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ANALYSE THE PROPERTIES OF FURNACE OIL AND TO COMPARE IT WITH BIO-LDO

Presented by – Under the guidance of-

Mr Aditya Shinde Mr S. Chandra SekharSRM University, DGM MetallurgyChennai Mr Bajirao Patil Manager(HTM)Training Period Mr Vishwas Patil30th May, 14- 10th June, 14 Senior Executive(HTM) Mr Dheeraj Misra Senior Executive(MNT)

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Objective

• To Compare and contrast the properties of Bio-LDO(Light Diesel Oil) and Furnace Oil.

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Contents:• Introduction

• Process Flow• Schematic representation of heat treatment cycle:• Comparison

• Advantages and Disadvantages

• Additive

• Benefits

• Savings

• Conclusions and Suggestions

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Introduction:

• Definitions a. Bio-LDO (methyl ester) Bio-LDO is a blend of distillate fuel with a small proportion of residual fuel. The average chemical formula for common diesel fuel is C12H23, ranging approximately from C10H20 to C15H28. LDO consists of the above strucurture

with blends of vegetable oil or lipids.

b. Furnace Oil: Furnace oil is a Dark, viscous residual fuel oil which is obtained by blending

residual products from various refining processes with suitable diluents usually middle distillates to obtain the required fuel oil grades.

Ref: Wikipedia

Process flow of heat treatment:

Schematic representation of heat treatment cycle:

Pusher Mechanism for loading tray into the furnace

Polymer QuenchingTank 1

Polymer QuenchingTank 2

Pusher Mechanism for loading tray into the furnace

Water tank

• Continuous-cycle Heating Furnace

A continuous heat treatment furnace (Bofco 2T/hr.) is used in MCIE for hardening and tempering. The burner type is Continental 52 forward flame excess air oil burner. The furnace used consists of 10 burners with 5 burners on either side of the furnace. The furnace is further divided into 3 zones marked with the positioning of the burners. The first six burners form the zone1, next two forming the zone 2, followed by two more forming the zone3.

Bofco 2T/hr Hardening furnace

Tempering furnace

Zone 1 2 3

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Comparison:Sr No.

Characteristic Bio-LDO RE-100

Furnace OilIS 1448

1. Kinematic Viscosity in 400C to 500C in CST

15.8 80-370

2. Calorific Value (Kcal/kg) 9720.9 9800-10200

3. Pour Point (0C) 120C-winter210C-summer

380C

4. Flash Point 660C 660C

5. Water, content percent by volume

0.042 1

6. Sulfur, percent by mass 0.045 3.5-4.5

7. Sediment, percent by mass

0.05 0.25

8. Ash, percent by mass 0.093 at 7500C 0.1

9. Carbon Residue, percent by mass

1.5 12-20%Fuel Comparision

Bio-LDO RE-100

Sr No.

Property Advantage Disadvantage Remarks

1. Kinematic Viscosity at 400C

FO-High Kinematic ViscosityHigher resistance to flow

2. Calorific Value

FO-Similar to LDO hence good in combustion

3. Pour Point FO-Lower Pour PointFlow problems

4. Water Content

FO-Higher water contentAffects the combustion

5. Sulfur FO-Higher sulfur contentCauses furnace chamber deposits, pipe corrosion and wear

6. Flash Point FO-Same as LDO

Advantages and Disadvantages(Furnace oil):

Sr No.

Property Advantage Disadvantage Remarks

7. Sediment FO-Higher sediment contentClogs filters and build up depositsin tanks and piping.

8. Ash FO-Higher ash contentLeads to abrasion, malfunctioningof injectors and high temperaturecorrosion in fuels.

9. CarbonResidue

FO-Higher carbon residuePoisonous in nature.

Note- The sediment, ash and carbon residue can be reduced by adding ethanol as additive. The kinematic viscosity and sulfur content can be brought down by using additive SK-5L.

Advantages and Disadvantages(Furnace oil):

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ADDITIVE IN FURNACE OIL (SK-5L) (Suggestion)

Additive name: SK-5LSK-5L Fuel additive is added in 1: 1000 proportion to FO for best results. When we add the additive in above mentioned proportion the additive cracks the longer carbon chain of above fuels to smaller sizes hence increasing the surface area of combustion resulting in best possible combustion with stable exhaust.

