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CTPL 2015|www.creatnettechnology.com EMULSIFIED FURNACE OIL A SINGLE SOLUTION TO MYRIAD PROBLEMS : -POLLUTION -HIGH COST OF FUEL -SHUTDOWN - BREAKDOWNS Slide 2 CTPL 2015|www.creatnettechnology.com Problems Of Furnace Oil Comprise of Residual & Waste Oils from the Petroleum refining process. H.F.O / Furnace Oil is very viscous & difficult both to handle and atomize. Suffers from Incomplete Combustion due to Poor Atomization. Burner, Strainer Blockages due to Asphaltenes & Sludge. Very Hydroscopic, which helps forms Tank Sludge. Black Smoke and Sulfur smell, Pollutants like NOx & SOx in Flue Gas. No Guarantees on fuel quality even by manufacturers. Very Often Adulterated by Dealers and Transporters. Slide 3 CTPL 2015|www.creatnettechnology.com Single Solution: Emulsified Furnace Oil Completely Homogenized. Zero Sludge, Free Water & Impurities. Reduced Un-burnt Carbon, Smoke and Particulate Matter. Total Fuel Utilization & Complete Combustion. Additional Fuel Economy by 3-10 % over Normal F.O. Doesnt require any Major Equipment changes. Clean & Economical Alternative to normal F.O. & Diesel. Slide 4 CTPL 2015|www.creatnettechnology.com Emulsified F.O. : Features 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. Slide 5 CTPL 2015|www.creatnettechnology.com Furnace Oil vs. Emulsified F.O. Normal F.O.Emulsified F.O. Under Microscope 100x Magnification Slide 6 CTPL 2015|www.creatnettechnology.com How It Works Fuel Emulsions 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 & reduces Waste-heat. The free carbon strips hydrogen from the steam, forming traces of SynGas. Slide 7 CTPL 2015|www.creatnettechnology.com Emulsified F. O.: Flame Diagram Slide 8 CTPL 2015|www.creatnettechnology.com Secondary Atomization in Flames Slide 9 CTPL 2015|www.creatnettechnology.com Emulsified F.O. Essentials F.O. must first be completely filtered and homogenized. 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. Burners must have Auxiliary air controls in Heating applications. Excess Air levels must be reduced. Fuel Emulsion shouldnt be pre-heated above prescribed levels. Slide 10 CTPL 2015|www.creatnettechnology.com Good Emulsion Vs. Bad Emulsion Under 100x Magnification Our FO Emulsion 100% Homogenised Uniform Dispersal Uniform Droplet Size Droplets < 5 microns 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 Poor FO Emulsion Un-homogenized Uneven Dispersal Uneven Droplet Size Droplets 5 - 50 microns Slide 11 CTPL 2015|www.creatnettechnology.com The Kilocalorie Question Theoretically the GCV of Emulsions is lower due to the water content. 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 loss. 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. Slide 12 CTPL 2015|www.creatnettechnology.com Benefits: Boilers Complete Combustion: Fuel economy of 5-10%. No Equipment changes needed, except adjustment of Burners. 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. Slide 13 CTPL 2015|www.creatnettechnology.com Benefits: Furnaces Complete Combustion: Fuel economy 3 - 7 %. 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. Slide 14 CTPL 2015|www.creatnettechnology.com Benefits: 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. Slide 15 CTPL 2015|www.creatnettechnology.com 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. Slide 16 CTPL 2015|www.creatnettechnology.com Zero Waste Fuel Normal H.F.O Tank Oil Sludge Water Emul H.F.O Tank Zero Waste fully- Homogenized & Emulsified Oil Slide 17 CTPL 2015|www.creatnettechnology.com Endorsed by Manufactures Siemens Turbines (Gas Turbines) - Germany. Wartsila Power (IC-Generators)- Finland. MAN Diesel & Turbo (IC-Generators) - Germany. Komatsu (IC-Generators) Japan. Ansaldo Energia (Gas Turbines) Italy. Pratt & Whitney Power Systems (Gas Turbines) USA. Slide 18 CTPL 2015|www.creatnettechnology.com Used Worldwide F.O.