ZYDEX INDUSTRIES Innovation Ascent Excellence. ZYDEX COMMITMENTS TO GREEN EARTH Eco- Production...
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Transcript of ZYDEX INDUSTRIES Innovation Ascent Excellence. ZYDEX COMMITMENTS TO GREEN EARTH Eco- Production...
ZYDEX COMMITMENTS TO GREEN EARTH
• Eco- Production technologies• Eco-products - Specialty polymers & chemicals
WHY ARE WE HERE & WHY THIS TECHNOLOGY
Global Warming
Estimated 150 million ton heavy fuel burn / year Rise in CO2 emissions - Green house effectPollution – carbon particulate matter, CO, NOx, SO3, etc
Environment : Weather Changes
Melting of ice caps / thinning of glaciersExtreme conditions (flood / hurricanes / draught)
160 countries pledged to reduce CO2 level Reduction of 5.2% from level in 1990 by 2010Leads to Carbon trading / CDM technologies
Kyoto Protocol
New Technology will surely help worldMaintaining global leadership in manufacturing facilities(by economizing the production cost )Reducing & Maintaining its level of green house gassesThus help in achieving GLOBAL ECONOMY & BETTER ENVIRONMENT
RECENT SCENARIO ON GREEEN HOUSE LEVEL
(data from “NEW SCIENTIST” (10 Nov 2005)
Growth Rate of CO2 level 1990- 1999 : 0.8% / year2000- 2005 : 3.2 % / year (400 % rise in just last 5 year)
China Position 1990 : Very low & reduced level2005 : Became the 2nd largest emitter of green house gases after U.S.A. With same rising trends By 2009 China will be world’s top emitter Other developing countries India & Brazil - also fast becoming large emitters
To follow Kyoto Protocol & in view of consequences of Global Warming 5- 10 % saving would lead to • Saved burning of 7.5 – 15 million tons of fuel • Reduced CO2 level by 22.5 -40 million tons / year
Even a small efforts will bring big resultsThis was the starting point for the development of
INTROCUCTION
ZYCRYL - 15 & ZYCRYL - 20
A New generation Fuel Efficiency Enhancer For Furnace Oil , Heavy / Residual Fuel Oil, Bunker Fuel
ZYCRYL-15
• Improves combustion efficiency of fuel oil
• Ensures 8-10% Fuel Saving
• By adding 5- 6 % water as stable micron size emulsion in Fuel Oil
• Using low shear / pressure emulsification technique
• At low capital investment ( $ 500 – 1000 ) .
(Patented)
F E A T U R E S
USE OF FUEL OIL
Heavy Fuel / Residual Fuel Oil / Furnace Oil / Bunker Oil
• Forging Shops
• Ceramics furnaces
• Power plants
• Industrial boilers
• Metallurgical furnaces
• Rolling mills (Steels)
• General industrial heating
At 6- 20 bar pressure pumping, burner atomizer produces a spray of fuel, resulting droplets size 100 to 200 microns (approx.) depending on the following
ATOMIZATION PROCESS IN INDUSTRIAL COMBUSTION
• Fuel Viscosity
• Temperature
• Atomizer design
Fuel Oil + Air (C H S) (O2 + N2)
COMBUSTION REACTION
Petroleum Fuel contains chiefly Carbon & Hydrogen (small quantity Sulfur)
Complete combustions gives
But large droplet size of the fuel oil leads to Incomplete combustion
CO2 + H2O + SO2 +N2 + Heat Energy
How ?
HOW & WHY ?
Large size droplets have low surface area Burning will starts at outer surface of fuel drop Initially only low boiling fraction will burn Continual depletion of this lower viscosity fraction increases the droplet viscosity This leads to the formation of some fine very hard, difficult to burn particle
Results Soot formation (Un-burnt fuel particle)Black smoke Higher SPMHigh Carbon deposit buildup around burner nozzle & heat transfer surface
Incomplete combustion also leads to CO : Indicates low heat energy releaseHigh SO3, : Corrosion due to acid formationHigh NOx : Environmental problem
(1st Step ) C + O → CO + 2,430 K cal / kg. of Carbon
(2nd Step) CO + O → CO2 + 5,654 K cal / kg. of Carbon
Total C + O2 → CO2 + 8,084 K cal / kg. of
Carbon
LOSS IN ENERGY GENERATION
Complete combustion : both the steps take place
C + O2 → CO2 + 8,084 K cal / kg. of Carbon
Incomplete combustion : only Step-1 takes place
C + O → CO + 2,430 K cal / kg. of Carbon
Loss of energy from II step means ~ 5654 K cal/ kg of carbon
Reduce the particle size of fuel oil
In surface tension reduction Adding wetting agent
Maximum reduction possible from 100- 200 microns to 70-80 microns
Results in Saving (increase in efficiency ) upto 1 - 2 % only
HOW TO IMPROVE COMBUSTION ?
Either by Reduce Surface Tension – Add Wetting Agent
Or by Secondary Atomization – Thru Emulsion Technology
Ideal option-Secondary atomization through water emulsion Adopt Emulsion Technology
Induce explosive vaporization
Results in fragmentation of larger fuel droplet.
