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Understanding Fuel Oils

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Page 1: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

UnderstandingFuel Oils

UnderstandingFuel Oils

Page 2: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

TopicsTopics IntroductionIntroduction Refining ProcessesRefining Processes Fuel oil compositionFuel oil composition Fuel Oil productionFuel Oil production A Modern refineryA Modern refinery Refining trends with exampleRefining trends with example ConclusionsConclusions Key quality indicatorsKey quality indicators Quality trends Vs Technology Quality trends Vs Technology Effect of Fuel oil quality on engine Effect of Fuel oil quality on engine

performanceperformance Storage & handling-A Recall Storage & handling-A Recall

Page 3: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

IntroductionIntroduction

Fuel oil is Cheap but has fair CVFuel oil is Cheap but has fair CV Residual FuelResidual Fuel Diesel CycleDiesel Cycle Low Cetane valueLow Cetane value Hence for Low/Medium speedHence for Low/Medium speed Natural sourceNatural source Not much can be done on qualityNot much can be done on quality Engines built to suit this fuelEngines built to suit this fuel

Page 4: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Viscosity,20°C

% asphaltenes

Gasoline (C5-80°)

Heavy gasoline (80-160°)

Kerosene (160-250°)

Middle distillate (250-300°)

Heavy distillate (300-400°)

Residue (400 +)

35.8

5.8

4.09

9.05

12.58

14.12

7.51

50.42

10.2

0.93

5.56

12.02

15.5

17.19

8.72

38.71

ARABIANHEAVY

ARABIANLIGHT

NIGERIANBONNY

11.2

0.08

5.06

15.0

9.32

25.2

44.6

FRACTIONS FROM 3 DIFFERENT CRUDESFRACTIONS FROM 3 DIFFERENT CRUDES

Page 5: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

CHARACTERISTICS OF SOME CRUDE OILS

CHARACTERISTICS OF SOME CRUDE OILS

Viscosity,20 °C,cSt

Sulfur,%

Vanadium, ppm

Nickel, ppm

Asphaltenes, %

Conradson carbon,%

Arabianlight

9.2

1.8

15

5

0.7

5.1

Arabianheavy

40

2.8

30

10

2.7

Ekofisk

10

0.12

< 1

1.4

0.88

Nigerialight

6.7

0.11

2

6

0.08

0.86

Basrahheavy

57

3.58

54

22

8.3

Boscan

250000

5.2

1200

100

10.8

16.4

Ural

12.5

1.8

65

20

2.7

Page 6: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Refinery ProcessRefinery Process

Page 7: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Crude oil desaltingCrude oil desalting

Water and inorganic salts are removed in an electrostatic field.

The main purpose of crude oil desalting is to protect the refining process units against corrosion.

Page 8: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Atmospheric distillationAtmospheric distillation

Crude oil is a product with a very wide boiling range.In an atmospheric distillation column the fractionsboiling below 360°C are distilled off under reflux, and,according to boiling range, recovered as naphtha,kero, and gasoil type stocks. Atmospheric distillation

islimited to a maximum temperature of 360°C, becauseotherwise coking would start to occur, and this is notdesirable at this stage of crude oil refining.

Page 9: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Vacuum distillationVacuum distillation

In order to distill off a heavier cut, without exceeding

the 360°C temperature limit, a second distillation is

done under reduced pressure: the vacuum distillation.

The distillate fraction of the vacuum distillation unit is

the feedstock for a catalytic cracking unit

Page 10: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Catalytic crackingCatalytic cracking The main feedstock for a catalytic cracker is vacuum

gasoil. The cracking operation breaks large molecules into smaller, lighter molecules. The process runs at high temperatures, and in the presence of the appropriate catalyst (crystalline aluminum silicate).

Atmospheric residue, with a low metal and MCR content, can also be used as catalytic cracker feed, necessitating an adjustment of the catalyst type.

The main purpose of a catalytic cracker is to produce light hydrocarbon fractions, which will increase the refinery gasoline yield.

Additional streams coming from the catalytic cracker are light cycle oil (increases the gasoil pool) and heavy cycle oil (base stock for carbon black manufacturing). Both streams are also used in heavy fuel oil blending.

Page 11: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Catalytic hydrocrackingCatalytic hydrocracking

Some refineries have catalytic hydrocracking as a supplementary operation to catalytic cracking.

