2. R.A.D.E 2017|www.rade.co.in
Problems Of Furnace Oil/HFO
• 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 maintained even by Manufacturers.
• Very Often Adulterated by Dealers and Transporters.
• Vague Metering Practices.
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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.
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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.
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How It Works
• Emulsified Fuel is embedded with micron sized water droplets.
• 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.
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The Kilocalorie Question
• 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.
• Hence burning of Fuel Emulsions reduce fuel consumption.
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Emulsified F.O. – Essentials for Success
• One size doesn’t fit all – Equipment and settings have to be customised.
• 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 up-to 90 Degrees.
• The Burners should ideally have separate controls for Auxiliary air.
• Excess Air levels must be reduced as per the recommendation.
• Fuel Emulsion shouldn’t be pre-heated above prescribed levels.
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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
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Advantages of our Batch Process
• Our design of Fuel Emulsifiers utilize a 5-Stage batch process.
• Our batch process provides complete control of all the parameters.
• Our batch process is extremely flexible towards Oil quality.
• Our batch process requires very little surfactants.
• Our batch process guarantees uniform water droplet size and dispersal.
• Our batch process homogenizes the Oil shredding sludge and asphalteen.
• Our batch process utilizes cavitation, static and dynamic mixing.
• Our Emulsifier units come in two sizes 3.5Kl & 5 Kl per hour.
• Our process is undergoing two patent applications.
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Our Batch Vs. Online Processes
• 5 - Stage process.
• Multi Pass recirculation.
• Water drop <10 microns.
• Uniform droplet size.
• Uniform droplet dispersal.
• Complete homogenization.
• Handles dirty or adulterated fuel.
• Low Additive Requirement.
• Single Stage Process
• Single Pass Process.
• Uneven droplet sizes 10-50 microns.
• Uneven dispersal.
• Incomplete homogenization.
• Cannot Handle dirty Fuel.
• High Additive requirement.
• Unstable Emulsion.
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Our Emulsion under Microscope
A 100x microscope image of an Emulsified HFO droplet created in our 5-stage batch
emulsifying process. Each dark speck on the screen is a droplet of water.
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Fuel Emulsifying - Process Blocks.
• Water Filtration and Treatment.
• Oil Filtration and Testing.
• Fuel Transfer.
• Fuel Preheating Section.
• Water pumping and Infusion.
• Fuel Emulsification Section.
• Emulsion Testing Section.
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Fully CAD Designed.
• Fully designed in 3D CAD programs.
• Complete computer simulation of process.
• All flow calculations made in specialized apps.
• All sections precision Laser cut and welded.
• Only DC arc and MIG welding on the tank.
• TIG Welding on Stainless Steel Parts.
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Laser Cut Precision.
• All critical parts shaped with CNC Laser.
• Machined with 0.05% precession.
• All Cavitator & Static Mixer parts from SS.
• Only SS 304 & 316 used in critical sections
• Only TIG welding on SS parts.
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Benefits: For 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.
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Benefits: For Furnaces
• Complete Combustion: Fuel economy 3 - 10 %.
• 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.
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Benefits: For 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.
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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.
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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
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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
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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.
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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
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Articles Featuring our Work
FORTUNE India
June 2015
MANUFACTURING
TODAY
June 2015
Moneycontrol.com
March 2015
Chemical Engineering
World
April 2016
* With Creatnet Technology Pvt Ltd
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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 we have partnered with Creatnet Technology in Delhi.
• We have been operating our Proof-Of-Concept Plant for one year in NCR.
• We have an In-House testing Laboratory and Firing Facility.
• Covered by publications like Fortune, Money Control, Manufacturing Today.
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Contact Us
For Queries :
R.A.DE INITIATIVE
Please leave a message in the Contact Page:
www.rade.co.in
610, Shiv Towers
Patto Plaza, Panaji
Goa 403001
Tel: +91-9953007470
