FID Reducer — Reduce Sludge, Retain Usable Fuel
Fuel Conditioning Before the Separator
Separator sludge contains more than contaminants. It also contains combustible fuel that has been purchased but is discharged as waste.
The FID Reducer conditions fuel before the separator, breaking down asphaltene agglomerates so that more usable fuel remains in the fuel stream. This improves separator performance and typically reduces sludge generation by 50–80%, depending on fuel quality, separator configuration and operating conditions.
Less fuel lost. Less sludge to handle. Lower fuel treatment costs.
Recover More Fuel from the Separation Process
Agglomerated fuel components can leave the separator with water and inorganic contaminants. Excessive sludge increases disposal costs and can place an additional burden on separator cleaning and maintenance.
The FID Reducer breaks down these combustible agglomerates before separation, retaining more of the fuel for use while supporting the removal of contaminants.
- Reduce separator sludge: Typically 50–80% less sludge generation
- Retain usable fuel: Reduce combustible material lost to the sludge tank.
- Improve separator performance: Support contaminant removal and reduce deposits.
- Extend operating intervals: Reduce desludging frequency and separator cleaning requirements where operating conditions allow.
- Lower waste-handling costs: Reduce sludge storage, transfer and disposal requirements
How the FID Reducer Works
The FID Reducer uses mechanical shear to break down fuel agglomerates before the fuel enters the separator. Smaller, dispersed combustible components remain available for use instead of being discharged with the sludge.
The homogenizer does not grind cat fines. Its rotor–stator design treats fuel agglomerates while hard inorganic particles pass through unaffected and remain available for removal by the separator.
Installation Options
The system can be installed as one unit per separator or as a central unit serving multiple separators. Selection depends on the combined operating flow, which separators run simultaneously, and the required operating flexibility.
Frame-mounted and separate-component arrangements are available to suit the installation space. Final positioning is coordinated with the fuel heaters, pumps, temperature controls and separator requirements.
For a detailed explanation of rotor–stator operation, cat fines and water separation, see What Is a Fuel Homogenizer?
Before and After: Witness the effect of the FID Reducer on your separator’s performance and sludge production.
Reduction in Sludge Production
Typical sludge reduction is 50–80%, depending on fuel quality, separator configuration and operating conditions. Retaining more usable fuel and reducing waste discharge lowers the cost of fuel treatment and sludge disposal.
Sludge volume, discharge frequency and recovered fuel are different measures. Recording them separately makes the operational and financial results clear.
Sludge Reduction on MV Schieborg
The published MV Schieborg example shows a reduction from 24 to 6 desludging operations per day — a 75% reduction in discharge frequency.
Discharge frequency is one measure of separator operation. Sludge volume and fuel recovery should be assessed separately, together with discharge settings and operating conditions.
MV Schieborg: reported desludging frequency reduced from 24 to 6 operations per day.
Planning a FID Reducer Installation
Can one FID Reducer serve two separators?
Yes. A central installation can supply more than one separator when the homogenizer capacity and pipe arrangement match the combined operating flow. A dedicated unit per separator offers independent operation. The best arrangement depends on the vessel’s or plant’s operating pattern and redundancy requirements.
What information is needed to select the capacity?
We need the separator make and model, actual feed flow, number of separators operating simultaneously, fuel type and operating temperature. A fuel-system drawing and photographs help establish the installation position and available space.
Selection is based on the flow through the treatment point, rather than engine fuel consumption alone.
How are savings evaluated?
Compare separator sludge production and operating records before and after installation under comparable conditions. Record the fuel processed, discharge frequency and settings, sludge quantity and, where available, sludge composition.
The financial benefit combines usable fuel retained, reduced sludge disposal and changes in maintenance. Homogenizer power consumption is included when calculating the net saving.
FID Reducer Specifications:
Treatment principle: Mechanical rotor–stator homogenization
Installation: In the fuel feed before the separator
Standard capacity range: 1,500–30,000 l/h; higher capacities available on request
Maximum operating pressure: 12 bar
Homogenizer housing: Aluminium 7075-T6 with proprietary hard coating
Drive: Magnetic coupling; no conventional mechanical shaft seal
Main power supply: 400 V / 50 Hz or 460 V / 60 Hz
Control supply: 230 V / 50 Hz or 250 V / 60 Hz
Protection class: IP54
Connections: SAE flanges
Configuration: Frame-mounted or arranged to suit the available space
Discuss Your Separator Installation
Looking to reduce sludge and retain more usable fuel? Send us your separator details, operating flow and fuel-system layout. We will help select the FID Reducer capacity and installation arrangement for your vessel or plant.