Catalytic hydrocracking further upgrades heavy aromatic stocks to gasoline, jet fuel and gasoil

type material. The heaviest aromatic fractions of a cat cracker are the normal feedstock for a hydrocracker.

Hydrocracking requires a very high investment , but

makes the refinery yield pattern nearly independent

from the crude oil feed.

Page 12: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

VisbreakingVisbreaking

The feedstock of a visbreaker is the bottom productof the vacuum unit, which has an extremely highviscosity. In order to reduce that viscosity and toproduce a marketable product, a relatively mildthermal cracking operation is performed. Theamount of cracking is limited by the overrulingrequirement to safeguard the heavy fuel stability.The light product yield of the visbreaker (around20%) increases the blendstock pool for gasoil.

Page 13: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Coking (delayed coking, fluid coking, flexicoking)

Coking (delayed coking, fluid coking, flexicoking)

Coking is a very severe thermal cracking process, and

completely destroys the residual fuel fraction. The

yield of a coker unit is lighter-range boiling material,

which ultimately goes to the blending pool for the

lighter products, and coke, which is essentially solid

carbon with varying amounts of impurities. The

heavier distillate fraction of a coker can be used as

feedstock for a hydrocracker

Page 14: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Catalytic reforming and Isomerization

Catalytic reforming and Isomerization

Both processes are in fact catalytic reforming, and are intended to upgrade low octane naphta fractions of the crude distillation unit into high octane components for gasoline production. The type of catalyst and the operating conditions determine if the reforming is mainly to iso-paraffins, or to aromatics. The terminology “reforming” is generally used for the change to aromatics, while the change to iso-paraffins is referred to as “isomerization”. Isomerization is normally done on a lighter fraction(C5/C6), while reforming is done on the heavy naphtha fraction (C7 and heavier, up to 150°C).

Page 15: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

AlkylationAlkylation

Process intended to increase the yield of valuable gasoline blend components. Alkylation is a catalyst steered combination reaction of low molecular weight olefins with an iso-paraffin to form higher molecular weight iso-paraffins. The feed to the alkylation unit is C3 and C4s from the catalytic cracker unit, and iso-butane.

Page 16: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

HydrotreatingHydrotreating

A hydrotreating process is, as the name indicates, a process, which uses hydrogen to remove impurities from product streams, and replaces them with hydrogen. Hydrotreating is generally used to remove sulphur (very low sulphur limits in the specifications of gasoline and gasoil) and is then called hydro-desulphurization. It is a catalytic process. The process is generally used on kerosene and gasoil fractions. Residual hydro-desulphurization is an existing process, and is in theory feasible, but the economics are not favorable.

Page 17: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

MeroxMerox

A merox unit is used on naphtha and kerosene streams. It is a catalytic process which is not intended to remove the sulphur from the stream, but to convert mercaptan sulphur type molecules (corrosive, and with a very obnoxious smell) into disulphide type molecules.

Page 18: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Modern RefineryModern Refinery

Atmospheric DistillationAtmospheric Distillation» ReformingReforming

Vaccum DistillationVaccum Distillation» Catalytic crackingCatalytic cracking» HydrocrackingHydrocracking» VisbreakingVisbreaking

DeasphaltingDeasphalting

Page 19: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Atmospheric distillationAtmospheric distillation

A

D

100T

GAS(3T)

KERO 11 T

ST. GASOLINE 16 T

GAS OIL 28 T

RESIDUE 42 T400 CST @ 50 deG C,S=3.1%

Page 20: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Vaccum distillationVaccum distillation

V

D

42TOFA.R

DISTILLATE 23.4T

18.6T

3000 cst @50degC,S=4.1%

Fluxing LGO

6.8T

25.4T

380 cst @50degC,S<4%

Page 21: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Vaccum distillation + FCCUVaccum distillation + FCCU

V

D

42TOFA.R

18.6T

3000 cst @50degC,S=4.1%

Fluxing(kERO)

2.0T

25.7T

380 cst @50degC,S<4%

23.4TFCCU

5.1T5.1T

6.9T

light gasoline

Heavy gasoline

1.4 THGO

3.7 TLGO

Page 22: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Vaccum distillation + FCCU + VBVaccum distillation + FCCU + VB

V

D

42TA.R 18.6T

3000 cst @50degC,S=4.1% 380 cst @50degC,S<4%

23.4TFCCU

5.1T

1.4 THGO

3.7 TLGO

5.1T

6.9T

light gasoline

Heavy gasoline

VIS BREAKER

2.8T Gas oil

.9TLGO

1.2T 1.2T

gas

gas15.3T

7000 cst@50degC,

Page 23: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Gas

AD

VD

Reforming

Visbreak.