Features of SK-5L:1. Copper strip corrosion of fuel after adding additive becomes negative indicating protection of storage tanks & conduit pipes from corrosion. It acts as corrosion inhibitor.2. SK-5L has specific gravity of 0.8 hence it is easily miscible in all the above oils once added before tank unloading will serve the purpose.3. Easy to applicant, any other capital investment not at all required.4. Density 0.8 at 29°C, Color yellow with greenish appearance, Flash Point 31°C, Calorific value – 10880 K Cal / Kg. Copper strip corrosion negative in proportion 1 in 3000 ltrs F.O. 

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Advantages when SK-5L additive is added: Due to dissolving of sulfur in SK-5L, sludge problem gets solved.

Due to more Fluidity Nozzle chocking also reduces considerably.

Due to lowering of sulfur percentage, 50% less corrosive gasses are evolved and can be verified by monitoring Exhaust gases. Hence metal chimney life also doubles.

Due to atomizing spray is very fine so 15 to 20% lesser oil inlet pressures can be maintained Hence initial firing problem is reduces considerably.

Due to better atomization spray improves. Hence due to complete combustion deposits on radiant tubes Reduces by 50%.

So periodic maintenance can be brought down by 50%.

Purging of Nozzles can be eliminated altogether since Oil Inlet Pressure can by reduced by up to 20% depending on dosage i.e. Improved fluidity.

Note- The present burners being used in the Bofco furnace to fire LDO can also be used in Furnace Oil combustion provided it is pre-mixed with an additive.

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Cost calculation for Bio-LDO and Furnace oil

Cost of Bio-LDO in rupees= 55Rs/literAmount of Bio-LDO Consumed in liters= 80liters/hourHence, Total cost of Bio-LDO for one hour= 55*80 = Rs 4400

Cost of Furnace Oil in rupees= 46Rs/literAmount of Furnace Oil Consumed in liters= 95liters/hour (As per theoretical calculation @10-15% increase in consumption than Bio-LDO) i.e. 10.4liters+80liters= 90.4litersHence, Total cost of Furnace Oil for one hour= 46*90.4 = Rs 4158.4Hence we see that Furnace Oil is Rs 241.6/hour cheaper as compared to Bio-LDO.

Note- As we do not have additive cost hence additive cost cannot be considered during calculation.

SUGGESTIONS:

Emulsification

Gear Pump

Electromagnetic Valve

1. EmulsificationEmulsification is blending of furnace oil and about 10 % of water with emulsifying agent(water-in-oil). The primary spray fuel droplets are further divided as a result of the explosive vaporization caused by rapid heating of the water dispersed within the individual fuel droplets. The internal water droplets undergo spontaneous nucleation of steam bubbles at a temperature well above 100°C, causing a violent conversion of the water droplet to steam. The vaporization, in turn, produces a rapid expansion of the surrounding oil droplets, fragmenting the oil into a vast number of smaller fuel droplets. For proper blending, Emulsified water in furnace oil can be separated with the help of de-emulsifying agent only. This Emulsified furnace oil can be used directly to any burner without any changes in existing system, to increase the combustion efficiency of the fuel, resulting in reduction of F.O. Consumption by approximately 5 to 7%, reducing the fuel cost. It also decreases the kinematic viscosity of furnace oil.

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2. Gear PumpThe pump used in the LDO pump is a pressure pump.

This pump can be replaced by a gear pump. This sucks the oil and increases the pressure

in the nozzles to 15 bar maximum. Usually a gear pump of the sickle type is used. This

type of pump is a simple and therefore cheap pump consisting of one or more radical

pairs of gears and with a very small space between the gears and the pump casing. Gear

pumps are used frequently in oil burners because of their simplicity, stability and low

price.

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3. Electromagnetic Valve:As the fuel supply is continuous many a times the fuel is supplied to the sprayer whennot required for combustion. Also sometimes the time taken for switching off the fuel supply is more. As a result afew liters of the fuel go waste. The fuel is not evenly purged inside the furnace during startup of the furnace.This can be solved using an electromagnetic valve. It enables fuel to be shut off from

the sprayer by electrical control. This helps avoid drips when it is inactivated. It also eases the purging of the burner of fuel mist, during start up, or while restarting after a misfire. If the burner were not purged the oil/air mixture could explode dangerously.

  1. Valve Body 4. Coil /

Solenoid 7. Plunger

2. Inlet Port 5. Coil Windings 8. Spring

3. Outlet Port 6. Lead Wires 9. Orifice

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Conclusion:

Hence we can conclude that Furnace Oil can be used to replace LDO provided it is combined in proper proportions with additive SK-5L. The exact cost can be calculated based on trials.The suggestions made can be applied and installing them in the furnace will be a one time investment.