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Fuel Handling, Combustion & Management Issues - For optimizing your HFO consumption for maximum economy.


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HFO or Furnace Oil is a residual oil which is cheap but not easily combustible and very often adulterated. Companies using it in their Furnaces and Boilers often look for solutions to improved fuel economy but themselves fail in maintaining basic fuel management and combustion parameters.

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Fuel Handling, Combustion & Management Issues - For optimizing your HFO consumption for maximum economy.

  2. 2. DISCLAIMER  Not all points listed here are applicable to all industries.  But most points are applicable in one way or another.  Discussing them often causes insecurity, denial or hurt egos.  Adulterated fuel is all-prevalent in South-Asia, CIS and Africa.  The intent of this presentation it to bring awareness.  And to dispel myths of “one-stop solutions” for fuel problems.
  3. 3. PROBLEM AREAS  Fuel Quality.  Adulteration.  Maintenance.  Burners.  Monitoring.  Auto-mization.  Human Factor.
  4. 4. FUEL QUALITY  HFO comprises of residual Oils of the refining process.  No Uniform Quality Standards.  Burner, Strainer Blockages due to Asphaltenes & Sludge.  Very Hydroscopic, which forms Tank Sludge.  Incomplete Combustion due to poor atomization.  High Sulfur content which creates SOx in Flue Gas.  Vague Metering Practices.  Rampant Adulteration.
  5. 5. ADULTERATION  Fuel Adulteration is a Rs.40,000 Cr industry in India.  Virtually all HFO is adulterated en-route from the refinery.  It can be anywhere from 5-25%.  HFO is adulterated with used oil, pitch, water etc.  Tankers have inbuilt systems for hiding adulterated material.  Normal sampling usually cannot detect adulteration.  Such oil has less kilocalories, which reflects on consumption.  It also causes extensive maintenance issues.
  6. 6. MAINTENANCE  Fuel Section often suffers from poor maintenance.  Filters don’t get cleaned, have holes or even missing.  Pumps replaced only when failing.  Gauges stuck or not accurate.  Optimum Fuel pressure not maintained.  Furnaces fuel system are usually mostly ignored.  Proper solvents and maintenance procedure is not used.
  7. 7. BURNERS  Incomplete Atomization.  Bad Burner Maintenance.  Nozzles not checked & changed.  Wrong Air-Fuel ratio.  Sometimes wrong burners installed.  Inadequate or excess Air supplied.  Wrong Fuel pressure.
  8. 8. MONITORING  Fuel is not tested or done regularly.  Testing systems not adequate.  Modern measuring system shunned.  Quantity and consumption measured inaccurately.  Air and Fuel pressure not monitored or recorded.  Emissions checked only for Pollution Control Dept.
  9. 9. AUTO-MIZATION  Many install Burner Auto-mization Systems.  Many are soon taken offline due to various factors.  Some cite drop in production, other’s maintenance issues.  Some of the causes are: i. Not optimized settings for respective furnace. ii.One size fits all approach. iii.Furnace being run over-capacity. iv.Failure of probes and sensors. v.Incorrect readings providing wrong settings. vi. Lack of proper training. vii.False sense of security.
  10. 10. HUMAN FACTORS  Inadequate training.  Wrong concepts.  Poor work-practices.  Non-prioritized section.  Slack supervision.  Poor or no reporting or recording system.  Corruption.  Non-cooperation of shop-floor staff.
  11. 11. REMEDIES-TECH. Technical: i. Resetting the system. ii. Stringent fuel tests. iii. Measuring instrumentation. iv. Parallel monitoring systems. v. Appropriate burners & controls. vi. Regular or online emission checking.
  12. 12. REMEDIES-HUMAN. Personnel: i. Training/Education. ii. Dedicated managerial responsibility. iii. Constant performance monitoring. iv. Enhanced routine maintenance. v. Weeding out corruption. vi. System of rewards and incentives.
  13. 13. FUEL SAVING TECH.  O2/CO2 trimmers.  Fuel Homogenizers.  Fuel-Water Emulsification.  Oxy-Fuel Combustion.
  14. 14. THANK YOU. For Queries : R.A.D.E INITIATIVE Please leave a message in the Contact Page: 610, Shiv Towers Patto Plaza, Panaji Goa 403001 Tel: +91-9953007470