Hydrocr.

Coking

FCC

DA

Naphta

GasolinesKeroseneDiesel oils

Heavy fuels SR 1

2

3

Gasolines

GasolinesKero,Diesel

Heavy fuels

H2, no HeavyFuels 4

AsphaltsHeavy fuels

REFINERY SCHEMESREFINERY SCHEMES

Page 24: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

About Fuel oilAbout Fuel oil

Page 25: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Straight run marine gasoil and distillate

Straight run marine gasoil and distillate

Marine diesel type MDO are manufactured from kero, light, and

heavy gasoil fractions. For DMC type gasoil, up to 10–15% residual fuel can

be added.

Straight run IFO 380 mm2/s (at 50°C) This grade is made starting from the atmospheric

residue fraction (typical viscosity of about 800 mm2/s at 50°C) by blending with a gasoil fraction.

Straight run lower viscosity grade IFOs Blending to lower grade IFOs is done from the IFO

380 mm2/s (at 50°C) using a gasoil type cutterstock or with marine diesel.

Page 26: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Complex RefineriesComplex Refineries

The main marine fuel blending components from a Fluidized Bed Catalytic Cracking (FCC) type refinery with visbreaker are the same distillates as those from a straight run refinery (light and heavy diesel) as well as light cycle (gas) oil (LC(G)O) and heavy cycle oil (HCO) from the catcracker and visbroken residue from the visbreaker.

Atmospheric residue is used as feedstock for the vacuum unit and will only seldom be available for fuel blending.

Page 27: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Complex RefineriesComplex RefineriesMarine gasoil (MGO/DMA) A new blend component has appeared — LC(G)O

(light cycle (gas) oil) — which contains about 60% aromatics. Due to the high aromatic nature of LC(G)O, the density of a marine gasoil blended with LC(G)O will be higher than when using gasoil of an atmospheric distillation type refinery. No performance or handling differences with atmospheric type gasoil

Distillate marine diesel (MDO/DMB) Distillate marine diesel typically has a lower cetane

number than marine gasoil, and a higher density. With the production slate of a catalytic cracking refinery, distillate marine diesel therefore contain a higher percentage of LC(G)O than marine gasoil.

Page 28: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Complex RefineriesComplex RefineriesBlended marine diesel (MDO/DMC) With atmospheric type refining, blended marine diesel (MDO/DMC) can

contain up to 10% IFO with either marine gasoil (MGO/DMA) or distillate marine diesel (MD)/DMB). With complex refining, blended marine diesel (MDO/DMC) no longer corresponds to a specific composition and extreme care needs be used when blending this grade to prevent stability and/or combustion problems.

IFO-380 This grade is usually manufactured at the refinery and contains

visbroken residue, HCO and LC(G)O These three components influence the characteristics of the visbroken IF-380 Vacuum distillation reduces the residue yield to about 20% of the crude feed, unavoidably leading to a concentration of the heaviest molecules in this fraction. Visbreaking converts about 25% of its vacuum residue feed into distillate fractions. This means that about 15% of the original crude remains as visbroken residue. The asphaltene1, sulphur and metal content in visbroken residue are 3 to 3.5 times higher than in atmospheric residue. Visbreaking affects the molecular structure: molecules are broken thermally and this can deteriorate the stability of the asphaltenes.

Page 29: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Complex RefineriesComplex Refineries HCO (typical viscosity at 50°C: 130 mm2/s) contains

approximately 60% aromatics, and is a high-density fraction: the density at 15°C is above 1 kg/l (typically 1.02). It is the bottom fraction of the FCC unit. The catalytic process of this unit is based on an aluminum silicate. Some mechanical deterioration of the catalyst occurs in the FCC process, and the resulting cat fines are removed from the HCO in the refinery. This removal however, is not 100% efficient, and a certain amount (ppm level) of cat fines remains in the HCO, and from there end up in heavy fuel blended with HCO. The aromaticity of HCO assists in ensuring optimum stability for the visbroken fuel blend.

