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ZYDEX INDUSTRIES

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

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ZYDEX INDUSTRIES

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  1. ZYDEX INDUSTRIES • Innovation • Ascent • Excellence

  2. ZYDEX COMMITMENTS TO GREEN EARTH • Eco- Production technologies • Eco-products - Specialty polymers & chemicals

  3. WHY ARE WE HERE & WHY THIS TECHNOLOGY Global Warming Estimated 150 million ton heavy fuel burn / year Rise in CO2 emissions - Green house effect Pollution – carbon particulate matter, CO, NOx, SO3, etc Environment : Weather Changes Melting of ice caps / thinning of glaciers Extreme conditions (flood / hurricanes / draught) Kyoto Protocol • 160 countries pledged to reduce CO2 level • Reduction of 5.2% from level in 1990 by 2010 • Leads to Carbon trading / CDM technologies

  4. RECENT SCENARIO ON GREEEN HOUSE LEVEL (data from “NEW SCIENTIST” (10 Nov 2005) Growth Rate of CO2 level 1990- 1999 : 0.8% / year 2000- 2005 : 3.2 % / year (400 % rise in just last 5 year) China Position 1990 : Very low & reduced level 2005 : 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 New Technology will surely help world Maintaining global leadership in manufacturing facilities (by economizing the production cost ) Reducing & Maintaining its level of green house gasses Thus help in achieving GLOBAL ECONOMY & BETTER ENVIRONMENT

  5. INTROCUCTION • 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 results • This was the starting point for the development of ZYCRYL - 15 & ZYCRYL - 20

  6. ZYCRYL-15 (Patented) A New generation Fuel Efficiency Enhancer For Furnace Oil , Heavy / Residual Fuel Oil, Bunker Fuel F E A T U R E S • 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 ) .

  7. 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

  8. ATOMIZATION PROCESS IN INDUSTRIAL COMBUSTION 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 • Fuel Viscosity • Temperature • Atomizer design

  9. COMBUSTION REACTION Petroleum Fuel contains chiefly Carbon & Hydrogen (small quantity Sulfur) Complete combustions gives Fuel Oil + Air (C H S) (O2 + N2) CO2 + H2O + SO2 +N2+ Heat Energy But large droplet size of the fuel oil leads to Incomplete combustion How ?

  10. INCOMPLETE COMBUSTION PROCESS HEAT Initial size- 100- 200 micron FUEL DROPLET HEAT HEAT HEAT

  11. INCOMPLETE COMBUSTION PROCESS Final unburnst particle HEAT HEAT HEAT HEAT

  12. 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 SPM High Carbon deposit buildup around burner nozzle & heat transfer surface Incomplete combustion also leads to CO : Indicates low heat energy release High SO3, : Corrosion due to acid formation High NOx : Environmental problem

  13. LOSS IN ENERGY GENERATION (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 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

  14. HOW TO IMPROVE COMBUSTION ? Reduce the particle size of fuel oil Either by Reduce Surface Tension – Add Wetting Agent Or by Secondary Atomization – Thru Emulsion Technology In surface tension reduction Adding wetting agent Maximum reduction possible from 100- 200 microns to 70-80 microns Results in Saving (increase in efficiency ) upto1 - 2 % only 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

  15. SECONDARY ATOMIZATION through CONVENTIONAL Emulsifier • 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 % ) Next generation polymers • to overcome above problem of interface stability • 10 time reduction of particle size to increase combustion

  16. ZYCRYL-15 • A Novel Polymer composition • Helps in making very stable emulsion (1-2 years) • 8-12% fuel savings at low capital investment • 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%)

  17. PROCESS OF COMPLETE COMBUSTION WITH ZYCRYL-15 EMULSION Oil droplet size 100 microns Oil droplet size 15-20 microns Water droplet Water-Oil emulsion Below 100 degree C. Water-Oil emulsion 100 – 250 degree C.

  18. HOW THIS EMULSION HELPS By inducing SECONDARY ATOMIZATION This Emulsion is 5-6 % water content in fuel oil with uniform particle size • 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.

  19. COMBUSTION WITHOUT ZYCRYL-15 Revised diagram of Furnace showing particle incomplete combustion

  20. COMBUSTION WITH ZYCRYL-15 Revised diagram of Furnace showing particle complete combustion Low stack temperature No Soot Shorter burnout dwell time Pre-atomized fuel

  21. NOVEL PROPERTIES OF EMULSION WITH ZYCRYL-15 Conventional surfactant vs Polymeric compositions • Better & uniform SECONDARY ATOMISATION • Viscous , elastic , expandable polymeric interface film • Better interface stability No premature burst of oil droplet • Uniform & smaller size particle • Much better enhancement of efficiency /saving ( 8-12%) • Easy emulsification • Lower shear • Low power •  Low capital investment • Stable 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

  22. WHAT IS HAPPENING EXACTLY Explosive vaporization of water droplets leads to the reduction in size of fuel particles. Combustion results in 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.

  23. HOW TO SET UP PLANT PFD For emulsion preparation using Zycryl-15 ZYCRYL-15 RETURN LINE Suggested Ratio Making Emulsion FO(49) : Water(49) : Zycryl-15 (2) Mixing Emulsion F.O (88-90) : EMULSION (10-12) WATER LINE EMULSION MAKING TANK MAIN STORAGE TANK FOR MIXING & New lines (Red color) Existing line (Black color) V3 V2 V1 V5 P V4 V6 PUMP TO BURNER / BOILER / FURNACE DIRECTLY THROUGH DAY TANK Duplex Filter 80-200 mesh FOR TANKER UNLOAD PUMP– Gear Pump, 5-6 kg pressure, Capacity -10-15 time of Emulsion volume per hour

  24. MAKE & MIX EMULSION 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

  25. CONCLUSION Eco friendly ZYCRYL-15 increases your profit level and helps in reducing pollution & global warming

  26. THANK YOU 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

  27. CRUDE OIL DISTILLATION

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