Sludge Reduction, Fuel Improvement and Water Fuel Emulsion for emission reduction
Heavy Fuel Oil (HFO) is not homogenous and has an average droplet size of 70 micron and larger. It contains numerous much larger clusters of asphaltenes and complex long-chain hydro-carbons. It is a refinery waste stream product with a high BTU content used as fuel oil. Centrifuges and automated filters are used to clean the fuel. A percentage of the purchased fuel ends up in the slop tank.
HFO needs to be heated and pressurized before it can be used to operated engines or boilers. Exposing fuel to heat and pressure will unavoidably increase the size and mass of the fuel droplet, change the physical condition of the oil and negatively impact the combustion process.
Implementing IPCO Power Fluid Shearing Technology reduces fuel droplet size to 3 micron and smaller to enhance the cleaning process and reduce the waste stream going to the slop tank for disposal. Smaller fuel droplets enhance combustion, lower emissions, improve fuel economy, extend engine overhaul intervals and lower overall operating costs. There is a 300 micron space between the rotor and stator. This distance will prevent the system from blocking the fuel lines and will assure that cat fines pass the homogenizer untouched.
The IPCO Power Fuel Treatment System can also be operated with bio fuel, crude oil, MDO etc.
HFO needs to be heated and pressurized before it can be used to operated engines or boilers. Exposing fuel to heat and pressure will unavoidably increase the size and mass of the fuel droplet, change the physical condition of the oil and negatively impact the combustion process.
Implementing IPCO Power Fluid Shearing Technology reduces fuel droplet size to 3 micron and smaller to enhance the cleaning process and reduce the waste stream going to the slop tank for disposal. Smaller fuel droplets enhance combustion, lower emissions, improve fuel economy, extend engine overhaul intervals and lower overall operating costs. There is a 300 micron space between the rotor and stator. This distance will prevent the system from blocking the fuel lines and will assure that cat fines pass the homogenizer untouched.
The IPCO Power Fuel Treatment System can also be operated with bio fuel, crude oil, MDO etc.
IPCO Power’s “Fluid Shearing Technology” homogenizes your HFO reducing size and mass of fuel particles. It is implemented in several applications on vessels and plants operating on HFO.
Sludge Reduction
IPCO Power’s FID Reducer Sludge Reduction Systems are installed directly before the centrifuge. As a result of the reduction in fuel droplet size, centrifuges and filters will be able to more effectively remove in-organic contaminants and stay clean much longer. Consequently, sludge generation from centrifuges and filters will be reduced by approx. 50 to 80%. As a result, centrifuge and automated filter flushing intervals will have to be adjusted and will be significantly extended.
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Combustion Improvement
IPCO Power’s FID Improver Combustion Improvement Systems homogenize heavy fuel oil after passing through heaters and pumps in the high pressure side of fuel injection system, supplying fine filters and injectors with fuel droplets of 3 micron or smaller. The improved atomization and more intensive contact of fuel with oxygen will significantly enhance combustion, reducing fuel consumption and lower emissions.
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Water in fuel emulsion
IPCO Power’s FID Injector is a combustion improvement system designed to create a stable “water in fuel” emulsion. The implementation of emulsified fuel significantly enhances fuel atomization and distribution in the combustion chamber. This results in more effective combustion, lower fuel consumption and a reduction of NOx, HC and PM pollutants, while the engine’s combustion chambers, pistons, exhaust system and lube oil will stay much cleaner. Read more.
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Location in the system
1 = FID Reducer
2 = FID Injector
3 = FID Improver
To effectively reduce the undesirable emissions, soot and improve the fuel quality of your facility, we recommend the FID Reducer and FID Improver or FID Injector combination. The FID Reducer will reduce the droplet size in the fuel system just before the separator and will assure that all useful fuel will pass the separator. Because of the heaters and pumps further in the system the fuel passes through piping towards the engine will normally re-agglomerates. To reverse this effect immediately before the engine an FID Improver/FID Injector is recommend. The FID Improver/FID Injector will reduce the droplet size again to a 3 micron for an improved combustion.
The two step fuel quality optimization process is environmentally supportive and will lower overall operating cost.
Advantages of our product combination:
Fuel efficiency
- Up to 1,25 % savings on 4 stroke engines (*)
- Up to 2,4 % savings on 2 stroke engines (*)
(*) based on ISO 3046/1
Maintenance
- Less separator maintenance
- Less engine maintenance
Environment
- Up to 80% sludge reduction
- Up to 5% NOx reduction
- Less black smoke
- Up to 70% PM reduction
2 = FID Injector
3 = FID Improver
To effectively reduce the undesirable emissions, soot and improve the fuel quality of your facility, we recommend the FID Reducer and FID Improver or FID Injector combination. The FID Reducer will reduce the droplet size in the fuel system just before the separator and will assure that all useful fuel will pass the separator. Because of the heaters and pumps further in the system the fuel passes through piping towards the engine will normally re-agglomerates. To reverse this effect immediately before the engine an FID Improver/FID Injector is recommend. The FID Improver/FID Injector will reduce the droplet size again to a 3 micron for an improved combustion.
The two step fuel quality optimization process is environmentally supportive and will lower overall operating cost.
Advantages of our product combination:
Fuel efficiency
- Up to 1,25 % savings on 4 stroke engines (*)
- Up to 2,4 % savings on 2 stroke engines (*)
(*) based on ISO 3046/1
Maintenance
- Less separator maintenance
- Less engine maintenance
Environment
- Up to 80% sludge reduction
- Up to 5% NOx reduction
- Less black smoke
- Up to 70% PM reduction
More applications:
Blending fuels to adjust viscosity or sulfur content
IPCO Power’s FID Blender is designed to blend fuels of different viscosities to produce a stable homogenous fuel of the desired viscosity. The system can also be utilized to blend batches of fuel to adjust for sulfur content. IPCO’s FID Blender provides a reliable, stable and completely homogeneous fuel to meet predetermined viscosity or sulfur content specifications.
Re-using sludge & waste oil
IPCO Power’s FID Recycler sets new standards in re-using any remaining sludge and waste oil. All installations operating on HFO produce sludge and waste oil, resulting in an expensive disposal problem. With the use of IPCO’S FID Recycler the current “waste stream” can now be converted to “fuel” to be used in boilers and incinerators. This “new” fuel will have the same efficiency as the conventional fuels typically used in HFO installations.
The FID Recycler can also operate over a storage tank to prevent fuel oil or crude oil to have a bottom layer with sludge.
The FID Recycler can also operate over a storage tank to prevent fuel oil or crude oil to have a bottom layer with sludge.
Maintenance
Based on experience, we recommend that our customers replace the homogenizer part of the system every 24.000 running hours. IPCO Power’s maintenance program provides a “Homogenizer Exchange Program”. No additional maintenance is required.
The IPCO Power Fuel Treatment Systems are all type approved by:
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