LC(G)O (typical viscosity at 50°C: 2.5 mm2/s) has the same aromaticity as HCO, but is a distillate fraction of the FCC unit, with a distillation range comparable to that of gasoil. With a typical density of 0.94 kg/l at 15°C, it is used to fine-tune the marine heavy fuel oil blending where generally a density maximum limit of 0.9910 kg/l has to be observed.

Page 30: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

CHEMICAL COMPOSITIONCHEMICAL COMPOSITION

RESIDUE OR HEAVY FUEL OILRESIDUE OR HEAVY FUEL OIL

ASPHALTENESASPHALTENESMALTENESMALTENES

"OIL""OIL"

"RESINS""RESINS"

SATURATED SATURATED AROMATICAROMATIC

Page 31: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

ComponentsComponents

OILOIL» Molecular weight < 800 Molecular weight < 800 » Mixture of paraffins,naphthenes & aromaticMixture of paraffins,naphthenes & aromatic

RESINRESIN» Molecular weight ~ 1000Molecular weight ~ 1000» condensed aromatics with aliphatic ring chainscondensed aromatics with aliphatic ring chains

ASPHALTENESASPHALTENES» Molecular weight between 1000 ~ 2000Molecular weight between 1000 ~ 2000» Highly condensed aromaticsHighly condensed aromatics

Page 32: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Conclusions-Macro levelConclusions-Macro level

Fuel oil yield dropFuel oil yield drop More of fluxingMore of fluxing Less of lighter componentsLess of lighter components More complications due to types of More complications due to types of

crudescrudes

Page 33: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Conclusions-Micro levelConclusions-Micro level

Increased densityIncreased density Increased ViscosityIncreased Viscosity Increased carbon residueIncreased carbon residue Increased asphaltenesIncreased asphaltenes Increased sulphurIncreased sulphur Reducing heating value ????Reducing heating value ???? Increasing trace metals ????Increasing trace metals ???? InstabilityInstability IncompatibilityIncompatibility

Page 34: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Key Quality IndicatorsKey Quality Indicators Specific gravitySpecific gravity

» Weight per unit volumeWeight per unit volume

Flash pointFlash point» Safe operating temperatureSafe operating temperature

Viscosity(Kinematic)Viscosity(Kinematic)» Resistance to flowResistance to flow

Pour PointPour Point» Lowest Flowable temperatureLowest Flowable temperature

Sulphur contentSulphur content» % wt of Sulphur in Fuel oil% wt of Sulphur in Fuel oil

Calorific valueCalorific value» Heat per unit weightHeat per unit weight

Page 35: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Key Quality IndicatorsKey Quality Indicators

Ash ContentAsh Content» Inorganic & non combustible matterInorganic & non combustible matter

CCAICCAI» Ignition qualityIgnition quality

Conradson carbon residue(CCR)Conradson carbon residue(CCR)» Residual matterResidual matter

Page 36: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

HFO CHARACTERISTICSHFO CHARACTERISTICS

PARAMETER A.D V.D FCCU VB

DENSITY 0.973 0.978 0.985 1.018

KV @ 50 DEG C 380 450 450 450

KV @ 100 DEG C 35 38 40 40

SULPHUR 3~4 3.5~4 3.8~4 3.9~4

ASPHALTENES % 2.7 3.3 5 6

CCR % 7.5 8.5 11.5 11~20

SODIUM ppm 15 15~40 15~40 25~60

VANADIUM ppm 35 40~80 70~110 80~150

NICKEL ppm 10 10~50 30~60 35~70

Page 37: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Effects of quality parameters on engine performance

Effects of quality parameters on engine performance

Page 38: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

ViscosityViscosity

Injection CharacteristicsInjection Characteristics» Droplet size of 10-100 micronsDroplet size of 10-100 microns» 10-15 Cst at nozzle tip10-15 Cst at nozzle tip

Injector pump wearInjector pump wear Fuel flow propertiesFuel flow properties Preheating to correct viscosity at nozzle Preheating to correct viscosity at nozzle

tiptip Certain cases upto 150 deg CCertain cases upto 150 deg C

Page 39: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

FUELFUEL INJ VISC INJ VISC INJ VISCINJ VISC 13 CST13 CST 17 CST 17 CST

120 120 100 100 91 91160 160 112 112 104 104

170170 115 115 107 107 180180 119 119 109 109 200200 121 121 111 111 220220 123 113 123 113

Page 40: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Ignition Characteristics(CCAI)Ignition Characteristics(CCAI)

