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ECH-A
Energy-Saving and Carbon-
Reducing Emulsified Heavy
Crude Oil Equipment
VAST CALIBRE TECHNOLOGY INC.
E- mail:VIGIRA@HOTMAIL.COM
TEL:886955111899(Rep) SKYPE: VIGIRA
1
Table of Contents
Use of Heavy Crude Oil and Problems 2
Related technologies 3
Comparison of related technologies 4
ECH-A Emulsification Device 5
ECH-A Performance Test and Comparison 9
Estimation and Comparison of ECH-A and Related Techniques in Their Oil-efficient Capacity 25
Water Addition Suggestion for Energy-saving Heavy Crude Oil. 29
2
Use of Heavy Crude Oil and Problems Characteristics and Use of Heavy Crude Oil
Heavy crude oil is the residues at the bottom of the tower left over from processing and cracking of crude oil. Its heating value (8,500 ~ 11,000 Kcal/kg) is high, so are its bitumen and sulfur content.
Because heavy crude oil has a high heating value and is relatively cheap, it is widely used.
Problems associated with use of heavy crude oil Incomplete burning is likely, which will lead to greater air
pollution and higher emission indexes (suspension particulates SS, SOx, NOx, NO, CO, and tail gas emission temperature)
Because heavy crude oil has greater viscosity and repeated heating is thus necessary, bitumen will sediment and oil silt will clog the nozzle and pipeline. As such, the frequency of cleaning the burner nozzles and the oil tank is relatively high, leading to economic losses.
3
Related technologies Additives in the heavy crude oil:
To enhance the burning performance of heavy crude oil, additives can be pour point depressants, demulsifiers, and bitumen dissipating agents.
Bottleneck problems Compared with the saved fuels, additives are expensive with limited
benefits.
Without auxiliary equipment, additives cannot be used separately.
Average oil-efficient rate after additives costs are deducted: 8%
With ECH-A, bottleneck problems are solved. There is no need for any additives and it saves on fuels, with numerous
benefits
There is no need to add auxiliary equipment. Installation is easy.
Ratio of water addition can be as high as 40%, depending on the needs. With addition of 18.5% of water, the oil-efficient rate is 16.19%.
Emulsifying water can be replaced by organic industrial waste water. It is more eco-friendly.
4
Comparison of related technologies
Related Techniques
Comparison Items
Use of additives ECH-A
1. Cost-saving
(Relatively reduced fuel
expenses)
Low (below 8%) High (With addition of 18.5%
of water, the oil-efficient rate
is 16.19%)
2. Air pollution
improvement
High High
3.Stability High High
4. Burner and peripheral
equipments
High Low
5. Overall economic
benefit
Low High
5
ECH-A Emulsification Device
ECH-A Design Concepts
Online reconstitution of energy-saving and eco-friendly emulsified heavy crude oil.
Complete emulsification of heavy crude oil + water to generate highly-efficient secondary nebulization and contribute to complete burning for enhanced oil-efficent rate.
Complete homogenizing emulsification. Storage and transportation is possible.
Complete homogenizing emulsification with stable burning conditions.
Optimized reconstitution ratio can be applied with the burning equipment on-site to reflect actual demand.
7
Energy-Saving and Eco-Friendly
Heavy Crude Oil Process of ECH-A
Raw material
heavy crude oil
(60 – 100%)
Water or organic
industrial waste
water
(0-40%)
Burning device
ECH-A energy-
saving and eco-
friendly heavy
crude oil
ECH-A Emulsification Device
8
Secondary nebulization of oil mist
in the burning chamber
(Micro-explosion) = The key for
ECH-A to enhance oil-efficient and
reduce emissions of pollutants.
9
ECH-A Performance Test and
Comparison
Testing Institution
Research Developments on Combustion, Science
and Technology, Department of Mechanical
Engineering, National Cheng Kung University
Secondary nebulization water drop distribution
and analysis
Comparison of ECH-A and heavy crude oil
Burning test
Air pollution test
11
From ECH-A oil mist to secondary nebulization
(micro-explosion)
1. ECH oil mist is heated
2. When the temperature exceeds 100℃, water in the oil mist starts to gasify and the volume starts to inflate.
3. When the water gasifying pressure is greater than the tension on the surface of the oil mist, the oil mist explodes.
4. The oil mist explodes to several particles with smaller diameters. Their oxygen-absorbing capability is enhanced, contributing to the burning.
12
ECH-A Emulsified Heavy Crude Oil –
Water Drop Distribution Analysis
Manufactured Date 03/25/2010 Location: Sanxia, Taipei
Test 1, 05/15/2010 Location: Guiren Campus, National
Cheng Kung University
Test 2, 06/21/2010 Location: Guiren Campus, National
Cheng Kung University
100 amplification factor 200 amplification factor 400 amplification factor 100 amplification factor 200 amplification factor 400 amplification factor
Figure 4 Distribution Map of Water Drop Diameters in Oil No. F03-25-10B (Test No.
