Use of Emulsified Fuels in the Power Genering Sector

R.A.D.E 2015 | www.rade.co.in

EMULSIFIED FURNACE OILA SINGLE SOLUTION TO MYRIAD PROBLEMS PLAGUING THE INDIAN THERMAL POWER GENERATION SECTOR :

- POLLUTION

- HIGH COST OF FUEL

- SHUTDOWN

- BREAKDOWNS


Indian Thermal Power Sector

• Almost 70% of India’s electricity is generated in Thermal Power Plants.

• 85% of India’s Thermal Power Plants run on Coal.

• Thermal Power Stations consume 70% of the country’s coal.

• Shortage of natural gas, has closed most Gas based plants.

• High Fuel Oil and Naphtha prices have also shut many Oil fired plants.

• Shutting down these plants has increased electricity shortage.


Problems of Coal Fired Plants

• Indian Coal has a high ash content and low calorific value.

• Plants using domestic coal use 0.7 kg of coal to generate 1 kWh, compared to USA where only 0.45 kg is used.

• They also generate very high levels Fly Ash and Bottom Ash.

• Thus overall efficiency levels of these plants are quite low.

• Coal transport & handling causes high ground, air & water pollution.

• Constantly require supplemental Fuels like Furnace Oil.

• Delhi’s Badarpur Thermal Power Station was recently declared the most polluting in the country by environmental body CESE.


Oil Fired Plants

• Mostly use Furnace Oil(FO) Heavy Fuel Oil(HFO) or Residual Fuel Oil (RFO).

• Most have a Steam Boiler and Steam Turbine to run the Generator.

• Some units are powered by a Gas Turbine firing Naphta or F.O.

• Small units use Heavy Oil Diesel Engines running on Diesel or F.O.

• Many are economically non-viable due to high Fuel Oil prices.

• Recent fall in Oil prices has made F.O., viable for Power Generation.


Furnace Oil in Power Sector

• As Direct Fuel in Oil Fired Power Plants.

• Used as a Start-up Fuel in Coal Fired Plants.

• Burned in both Boilers and Gas Turbines.

• Also used as supplementary fuel in Coal Fired Power-Plants.

• Power Sector consumed over 5.4 million MT or 9.32 % of F. Oil in 2013-14*.

• F.O consumption in Power Sector is valued at over Rs.1608 Crores .

*DATA FROM GOVERNMENT OF INDIA MINISTRY OF PETROLEUM & NATURAL GAS ECONOMICS AND STATISTICS DIVISION NEW DELHI


Problems Of Furnace Oil

• Comprise of Residual & Waste Oils from the Petroleum refining process.

• Suffer from Incomplete Combustion due to Poor Atomization.

• Burner, Strainer Blockages due to Asphaltenes & Sludge.

• Black Smoke and Sulfur smell, Pollutants like NOx & SOx in Flue Gas.

• No Uniform Guaranteed Quality from Manufacturers.

• Very Often Adulterated with Water & Other Impurities.

• Vague Metering Practices.


Single Solution: Emulsified Furnace Oil

• Improved Fuel Economy by 3-5 % over Normal F.O .

• Doesn’t require any Major Equipment changes.

• Zero Sludge, Free Water & Impurities: Zero Waste Oil – Total Utilization.

• Complete Combustion with Shorter, Bright, Wide Flames.

• No Un-burnt Carbon, Smoke and Particulate Matter .

• Clean & Economical Alternative to F.O. , Diesel & Naphta.


Furnace Oil vs. Emulsified F.O.

Normal F.O. Emulsified F.O.

Under Microscope 100x Magnification


Emulsified F.O. : Characteristics

• Emulsions are stable blends of immiscible liquids like Oil & Water.

• Fuel Emulsions contain suspended micron sized water droplets.

• Secondary Atomization allows Complete Combustion of Fuel.

• Provides better economy, less smoke and lower pollutant levels.

• The Emulsifying process can also reduce the Sulfur in F.O.

• Used in Steam Boilers, IC Engines, Gas Turbines or as support Fuel.


Emulsified Furnace Oil: Flame


Benefits: Steam Boilers

• Can be used both as a Direct Fuel or Supplemental Fuel to Coal.