Shell proposedShell proposed Calculated Carbon Aromaticity IndexCalculated Carbon Aromaticity Index D-140.7LOG LOG (V+.85)-80.6D-140.7LOG LOG (V+.85)-80.6

» D:Specific Gravity @ 15deg CD:Specific Gravity @ 15deg C» V:Viscosity @ 50 deg CV:Viscosity @ 50 deg C

Nomographic method most suitableNomographic method most suitable Max acceptable around 900Max acceptable around 900 BP's CCI also usedBP's CCI also used Diesel IndexDiesel Index

» (API gravity*aniline point deg F)/100 (API gravity*aniline point deg F)/100

Page 41: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

SulphurSulphur

SOx + water ----> Sulphuric acidSOx + water ----> Sulphuric acid Temp drops below dew pointTemp drops below dew point Corrosion Corrosion Cold corrosionCold corrosion Control of temperaturesControl of temperatures LubricantLubricant

Page 42: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Conradson Carbon residueConradson Carbon residue

Formation carbon depositsFormation carbon deposits» "Trumpets""Trumpets"

Injection characreristics are alteredInjection characreristics are altered» lower the speed more the tolerance for CCRlower the speed more the tolerance for CCR

Indicative of apshaltene contentIndicative of apshaltene content» CCR% = 2* asphaltenesCCR% = 2* asphaltenes

Page 43: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Ash Ash

Na,V,Si,Fe compoundsNa,V,Si,Fe compounds» Hot CorrosionHot Corrosion» At melting points they form depositsAt melting points they form deposits» Hard At hot spotsHard At hot spots

Cooler valve seats etcCooler valve seats etc

Page 44: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Calorific ValueCalorific Value

heat energy containedheat energy contained Emperical formulaeEmperical formulae

» HSDHSD GCV(btu)=1.8(12400-2100d*d)GCV(btu)=1.8(12400-2100d*d) d-Spec gravity @ 60 deg Fd-Spec gravity @ 60 deg F

FUEL OILSFUEL OILS» GCV=80.84*C +289.2H+22.24SGCV=80.84*C +289.2H+22.24S

C,H,S % OF carbon,hydrogen & SulphurC,H,S % OF carbon,hydrogen & Sulphur

Page 45: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Calorific ValueCalorific Value

Specific Energy (Gross) MJ/kg

Qg = (52.190 - 8.802 p2 10-6) [1 - 0.01 (x+y+s)] + 9.420 (0.01s)

Specific Energy (Net) MJ/kg

Qn = (46.704 - 8.802p210-6 + 3.167p10-3) [1-0.01(x+y+s)] + 0.01 (9.420s - 2.449x)

p = the density at 15 °C, kg/m³x = the water content, % (m/m)y = the ash content, % (m/m)s = the sulphur content, % m/m

Page 46: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Typical % of C,H,STypical % of C,H,S

FUEL CARBON HYDROGEN SULPHUR

FO 85.2 11.5 3.3

LSHS 87 12.3 0.7

LDO 86.4 12.7 0.9

HSD 86 13.5 0.5

Page 47: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Storage & HandlingStorage & Handling

Page 48: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

MODEL OF ASPHALTENE MOLECULEMODEL OF ASPHALTENE MOLECULE

S

CH2

CH3

CH2

CH3

CH3

CH

CH2

CH2

CH3

CH2CH2CH3

CH2CH2

S

S

CH2

CH2

CH3

CH2

S

CHCH2

CH2

CH3

CH2

CH2

CH3

CH

CH2

CH2

CH3

CH2 CH2CH3

N

CH3

CH2

CH3

CH3

CH2

CH3

CH3

CH3

CH2CH2

O

CH2

S

CH2

CH2

CH2

CH

CH2

CH2

CH3CH3

CH2CH3

CH3

CH3

Page 49: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

ASPHALTENES CHARACTERISTICS

ASPHALTENES CHARACTERISTICS

Polycondensed aromatic structures with few Polycondensed aromatic structures with few alkyl chainsalkyl chains

Contains hetero-atoms: S, N, OContains hetero-atoms: S, N, O

Contains metals: V, Ni, NaContains metals: V, Ni, Na

Not soluble in oilNot soluble in oil

Size of the micellar unit: 8 - 20 ASize of the micellar unit: 8 - 20 A

Cannot boil even under reduced pressureCannot boil even under reduced pressure

Molecular structure depends on crude oil Molecular structure depends on crude oil originorigin