M06-21-10B) Figure 3 Distribution Map of Water Drop Diameters in Oil No. F03-25-10B (Test No.
M05-15-10B)
Test No. M05-15-10B M06-21-10B
Measured water drop quantity 200 200
Average diameter (μm) 4.96 5.3
Standard deviation (μm) 3.09 2.6
Maximum diameter (μm) 19.25 18.3
Minimum diameter (μm) 1.16 2.2
Distribution Map of Water Drop
Diameters
Fig. 3 Fig. 4
13
Heavy Crude Oil VS. ECH-A Emulsified
Heavy Crude Oil
Burning Temperature Test – Testing
Platform
Figure 2 Photographs of Multiple-Fuel Burning Test Equipment
Figure 3 Configuration Layout of Temperature Measurements for Horizontal Burners.
14
Heavy Oil VS. ECH-A Emulsified Heavy Crude Oil
Comparison Table and Statistics of Burning
Temperatures
Fuel oil Content % Water
addition ratio
%
Minimum
flame
temperature
℃(R7)
Maximum
flame
temperature
℃(R7)
Heavy crude
oil
100% 0 % 1104 1136
ECH-A
Emulsified oil
81.5 % 18.5 % 1057 1095
15
Heavy Crude Oil VS. ECH-A Emulsified Heavy Crude Oil
Comparison Table of Burning Temperatures – Actual
Measurement Record Sheet
ECH-A
Burning Performance (Oil No. F06-07-10A; Test No.: B06-16-10A)
Burning Performance (Oil No. F06-07-10B; Test No.: B06-16-10B)
Time*(minute )
Original Data
Original Data
6%O2 Modification
6%O2 Modification
6%O2 Modification
6%O2 Modification
Original Data
Original Data
*Timing starts after the oil has gone through the pre-burn test for 1 hour.
Time*(minute )
Heavy crude oil
16
Heavy Crude Oil VS ECH-A Emulsified
Heavy Crude Oil
Comparison Table of Secondary Air Supply
Fuel oil Content % Water
addition ratio
%
Consumption
L/Hr
Secondary air
supply
M3/hr
Heavy crude
oil
100% 0 % 20 210
ECH-A
Emulsified oil
81.5 % 18.5 % 20 195
17
Heavy Crude Oil VS ECH-A Emulsified
Heavy Crude Oil
Comparison of Secondary Air Supply – Actual
Measurement Record Sheet Heavy crude oil ECH-A
18
Heavy Crude Oil VS ECH-A Emulsified
Heavy Crude Oil
Comparison Table of Burning Efficiency
Fuel oil Content % Water
addition ratio
%
Minimum
efficiency %
Maximum
efficiency %
Heavy crude
oil
100% 0 % 84 85
ECH-A
Emulsified oil
81.5 % 18.5 % 85 86
19
Heavy Crude Oil VS ECH-A Emulsified Heavy
Crude Oil
Comparison Table of Efficiency and Stability –
Actual Measurement Record Sheet Heavy crude oil ECH-A
20
Heavy Crude Oil VS ECH-A Emulsified
Heavy Crude Oil
Comparison Table of Heating Values
Fuel oil Heavy crude
oil content %
Water
addition ratio
%
Net heating
value
cal/g
Heavy crude
oil
100% 0 % 9711
ECH-A
Emulsified oil
81.5 % 18.5 % 9440
21
Heavy Crude Oil VS ECH-A Emulsified Heavy
Crude Oil
Comparison Table and Statistics of Heating Values ECH-AHeavy crude oil Oil No.
Density@60℉, g/mL
Flash point, ℃
Sulfur content, %
Flow, ℃
Dynamic
viscosity cSt
Total aromatic hydrocarbons, wt%
Water content, vol%
Carbon content, wt%
Hydrogen content, wt%
Nitrogen content, μg%
Net heating value, cal/g
Total heating value, cal/g
Note: “-" in the table means that the analysis was not performed.
Test method
22
#6 Heavy Crude Oil VS ECH-A Emulsified
Heavy Crude Oil
Comparison of Air Pollution Emissions
Air Pollution Emissions Testing Equipment
23
Heavy Crude Oil VS ECH-A Emulsified
Heavy Crude Oil
Comparison Table of Air Pollution Emissions Fuel oil O2 % max CO2 % max CO (ppm)
min
NOx (ppm)
max
Sox (ppm)
max
Heavy
crude oil
6.2 10.9 0 369 199.5
ECH-A
Emulsified
oil
Water
Content
18.5%
6.15 10.5 0 286.6 180.6
24
Heavy Crude Oil VS ECH-A Emulsified Heavy Crude Oil
Comparison Table and Statistics of Air Pollution
Emissions
ECH-A
Burning Performance (Oil No. F06-07-10A; Test No.: B06-16-10A)
Original Data
6%O2
Modification
Original Data
6%O2
Modification
Original Data
6%O2
Modification
Original Data
6%O2
Modification
Time*(minute )
Time*(minute )
Burning Performance (Oil No. F06-07-10B; Test No.: B06-16-10B)
*Timing starts after the oil has gone through the pre-burn test for 1 hour.
