ZYDEX INDUSTRIES

• Innovation• Ascent• Excellence

ZYDEX COMMITMENTS TO GREEN EARTH

• Eco- Production technologies• Eco-products - Specialty polymers & chemicals

WHY ARE WE HERE & WHY THIS TECHNOLOGY

Global Warming

Estimated 150 million ton heavy fuel burn / year Rise in CO2 emissions - Green house effectPollution – carbon particulate matter, CO, NOx, SO3, etc

Environment : Weather Changes

Melting of ice caps / thinning of glaciersExtreme conditions (flood / hurricanes / draught)

160 countries pledged to reduce CO2 level Reduction of 5.2% from level in 1990 by 2010Leads to Carbon trading / CDM technologies

Kyoto Protocol

New Technology will surely help worldMaintaining global leadership in manufacturing facilities(by economizing the production cost )Reducing & Maintaining its level of green house gassesThus help in achieving GLOBAL ECONOMY & BETTER ENVIRONMENT

RECENT SCENARIO ON GREEEN HOUSE LEVEL

(data from “NEW SCIENTIST” (10 Nov 2005)

Growth Rate of CO2 level 1990- 1999 : 0.8% / year2000- 2005 : 3.2 % / year (400 % rise in just last 5 year)

China Position 1990 : Very low & reduced level2005 : Became the 2nd largest emitter of green house gases after U.S.A. With same rising trends By 2009 China will be world’s top emitter Other developing countries India & Brazil - also fast becoming large emitters

To follow Kyoto Protocol & in view of consequences of Global Warming 5- 10 % saving would lead to • Saved burning of 7.5 – 15 million tons of fuel • Reduced CO2 level by 22.5 -40 million tons / year

Even a small efforts will bring big resultsThis was the starting point for the development of

INTROCUCTION

ZYCRYL - 15 & ZYCRYL - 20

A New generation Fuel Efficiency Enhancer For Furnace Oil , Heavy / Residual Fuel Oil, Bunker Fuel

ZYCRYL-15

• Improves combustion efficiency of fuel oil

• Ensures 8-10% Fuel Saving

• By adding 5- 6 % water as stable micron size emulsion in Fuel Oil

• Using low shear / pressure emulsification technique

• At low capital investment ( $ 500 – 1000 ) .

(Patented)

F E A T U R E S

USE OF FUEL OIL

Heavy Fuel / Residual Fuel Oil / Furnace Oil / Bunker Oil

• Forging Shops

• Ceramics furnaces

• Power plants

• Industrial boilers

• Metallurgical furnaces

• Rolling mills (Steels)

• General industrial heating

At 6- 20 bar pressure pumping, burner atomizer produces a spray of fuel, resulting droplets size 100 to 200 microns (approx.) depending on the following

ATOMIZATION PROCESS IN INDUSTRIAL COMBUSTION

• Fuel Viscosity

• Temperature

• Atomizer design

Fuel Oil + Air (C H S) (O2 + N2)

COMBUSTION REACTION

Petroleum Fuel contains chiefly Carbon & Hydrogen (small quantity Sulfur)

Complete combustions gives

But large droplet size of the fuel oil leads to Incomplete combustion

CO2 + H2O + SO2 +N2 + Heat Energy

How ?

INCOMPLETE COMBUSTION PROCESS

HEAT

HEAT

HEAT

HEAT

FUELDROPLET

Initial size- 100- 200 micron

INCOMPLETE COMBUSTION PROCESS

HEAT

HEAT

HEAT

HEAT

Final unburnst particle

HOW & WHY ?

Large size droplets have low surface area Burning will starts at outer surface of fuel drop Initially only low boiling fraction will burn Continual depletion of this lower viscosity fraction increases the droplet viscosity This leads to the formation of some fine very hard, difficult to burn particle

Results Soot formation (Un-burnt fuel particle)Black smoke Higher SPMHigh Carbon deposit buildup around burner nozzle & heat transfer surface

Incomplete combustion also leads to CO : Indicates low heat energy releaseHigh SO3, : Corrosion due to acid formationHigh NOx : Environmental problem

(1st Step ) C + O → CO + 2,430 K cal / kg. of Carbon

(2nd Step) CO + O → CO2 + 5,654 K cal / kg. of Carbon

Total C + O2 → CO2 + 8,084 K cal / kg. of

Carbon

LOSS IN ENERGY GENERATION

Complete combustion : both the steps take place

C + O2 → CO2 + 8,084 K cal / kg. of Carbon

Incomplete combustion : only Step-1 takes place

C + O → CO + 2,430 K cal / kg. of Carbon

Loss of energy from II step means ~ 5654 K cal/ kg of carbon

Reduce the particle size of fuel oil

In surface tension reduction Adding wetting agent

Maximum reduction possible from 100- 200 microns to 70-80 microns

Results in Saving (increase in efficiency ) upto 1 - 2 % only

HOW TO IMPROVE COMBUSTION ?

Either by Reduce Surface Tension – Add Wetting Agent

Or by Secondary Atomization – Thru Emulsion Technology

Ideal option-Secondary atomization through water emulsion Adopt Emulsion Technology

Induce explosive vaporization

Results in fragmentation of larger fuel droplet.