Page 50: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

RESINS CHARACTERISTICSRESINS CHARACTERISTICS

Chemical structure close to asphaltenes Chemical structure close to asphaltenes

structure but:structure but: LONGER ALKYL CHAINSLONGER ALKYL CHAINS

LESS CONDENSED RINGSLESS CONDENSED RINGS

MORE SOLUBLE IN OILMORE SOLUBLE IN OIL

Molecular structure depends on crude oil Molecular structure depends on crude oil

originorigin

Presence necessary to provide a good Presence necessary to provide a good

stability to the fuelstability to the fuel

Page 51: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

HEAVY FUEL OILSHEAVY FUEL OILS

DISPERSED AND STABLE FLOCULATEDResins ensure seperation of heavy asphaltene molecules. Flocculated Asphaltene molecules tend to form sludge and settle at the bottom of the tank.

Page 52: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

InstabilityInstability

Asphaltenes "peptized" by resinsAsphaltenes "peptized" by resins Instability occurs when this peptization Instability occurs when this peptization

breaksbreaks Apshaltenes "flocculate"Apshaltenes "flocculate" Precipitation occursPrecipitation occurs Filter clogging,Overloading of Filter clogging,Overloading of

Centrifuge,deposits in tanksCentrifuge,deposits in tanks "No more a major problem""No more a major problem"

Page 53: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

IncompatibiltyIncompatibilty

When 2 different source FO's mixWhen 2 different source FO's mix Effects will be similar to InstabilityEffects will be similar to Instability ASTM D 4740 "spot test" ASTM D 4740 "spot test" "Avoid mixing FO's from different "Avoid mixing FO's from different

refineries"refineries"

Page 54: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Pre-PreparationPre-Preparation

SettlingSettling PurificationPurification ClarificationClarification HomogenisationHomogenisation

» AdditivesAdditives» CostlyCostly» Uncertain efficiencyUncertain efficiency

FilterationFilteration

Page 55: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

ISO 8217 FUEL STANDARD FOR MARINE DISTILLATE FUELS

ISO 8217 FUEL STANDARD FOR MARINE DISTILLATE FUELS

----0.300.30Max%m/mMICRO CARBON RESIDUE

ON 10% DIST. BOTTOMS

-------16Max°CCLOUD POINT

660--Max°CPOUR POINT, SUMMER

00-6--Max°CPOUR POINT, WINTER

60606043Min°CFLASH POINT

14.011.06.005.50Maxmm2/s

----1.501.40Minmm2/sVISCOSITY @ 40°C

920.0900.0890.0--Maxkg/mDENSITY @ 15°C

DMCDMBDMADMXLIMITSUNITSCHARACTERISTIC

Page 56: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

ISO 8217 FUEL STANDARD FOR MARINE DISTILLATE FUELS

ISO 8217 FUEL STANDARD FOR MARINE DISTILLATE FUELS

25------Maxmg/kgALUMINIUM & SILICON

100------Maxmg/kgVANADIUM

2.02.01.51.0Max%m/mSULFUR

----ClearClear----VISUAL INSPECTION

--354045Min--CETANE NUMBER

0.30.3----Max% V/VWATER

0.10------Max%m/mTOTAL SEDIMENT EXISTENT

--0.07----Max%m/mSEDIMENT BY EXTRACTION

0.050.010.010.01Max%m/mASH

2.500.30----Max%m/mMICRO CARBON RESIDUE

Page 57: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

ISO FUEL STANDARD 8217, 1ST REVISION 1996, FOR MARINE RESIDUAL FUELS

ISO FUEL STANDARD 8217, 1ST REVISION 1996, FOR MARINE RESIDUAL FUELS

RMK 55

DENSITY @ 15°C kg/m Max 975 981 981 985 991 991 991 991 1010 991 1010 - 991 1010 -

VISCOSITY @ 100°C mm2/S Max 10 10 10 15 25 25 35 35 35 45 45 45 55 55 55

APPROX VISC. @ 50°C * mm2/s 50 50 50 100 225 225 390 390 390 585 585 585 810 810 810FLASH POINT °C Min 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60POUR

POINT, WINTER °C MAX 0 24 24 30 30 30 30 30 30 30 30 30 30 30 30

POUR POINT,

SUMMER °C Max 6 24 24 30 30 30 30 30 30 30 30 30 30 30 30MCR % m/m Max 10 10 14 14 15 20 18 22 22 22 22 -- 22 22 --ASH % m/m Max 0.1 0.1 0.1 0.1 0.1 0.15 0.15 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2