Heavy crude oil
26
ECH-A Average Oil-efficient Rate Estimate Table * Based on Test
Report on 07/09/2010
Example: Water Content of 20%
I. Oil-efficient rate
1. #6 Heavy crude oil total heating value: 10,260 cal/g = 10,260,000 kcal/MT
2. Total heating value of ECH-A (including 18.5% of water) emulsified heavy crude oil
3. For ECH-A emulsified heavy crude oil to reach the total heating value 10,260,000 kcal/MT, the fuels that need to be used are 10,260,000 kcal/MT /9,986,000 kcal/MT = 1.027MT = 1,027kg. In other words, to maintain the same heating value when ECH-A is used, additional 1,027 – 1,000 kg = 27kg of ECH-A fuel oil that contains 18.5% of water needs to be used.
4. Therefore, the oil-saving rate when ECH-A emulsified heavy crude oil is used is 1,000 kg – (815.0 kg + 27 kg)=158.0kg. In other words, the oil-efficient rate is 158.0kg/1,000kg=15.8%.
II. Saved expenditure
Suppose the cost for each ton of #6 heavy crude oil is NT 19,528 / MT
5. The cost for each ton of ECH-A emulsified heavy oil is NT 19,528 /MT*0.815(fuel oil) + (NT65*0.1850)(Water)+ (NT 2.74kw-h*2.2kw- h)(electricity cost)= NT15,915 + 12.0 + 7.0 = NT 15,934
6. When ECH-A with an equivalent heating value is used, it is NT 15,934/MT*1.027 MT = NT 16365.
7. Saved fuel cost with ECH-A = NT 19,528 –NT 16365 = NT3,163
8. Saved expenditure with ECH-A = NT3,163 / NT 19,528 = 16.19%
Saved expenditure with water addition ratio of 18.5%= 16.19%.
27
Estimate Table of Average Oil-efficient Rates for Related Technologies (GFXP) Example: Water content of 12.85% and emulsifying agent of 0.65%
I. Oil-efficient rate
#6 Heavy crude oil total heating value: 10,260 cal/g = 10,260,000 kcal/MT
2. Total heating value of GFXP (including 18.5% of water) emulsified heavy crude oil = 10,162 cal/g =10,162,000kcal/MT
3. For GFXP emulsified heavy crude oil to reach the total heating value 10,627,000 kcal/MT, the fuels that need to be used are 10, 627,000 kcal/MT / 10,162,000 kcal/MT = 1.046MT = 1,046kg. In other words, to maintain the same heating value, additional 1,046 – 1,000 kg = 46kg of GFXP fuel oil that contains 12.85% of water and 0.65% of emulsifying agent needs to be used.
4. Therefore, the oil-saving rate when GFXP emulsified heavy crude oil is used is 1,000 kg – (865.5 kg + 46 kg)=88.5kg. In other words, the oil-efficient rate is 88.5kg/1,000kg=8.85%.
II. Saved expenditure
Suppose the cost for each ton of #6 heavy crude oil is NT 19,528 / MT
5. Cost for each ton of GFXP emulsified heavy crude oil= = NT 19,528 /MT*0.8655 (fuel oil) + (NT65*0.1280)(Water)+ (NT29,100*0.0065)(emulsifying agent)(NT 2.74kw-h*7.6kw- h)(electricity cost)= NT16,901 + 8.32 + 189.15 + 20.824 = NT 17,119
6. When GFXP with an equivalent heating value is used, it is NT 17,119/MT*1.046 MT = NT 17,907.
7. Saved fuel cost with GFXP = NT 19,528 –NT 17,907 = NT1,621
8. Saved expenditure with GFXP = NT1,621 / NT 19,528 = 8.3%
Saved expenditure with water addition ratio of 18.5%= 8.3%.
28
Comparison Table of ECH-A and Related
Technologies (GFXP) in Energy-Saving
Energy-saving technology Oil-efficient rate Saved expenditure
ECH-A
(Water content of 18.5%)
15.8% 16.19%
GFXP
(Water content of 12.85% and
emulsifying additives of
0.65%)
8.85% 8.3%
29
Recommended water addition rates for
ECH-A emulsified heavy crude oil used
in different industries Industry Application Water addition
rates
Glass fiber manufacturers, glass
industries, ceramics industries,
cement industries, metallurgical
industries, mining industries,
asphalt factories, power plants
Furnaces,
melting pots,
baking ovens
~20%
Pharmaceutical industries,
petrochemical industries, dyeing
and finishing industries, printing
and dyeing industries, textiles, dairy
industries, chemical industries, dye
industries
Steam boilers ~30%
Food industry, hospitals, hotels,
swimming pools, public architecture,
general industries
Steam boilers,
Hot water boilers ~40%
Recommended