• Low Carbon and Soot deposits on Tubes: Reduced maintenance.

• Enhances Thermal transfer due to release of Super Heated Steam.

• Requires Less Excess Air : Reduced Waste Heat generation.

• Complete Combustion: Fuel economy.

• Cleaner Emissions.


Benefits: Gas Turbines

• Less Ash fouling of Combustor and Vanes: Reduced Downtime.

• More Pressure due to Steam from Emulsion Flame: Improved Efficiency


• Peak Temperature Reduction: Longer Service Life.

• Cleaner Emissions.

• Recommended by leading manufacturers.

• Cheap, easily available Alternative Fuel to Naphta and Natural Gas.


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.


• Peak Temperature Reduction: Longer Engine Life.

• Very Clean Emissions.


Ecological Benefits: All Segments

• Emulsified F.O. combustion uses almost 20% less Oxygen.

• Emulsified F.O. requires less “excess-air” for Combustion.

• Emulsified F.O. generates 20-30% 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.


Endorsed by Manufactures

• Siemens Turbines (Gas Turbines) - Germany.

• Wartsila Power (IC-Generators)- Finland.

• MAN Diesel & Turbo (IC-Generators) - Germany.

• Ansaldo Energia (Gas Turbines) – Italy.

• Pratt & Whitney Power Systems (Gas Turbines) – USA.


Accepted Worldwide

• F.O.-Water Emulsion Fuels are widely used in Ships, Generators & Turbines.

• Santa Rita in Philippines was the 1st power plant with two 250MW Siemens V-series Gas Turbine to run on Fuel 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, cumulative running hours with ORIMULSION for 150,000 hr in a Wartsila Generator.

• Vlore, Power Plant of KESH Albania Power Corporation, Albania uses Ansaldo Energia AE64.3A+ gas turbine firing HFO Emulsion.


Kobe University(Japan) - Case Study


Enel S.p.a (Italy) - Case Study

Company Enel S.p.a.

Plant Type Thermal Power Station

Turbine Manufacturer Ansaldo Energia

Model AE94.2

Rating 180 MW

Fuel Emulsified HFO

Emulsion Ratio 30% Water

Economy 9.7%

NOx - 28%

PM -56%

Smoke - 64%

* Source: Enel S.P.a, Italy


EPA (USA)-Case Study 1(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


EPA (USA)- Case Study 2(Emissions)

* Source: U.S. EPA AP-42 Section 1.3


Siemens AG(Germany) – Case Study

Tests on Siemens SGT5-4000F Gas Turbine using F.O. Emulsion with 15% Water showed that Peak Temperatures reduced NOx to less than of 42 ppm.*

* Source: SGT5-4000F Gas Turbine & Combined Cycle Power Plant Evolution reflecting the changingMarket Requirements- Eberhard Deuker, Siemens AG, Energy Sector, Germany


Fuel Emulsions in the Global Press


About Us

• RADE Initiative is a India based Energy Efficiency Technology Developer.

• Pioneer in introducing Fuel Emulsification concepts & Technology in India.

• Invited by UNDP-GEF on numerous occasions to speak in their Seminars.

• Since 2013 have partnered with Creatnet Technology for Fuel Emulsions.

• Creatnet Technology is India’s only active F.O. Emulsion manufacturer.

• We have been operating our Proof-Of-Concept Plant for one year in NCR.

• We have an In-House testing Laboratory and Firing Facility.

• Featured by publications like Fortune, Money Control, Manufacturing Today.

• Bharat Petroleum Website has also highlighted our work in Creatnet Technology.


Synopsis

• Emulsified F.O. is used globally and accepted as Clean Fuels.

• Its has cleaner emissions than normal stock fuel.

• Provides better economy due to complete combustion.

• It can being used in Gensets, Boilers and Gas Turbines of Power Stations.

• Switching over to Emulsified Fuels doesn't’t require equipment changes.

• Adoption of Emulsified F.O. in Power Plants can save Crores of Rupees.

• Even as a supplemental fuel to Coal, Emulsified F.O. decreases pollution.


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