WATER % V/V Max 0.5 0.5 0.5 0.8 1 1 1 1 1 1 1 1 1 1 1SULFUR % m/m Max 3.5 3.5 3.5 4 5 5 5 5 5 5 5 5 5 5 5

VANADIUM mg/kg Max 150 150 300 350 200 500 300 600 600 600 600 600 600 600 600

ALUMINIUM &

SILICON mg/kg Max 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80TOTAL

SEDIMENT POT % m/m Max 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1

RML 55RMH 45 RMK 45 RML 45 RMH 55RMF 25 RMG 35 RMH 35 RMK 35RMB 10 RMC 10 RMD 15 RME 25CHARACTERISTIC UNITS LIMIT RMA 10

Page 58: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

ISO 8217:1996

Revised ISO 8217 (likely early 2006)

Al+ Si ISO 10478 (ICP and atomic absorption)

ISO 10478 (equivalent to IP 377) is the reference method

New : IP 501 New : IP 470 Ca Not

included IP 501 (ICP)

IP 470 (atomic absorption) Zn Not

included IP 501 (ICP)

IP 470 (atomic absorption) P Not

included IP 501

IP 500 (UV spectrometry) V ISO 14597

(X-ray) IP 501 (ICP)

IP 470 (atomic absorption)

Page 59: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

Revision of ISO 8217Revision of ISO 8217

Release end 2005, early 2006 ?Release end 2005, early 2006 ?

Main changesMain changes : : Fuel grades basis viscosity at 50 °C instead of 100 °CFuel grades basis viscosity at 50 °C instead of 100 °C

RMC 10 no longer existsRMC 10 no longer exists

RMA 30 , RMB 30 and RMD 80 : lower max. densityRMA 30 , RMB 30 and RMD 80 : lower max. density

Water content : max. 0.5 v/v % for all gradesWater content : max. 0.5 v/v % for all grades

Ash content : Ash content : Fuel grades with a max ash of 0.10 m/m % : no changesFuel grades with a max ash of 0.10 m/m % : no changes

Fuel grades with a max ash of 0.20 m/m % : new max limit : 0.15 m/m %Fuel grades with a max ash of 0.20 m/m % : new max limit : 0.15 m/m %

Sulphur content : as of RME 180 : 4.5 m/m % max.Sulphur content : as of RME 180 : 4.5 m/m % max.

Limits for used lubricating oils (ULO): Limits for used lubricating oils (ULO): A fuel shall be considered to be A fuel shall be considered to be free of ULO if one or more of the elements Zn, P and Ca are below or at free of ULO if one or more of the elements Zn, P and Ca are below or at the specified limits (resp. 30/15/15 mg/kg)the specified limits (resp. 30/15/15 mg/kg)

Page 60: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

SN

1 mg/KoH/g

2 % wt.

3 kg/m3

4 O C

5 cst

6 % wt.

7 % wt.

8 % vol.

9 O C

10 ppm

11 ppm

12 ppm

13 K cal/kg

14 K cal/kg

15 % wt.

16 % wt.

17 ppm

18 ppm

19 ppm

20 ppm

P:30

Pb

Fe

ICP/AAS

ICP/AAS

ICP/AAS

Ni

NCV

Asphaltenes Content

Aluminium ICP/AAS

P:7

IP 143

+3

65

2

Pour point

Vanadium

Sodium

D-97

ICP/AAS

ICP/AAS

D-95

RCR

1

Sediment

2

GCV P:7

D:524

D-482

0.10

Si ICP/AAS

973.3

Total sulphur D 4294 3.60

Water content

Kinematic viscosity at 50 deg.C D-445

Density at 15 deg.C D-1298

Flash point (PMCC) D-93

Ash

Characteristics Unit

NilAcidity, inorganic D-974

ResultMethod of Test [P] of IS:1448 / ASTM

11.6

343

84

0.06

5

1

7

10150

9566

4

0

Page 61: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends

FUELFUEL VISC VISC Temp cStTemp cSt

40 40 720 720 100 100 33 33

110110 24 24 115115 20 20 120120 18 18 125125 15 15 130 130 1313

Page 62: Understanding Fuel Oils. Topics F Introduction F Refining Processes F Fuel oil composition F Fuel Oil production F A Modern refinery F Refining trends