15 – 20 micron particle size

These are

• Low molecular weight surfactant

• Poor surface stability

• Leads to premature burst non- uniform / large size droplets

• Saving Fuels ( efficiency increase) are not much (2 -3 % )

SECONDARY ATOMIZATION

through CONVENTIONAL Emulsifier

Next generation polymers

to overcome above problem of interface stability 10 time reduction of particle size to increase combustion

Advantage of polymer based interface film

• Forms a viscous & polymeric interface film (oil/water interface)

• The interface film has better elasticity / stretching

• Better tolerance to expansion of particle

• Better interface stability

• No premature burst of oil droplet

• Uniform & smaller size particle

• Better enhancement of efficiency /saving ( 8-12%)

ZYCRYL-15

A Novel Polymer composition Helps in making very stable emulsion (1-2 years) 8-12% fuel savings at low capital investment

PROCESS OF COMPLETE COMBUSTION WITH ZYCRYL-15 EMULSION

Oil droplet size 100 microns

Water-Oil emulsionBelow 100 degree C. Water-Oil emulsion

100 – 250 degree C.

Oil droplet size 15-20 microns

Waterdroplet

•Fuel droplet size - 100 to 200 micron

•Water droplet size - 4 to 6 micron (inside fuel droplet)

•This emulsified fuel droplets, due to high temperature zone inside the furnace /boiler,

convert within micro-second in to steam vapor.

•Rapid expansion of water vapor within Fuel droplet results in the burst / fragmentation

of 100-200 micron in to very small size particles (around 10-20 micron).

•Larger surface area large air interface better combustion enhanced efficiency

•Smaller the particle - Burning more rapidly in smaller area

•Reduction in flame length.

HOW THIS EMULSION HELPS

By inducing SECONDARY ATOMIZATION

This Emulsion is 5-6 % water content in fuel oil with uniform particle size

Revised diagram of Furnaceshowing particle incomplete combustion

COMBUSTION WITHOUT ZYCRYL-15

COMBUSTION WITH ZYCRYL-15

Revised diagram of Furnaceshowing particle complete combustion

NoSoot

Low stack temperature

Shorter burnout dwell time Pre-atomized fuel

Better & uniform SECONDARY ATOMISATION Viscous , elastic , expandable polymeric interface filmBetter interface stability No premature burst of oil droplet Uniform & smaller size particleMuch better enhancement of efficiency /saving ( 8-12%)

Easy emulsification Lower shear Low power Low capital investmentStable emulsion Emulsion is stable for 1-2 years Short flame - how it helps

Higher flame temperature ( same fuel burnt in smaller area )Majority of heat transfer is through radiation, It is substantially improved due to T4 dependence of radiation heat transfer

Conventional surfactant vs Polymeric compositions

NOVEL PROPERTIES OF EMULSION WITH ZYCRYL-15

Flame length Reduced & become sharp

Heat transfer due to radiant heat will be higher than convection /conduction heat transfer

Reduced stack temperature

Almost elimination of CO generation.

Substantially reduced deposits of Carbon buildup on burner frequency of cleaning reduced & also cleaner heat transfer surfaces.

Practically eliminates the black smoke.

Reduction in air to fuel ratio.

Reduces SO3 concentration.

Improves CO2 generation i.e. efficient burning.

All these give 8-12% average saving & efficiency improvement at low capital investment.

WHAT IS HAPPENING EXACTLY

Explosive vaporization of water droplets leads to the reduction in size of fuel particles. Combustion results in

HOW TO SET UP PLANT

PFD For emulsion preparation using Zycryl-15

New lines (Red color) Existing line (Black color)

PUMP– Gear Pump, 5-6 kg pressure, Capacity -10-15 time of Emulsion volume per hour

Suggested Ratio

Making Emulsion

FO(49) : Water(49) : Zycryl-15 (2)

Mixing Emulsion

F.O (88-90) : EMULSION (10-12) EMULSIONMAKING

TANK

MAINSTORAGE

TANKFOR

MIXING &

PUMP TO BURNER / BOILER / FURNACE DIRECTLYTHROUGH DAY TANK

RETURN LINEZYCRYL-15

WATER LINE

FOR TANKER UNLOAD

P

V3

V5

V2

V1

V6 V4Duplex Filter

80-200 mesh

Emulsion preparation using Zycryl-15 Take 49 kg. heavy Fuel Oil (HFO) at 30- 60 OC and 2 kg. Zycryl-15

Mix (re-circulate) for 5 minutes with the help of gear pump

Recirculation flow (Pump capacity ) should ensure entire emulsion volume rotation (turning) at least 10-15 time per hour

Add 49 kg. water (of ambient temperature) slowly over a period (minimum 90 minutes

After complete addition of water, continue mixing further for 30 minutes

Test for emulsion (mechanical stability etc)

The emulsion is now ready to be mixed with FO (to be mixed with main FO)

Transfer a pre-calculated quantity of emulsion to the Main storage tank / day tank .(Mixing ratio- 10 part of emulsion with 90 part FO)

Mix it properly. This final mixed (emulsified FO) is now ready to be fed to the burner

MAKE & MIX EMULSION

CONCLUSION

Eco friendly ZYCRYL-15

increases your profit level

and helps in reducing

pollution & global warming

Eco friendly ZYCRYL-15

increases your profit level

and helps in reducing

pollution & global warming

ZYDEX INDUSTRIES

25-A, Gandhi Oil Mill Compound,

Gorwa, Vadodara-390 016, India.

Tel: +91 265 228 0120 / 0865 / 3386 / 3742

Fax: +91 265 2280872

Mob- +91-9328219812

E-mail: info@zydexonline.com

Website: www.zydexindustries.com

ZYDEX INDUSTRIES

25-A, Gandhi Oil Mill Compound,

Gorwa, Vadodara-390 016, India.

Tel: +91 265 228 0120 / 0865 / 3386 / 3742

Fax: +91 265 2280872

Mob- +91-9328219812

E-mail: info@zydexonline.com

Website: www.zydexindustries.com

THANK YOU

CRUDE OIL DISTILLATION