|www.rade.co.in Ecological Benefits: All Segments • Emulsified F.O. combustion uses almost 20% less Oxygen. • Emulsified F.O. generates 10-30% less waste-heat. • Emulsified F.O. Combustion released up to 30% less NOx . • Particulate Matter(PM) reduction by 30-50%. • Drastic reduction of CO, CO2 & even SOx(with special additives). • Reduces pollution even when fired along with Pulverized Coal.
  16. 16. R.A.D.E 2015|www.rade.co.in Zero Waste Fuel Normal H.F.O Tank Oil Sludge Water Emul H.F.O Tank Zero Waste fully- Homogenized & Emulsified Oil
  17. 17. R.A.D.E 2015|www.rade.co.in Approved by Manufactures • Siemens Turbines (Gas Turbines) - Germany. • Wartsila Power (IC-Generators)- Finland. • MAN Diesel & Turbo (IC-Generators) - Germany. • Komatsu (IC-Generators) – Japan. • Ansaldo Energia (Gas Turbines) – Italy. • Pratt & Whitney Power Systems (Gas Turbines) – USA.
  18. 18. R.A.D.E 2015|www.rade.co.in Used Worldwide • F.O.-Water Emulsion Fuels are widely used in Ships, Generators & Turbines. • Santa Rita in Philippines was the 1st power plant to run on H.F.O emulsion. • ORIMULSION, an emulsified Fuel produced by PDVSA of Venezuela was used in Power Stations of UK, Denmark, Canada, USA & China. • Planta Arizona, 150 MW Power Plant in Guatemala, used ORIMULSION for 150,000 hrs in a Wartsila Generator. • Vlore, Power Plant of KESH Albania Power Corporation, Albania uses Ansaldo Energia AE64.3A+ gas turbine firing HFO Emulsion. • MSAR II Emulsified Fuel was recently approved by Shipping giant Maersk.
  19. 19. R.A.D.E 2015|www.rade.co.in Case Study - Kobe University(Japan) -
  20. 20. R.A.D.E 2015|www.rade.co.in Enel S.p.a (Italy) - Case Study Company Enel S.p.a. Plant Type Thermal Power Station Turbine Manufacturer Ansaldo Energia Model AE94.2 Rating 180 MW Fuel Emulsified HFO Emulsion Ratio 30% Water Economy 9.7% NOx - 28% PM -56% Smoke - 64% * Source: Enel S.P.a, Italy
  21. 21. R.A.D.E 2015|www.rade.co.in Case Study 1- EPA, USA (Thermal Output) According to the study of NRMRL (National Risk Management Research Laboratory) on behalf of EPA (Environment Protection Agency, USA),Emulsified Class 6 Heavy Oil (Furnace Oil),containing 10% water released 16,604 BTU/LB while normal Oil released only 10,390 BTU/LB.* * Source: EPA-600/R-02-093
  22. 22. R.A.D.E 2015|www.rade.co.in Case Study 2 – EPA, USA (Emissions) * Source: U.S. EPA AP-42 Section 1.3
  23. 23. R.A.D.E 2015|www.rade.co.in Case Study – Boiler (Consumption) MONTH HOURS F.O. TYPE STEAM KG FUEL CONS. LITRES STEAM kg/LTR F.O DIFF. IMPROVEMENT Apr-15 380.20 F.O.-BPCL 9,78,510.57 56,021.00 17.467 May-15 410.23 EMUL.F.O 9,46,013.00 59,948.00 16.380 +1.087 Actual F.O. Consumption minus 12.5% Water 49,596.80 19.074 -1.61 + 9.20% COMPARISON OF FUEL CONSUMPTION OF Bharat Petroleum F.O vs. EMUL.FO. WITH 12.5% WATER IN A THERMAX 6TON BOILER.
  24. 24. R.A.D.E 2015|www.rade.co.in Case Study – Steel Furnace (Consumption)
  25. 25. R.A.D.E 2015|www.rade.co.in Case Study – Aluminum (Emissions) Emissions with normal F. O. Date: 6/12/14 CO(ppm):240 CO2 %: 13 SO2 (mg/Nm3) : 984 NOx (mg/Nm3): 600 Emissions with Emulsified F.O. Date: 10/12/14 CO(ppm): 4 CO2 %: 4 SO2 (mg/Nm3) : 334 NOx (mg/Nm3): 40
  26. 26. R.A.D.E 2015|www.rade.co.in About Fuel Emulsions in the Global Press
  27. 27. R.A.D.E 2015|www.rade.co.in Articles About Creatnet Technology FORTUNE India June 2015 MANUFACTURING TODAY June 2015 Moneycontrol.com March 2015 Smetimes.com May 2015 Delhi Based Creatnet Technology Pvt Ltd is the partner for RADE Initiatives H.F.O. Emulsification Technology in India.
  28. 28. R.A.D.E 2015|www.rade.co.in About Us • RADE Initiative is a India based Energy Efficiency Technology Developer. • Pioneer in introducing Fuel Emulsification concepts & Technology in India. • Invited by UNDP-GEF on numerous occasions to speak in their Seminars. • Since 2013 have partnered with Creatnet Technology for Fuel Emulsions. • Creatnet Technology is India’s only active F.O. Emulsion manufacturer. • We have been operating our Proof-Of-Concept Plant for one year in NCR. • We have an In-House testing Laboratory and Firing Facility. • Featured by publications like Fortune, Money Control, Manufacturing Today.
  29. 29. R.A.D.E 2015|www.rade.co.in Synopsis • Emulsified F.O. is used globally across different sectors. • Its has cleaner emissions than normal stock fuel. • Provides better economy due to Complete Combustion. • Better Thermal utilization due to reduction of Excess Air. • It is perfect for Boilers and Non-Ferrous Metal Furnaces. • It can be even be used in HFO Engines and Gas Turbines. • Switching over to Emulsified Fuels doesn’t require equipment changes.
  30. 30. R.A.D.E 2015|www.rade.co.in The Last Word. “Emulsified fuels are found to give much better emission reduction towards reduced particulate and Oxides of Nitrogen emission reduction along with fuel saving that it is now implemented in most of the developed countries.” Dr. APJ Abdul Kalam 11th President of India
  31. 31. R.A.D.E 2015|www.rade.co.in Contact Us For Queries from Other Countries: R.A.DE INITIATIVE Please leave a message in Contact Page: www.rade.co.in For Queries In India: CREATNET TECHNOLOGY PVT LTD 215, SouthEx Plaza – 1, Masjid Moth, South Ext – II, New Delhi -110049 Please leave a message in Contact Page: www.creatnettechnology.com

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