-Water Emulsion Fuels are widely used in Ships, Generators & Turbines. Santa Rita in Philippines was the 1 st power plant to run on H.F.O emulsion. ORIMULSION, an emulsified Fuel produced by PDVSA of Venezuela was used in Power Stations of UK, Denmark, Canada, USA & China. Planta Arizona, 150 MW Power Plant in Guatemala, used ORIMULSION for 150,000 hrs in a Wartsila Generator. Vlore, Power Plant of KESH Albania Power Corporation, Albania uses Ansaldo Energia AE64.3A+ gas turbine firing HFO Emulsion. MSAR II Emulsified Fuel was recently approved by Shipping giant Maersk. Slide 19 CTPL 2015|www.creatnettechnology.com Case Study - Kobe University(Japan) - Slide 20 CTPL 2015|www.creatnettechnology.com Enel S.p.a (Italy) - Case Study CompanyEnel S.p.a. Plant TypeThermal Power Station Turbine ManufacturerAnsaldo Energia ModelAE94.2 Rating180 MW FuelEmulsified HFO Emulsion Ratio30% Water Economy9.7% NOx- 28% PM-56% Smoke- 64% * Source: Enel S.P.a, Italy Slide 21 CTPL 2015|www.creatnettechnology.com 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 Slide 22 CTPL 2015|www.creatnettechnology.com Case Study 2 EPA, USA (Emissions) * Source: U.S. EPA AP-42 Section 1.3 Slide 23 CTPL 2015|www.creatnettechnology.com Case Study Boiler (Consumption) MONTHHOURSF.O. TYPESTEAM KG FUEL CONS. LITRES STEAM kg/LTR F.ODIFF.IMPROVEMENT Apr-15380.20F.O.-BPCL9,78,510.5756,021.0017.467 May-15410.23EMUL.F.O9,46,013.0059,948.0016.380+1.087 Actual F.O. Consumption minus 12.5% Water49,596.8019.074-1.61+ 9.20% COMPARISON OF FUEL CONSUMPTION OF F.O vs. EMUL.FO. WITH 12.5% WATER IN A THERMAX 6TON BOILER. Slide 24 CTPL 2015|www.creatnettechnology.com Case Study Steel Furnace (Consumption) Slide 25 CTPL 2015|www.creatnettechnology.com Case Study Aluminum (Emissions) Emissions with normal F. O. Date: 6/12/14 CO(ppm):240 CO2 %: 13 SO2 (mg/Nm 3 ) : 984 NOx (mg/Nm3): 600 Emissions with normal F. O. Date: 6/12/14 CO(ppm):240 CO2 %: 13 SO2 (mg/Nm 3 ) : 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 Emissions with Emulsified F.O. Date: 10/12/14 CO(ppm): 4 CO2 %: 4 SO2 (mg/Nm3) : 334 NOx (mg/Nm3): 40 Slide 26 CTPL 2015|www.creatnettechnology.com About Fuel Emulsions in the Global Press Slide 27 CTPL 2015|www.creatnettechnology.com Articles About Creatnet Technology FORTUNE India June 2015 MANUFACTURING TODAY June 2015 Moneycontrol.com March 2015 Smetimes.com May 2015 Slide 28 CTPL 2015|www.creatnettechnology.com About Us Creatnet Technology is Indias only active F.O. Emulsion manufacturer. We utilize a 5-stage batch process, with components sourced from Russia, Our Team members have decades long experience in this field of Fuel & Emulsions. We have been operating our Proof-Of-Concept Plant for one year in NCR. Our F.O. Emulsions have been supplied regularly as trial to various Industries. We have an In-House testing Laboratory and Firing Facility. Featured by publications like Fortune, Money Control, Manufacturing Today. Slide 29 CTPL 2015|www.creatnettechnology.com Our Clients List Akums Drug & PharmaceuticalsDiwakar Enterprises. Gravita India Ltd. M.J. Engineering Works Metenere Ltd.Vishal Pipes Ltd. I.T.C Ltd.Kiwi Foods Ltd. Dewan Rubber Industries LtdA.S.Tubes Pvt Ltd Pushpsons Fibrol P. LtdStyle Solution Pvt Ltd Vishal LPG IndustriesJubilant* Bihariji Containers Pvt LtdWipro* * Awaiting Trials Slide 30 CTPL 2015|www.creatnettechnology.com Synopsis Emulsified F.O. is used globally across different sectors. Its has cleaner emissions than normal stock fuel. Provides better economy due to Complete Combustion. Better Thermal utilization due to reduction of Excess Air. It is perfect for Boilers and Non-Ferrous Metal Furnaces. It can be even be used in HFO Engines and Gas Turbines. Switching over to Emulsified Fuels doesnt require equipment changes. Slide 31 CTPL 2015|www.creatnettechnology.com Creatnets F.O. Emulsifying Process Slide 32 CTPL 2015|www.creatnettechnology.com The Last Word. Emulsified fuels are found to give much better emission reduction towards reduced particulate and Oxides of Nitrogen emission reduction along with fuel saving that it is now implemented in most of the developed countries. Dr. APJ Abdul Kalam 11th President of India Slide 33 CTPL 2015|www.creatnettechnology.com Contact Us CREATNET TECHNOLOGY PVT LTD 215, SouthEx Plaza 1, Masjid Moth, South Ext II, New Delhi -110049 www.creatnettechnology.com Ravi Deka: +91-9953007470 email: ravi.deka@creatnet.com Sameer Shah: +91-9873327470 email: sameer.shah@creatnet.com