15 – 20 micron particle size
These are
• Low molecular weight surfactant
• Poor surface stability
• Leads to premature burst non- uniform / large size droplets
• Saving Fuels ( efficiency increase) are not much (2 -3 % )
SECONDARY ATOMIZATION
through CONVENTIONAL Emulsifier
Next generation polymers
to overcome above problem of interface stability 10 time reduction of particle size to increase combustion
Advantage of polymer based interface film
• Forms a viscous & polymeric interface film (oil/water interface)
• The interface film has better elasticity / stretching
• Better tolerance to expansion of particle
• Better interface stability
• No premature burst of oil droplet
• Uniform & smaller size particle
• Better enhancement of efficiency /saving ( 8-12%)
ZYCRYL-15
A Novel Polymer composition Helps in making very stable emulsion (1-2 years) 8-12% fuel savings at low capital investment
PROCESS OF COMPLETE COMBUSTION WITH ZYCRYL-15 EMULSION
Oil droplet size 100 microns
Water-Oil emulsionBelow 100 degree C. Water-Oil emulsion
100 – 250 degree C.
Oil droplet size 15-20 microns
Waterdroplet
•Fuel droplet size - 100 to 200 micron
•Water droplet size - 4 to 6 micron (inside fuel droplet)
•This emulsified fuel droplets, due to high temperature zone inside the furnace /boiler,
convert within micro-second in to steam vapor.
•Rapid expansion of water vapor within Fuel droplet results in the burst / fragmentation
of 100-200 micron in to very small size particles (around 10-20 micron).
•Larger surface area large air interface better combustion enhanced efficiency
•Smaller the particle - Burning more rapidly in smaller area
•Reduction in flame length.
HOW THIS EMULSION HELPS
By inducing SECONDARY ATOMIZATION
This Emulsion is 5-6 % water content in fuel oil with uniform particle size
COMBUSTION WITH ZYCRYL-15
Revised diagram of Furnaceshowing particle complete combustion
NoSoot
Low stack temperature
Shorter burnout dwell time Pre-atomized fuel
Better & uniform SECONDARY ATOMISATION Viscous , elastic , expandable polymeric interface filmBetter interface stability No premature burst of oil droplet Uniform & smaller size particleMuch better enhancement of efficiency /saving ( 8-12%)
Easy emulsification Lower shear Low power Low capital investmentStable emulsion Emulsion is stable for 1-2 years Short flame - how it helps
Higher flame temperature ( same fuel burnt in smaller area )Majority of heat transfer is through radiation, It is substantially improved due to T4 dependence of radiation heat transfer
Conventional surfactant vs Polymeric compositions
NOVEL PROPERTIES OF EMULSION WITH ZYCRYL-15
Flame length Reduced & become sharp
Heat transfer due to radiant heat will be higher than convection /conduction heat transfer
Reduced stack temperature
Almost elimination of CO generation.
Substantially reduced deposits of Carbon buildup on burner frequency of cleaning reduced & also cleaner heat transfer surfaces.
Practically eliminates the black smoke.
Reduction in air to fuel ratio.
Reduces SO3 concentration.
Improves CO2 generation i.e. efficient burning.
All these give 8-12% average saving & efficiency improvement at low capital investment.
WHAT IS HAPPENING EXACTLY
Explosive vaporization of water droplets leads to the reduction in size of fuel particles. Combustion results in
HOW TO SET UP PLANT
PFD For emulsion preparation using Zycryl-15
New lines (Red color) Existing line (Black color)
PUMP– Gear Pump, 5-6 kg pressure, Capacity -10-15 time of Emulsion volume per hour
Suggested Ratio
Making Emulsion
FO(49) : Water(49) : Zycryl-15 (2)
Mixing Emulsion
F.O (88-90) : EMULSION (10-12) EMULSIONMAKING
TANK
MAINSTORAGE
TANKFOR
MIXING &
PUMP TO BURNER / BOILER / FURNACE DIRECTLYTHROUGH DAY TANK
RETURN LINEZYCRYL-15
WATER LINE
FOR TANKER UNLOAD
P
V3
V5
V2
V1
V6 V4Duplex Filter
80-200 mesh
Emulsion preparation using Zycryl-15 Take 49 kg. heavy Fuel Oil (HFO) at 30- 60 OC and 2 kg. Zycryl-15
Mix (re-circulate) for 5 minutes with the help of gear pump
Recirculation flow (Pump capacity ) should ensure entire emulsion volume rotation (turning) at least 10-15 time per hour
Add 49 kg. water (of ambient temperature) slowly over a period (minimum 90 minutes
After complete addition of water, continue mixing further for 30 minutes
Test for emulsion (mechanical stability etc)
The emulsion is now ready to be mixed with FO (to be mixed with main FO)
Transfer a pre-calculated quantity of emulsion to the Main storage tank / day tank .(Mixing ratio- 10 part of emulsion with 90 part FO)
Mix it properly. This final mixed (emulsified FO) is now ready to be fed to the burner
MAKE & MIX EMULSION
CONCLUSION
Eco friendly ZYCRYL-15
increases your profit level
and helps in reducing
pollution & global warming
Eco friendly ZYCRYL-15
increases your profit level
and helps in reducing
pollution & global warming
ZYDEX INDUSTRIES
25-A, Gandhi Oil Mill Compound,
Gorwa, Vadodara-390 016, India.
Tel: +91 265 228 0120 / 0865 / 3386 / 3742
Fax: +91 265 2280872
Mob- +91-9328219812
E-mail: [email protected]
Website: www.zydexindustries.com
ZYDEX INDUSTRIES
25-A, Gandhi Oil Mill Compound,
Gorwa, Vadodara-390 016, India.
Tel: +91 265 228 0120 / 0865 / 3386 / 3742
Fax: +91 265 2280872
Mob- +91-9328219812
E-mail: [email protected]
Website: www.zydexindustries.com
THANK YOU