promax trials at universal chemicals

8/13/2019 Promax Trials at Universal Chemicals

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REPORT ON

Performance TrialsPerformance TrialsPerformance TrialsPerformance Trials

OFOFOFOF

Fuel Additive PROMAX 21Fuel Additive PROMAX 21Fuel Additive PROMAX 21Fuel Additive PROMAX 21

Client :

M/S Universal Chemicals Ambernath.

Assignment Executed By

M/S ENERGYTECH PRODUCTSM/S ENERGYTECH PRODUCTSM/S ENERGYTECH PRODUCTSM/S ENERGYTECH PRODUCTS

DOMDOMDOMDOMBIVLIBIVLIBIVLIBIVLI


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I N D E X

1. Background 1

2. Methodology 1

3. Equipment Calibration 2

4. Data Logging 2

5. SFR Calculation Procedure 2

6 Important Facts 3

7 Data Summary 3

8 Data Analysis 4

9 Conclusion & Recommondations 5

10 Annexure 1 6

11 Annexure 2 7

12 Annexure 3 8


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RRRReeeeport of Fuel Additive Trialsport of Fuel Additive Trialsport of Fuel Additive Trialsport of Fuel Additive Trials

Client : M/S Universal Chemicals Ambernath

Additive Used: PROMAX 21 of M/s Energytech Products Dombivli

Fuel Used: Furnace OilPersons Involved: Universal chemicals: Mr. Suhas Ganjewar (Engg. Manager)

Energytech Products: Mr. Dilip Katekar

Mr. Milind Khire

Background:

M/s Universal Chemicals Ambernath use Furnace oil in their plant. Furnace oil is usedfor Steam boiler and for furnaces. In order to reduce furnace oil consumption

management decided to evaluate use of fuel oil additive for the same. M/s Energytech

Products was given an opportunity to take trials with their fuel additive Promax 21.Inorder to check effectiveness of additive it was decided to study boiler performance under

identical conditions. Steam To Fuel Ratio (SFR) is the best indicator to study

improvement due to fuel additive. So SFR was studied for 6 T IBR boiler before and afteraddition of the Promax 21.

Methodology:To determine SFR it was necessary to calculate furnace oil consumption and steam

generation from boiler. This was done as follows

1) Furnace oil consumption:Furnace oil is pumped in day tank through Kent Flow Meter. Readings of Kent Flow

meter was considered as basis for fuel consumption. Also difference in initial level in

day tank and final level in day tank was noted. This was added/subtracted as perdecrease/increase in day tank level.

2) Steam Generation:Steam generated is supplied to KMO4 and PAA plant. Majority of the condensate is

returned to boiler water feed tank. There is a steam flow meter on KMnO4 plant line

but there is no such arrangement on PAA plant steam line. So to find out steam

generation it was decided to find out amount of water pumped to boiler and withnecessary correction of blow down water, amount of steam generation could be found

out. Fitting water flow meter on boiler water feed line was best solution. However

since boiler feed water was is at higher temperature, accuracy of water meter was

doubtful. So it was decided to fit hour meter to boiler feed pump. Knowing pumprunning hours and flow rate of pump, amount of water pumped to boiler was

calculated. By subtracting quantity of blowdown water, net generation of steam wasfound out.


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Equipment Calibration:

Before starting data collection it was necessary to calibrate /verify calibration of the

equipments /instruments used.

1) Kent Oil Meter:This was calibrated and was functioning satisfactorily2) Fuel Oil Day tank:Calibration for this was available. It was 18.5 lit/cm3) Water Hour Meter:

This was tested in workshop for its functioning and found satisfactory. Calibration of

water hour meter was also rechecked during course of studies.4) Feed water pump flow rate:When PAA plant was closed, steam flow meter on KMnO4 plant line gave exact

amount of steam generated by boiler. For 2 shifts no blowdown was given. Steam

generated is same as water pumped. Knowing pump-running time from hour meter,pump flow rate was found out. It was 226 lit/min. This was crosschecked with

performance curve of water feed pump. Both matched exactly. This was once againreconfirmed during course of studies.5) Water blowdown:

Blowdown flow rate was established practically by giving blowdown for specified

time and checking water quantity discharged. Blow down rate was 8.5 lit/sec

Data Logging:

Following data was logged everyday.1) Furnace oil day tank: Furnace oil level was noted every hour2) Kent oil meter: Whenever oil was pumped from storage tank to boiler feed tank, it

was measured through Kent Oil Meter and readings were noted down.3) Water Hour Meter: Readings were noted at start of every shift.4) Blowdown: Time for which water was blowdown was noted.SFR Calculation Procedure:

Refer Annexure 1 for sample calculation

1) Calculate furnace oil pumped from storage tank to day tank2) Find out difference in day tank level at start and end of the day. Add it to above

figure if level has gone up or subtract it otherwise.

This gave total Furnace oil consumption everyday.3) Note difference in water hr meter. Multiplying by pump flow rate gives amount

of water pumped.

4) Find out total blowdown time in a day. Multiply by blowdown rate to get totalblowdown quantity. Subtract it from water pumped.

This gave total steam generated

5) Ratio of steam generated and furnace oil used gives Steam to Fuel Ratio (SFR)


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Important Facts:

1) Pre additive trials were conducted for 4 weeks and post additive trials were

conducted for 5 weeks.

2) Since trials were to be conducted under identical conditions, operating parametersof boiler were kept unchanged.3) Whenever system was not fully functional, readings on those days are not

considered for analysis.4) Readings on account of following failures are not considered.

a) Kent Meter Failure:This had occurred on following daysJuly: 27 July to 31 July

August: 1 August to 5 August,

September: 9 Sept., 10 Sept., 16 Sept., 17 September

b) Water Hr Meter Not Available:This had occurred on followings daysAugust: 29 August to 30 August,September: 4 Sept. to 6 Sept.

c) Major shut down of boiler:This had occurred on followings day.

August: 8 August,

5) MSEB power failure:Since this is order of the day, it is not considered as system failure. This was

common to both pre additive and post additive trials.

Data Summary:

1) Data was summarized and analyzed using Excel Spreadsheet.

2) Annexure 2: This summarizes SFR readings and gives average value of SFR and

percentage improvement in the same.

3) Annexure 3: This gives statistical distribution of the data in different categories. It also

provides Histogram for the same.

4) Pre additive Trials: This covers period of 12 July to 14 August. Total 23 readings are

obtained in this period.

5) Post Additive Transition Phase: When additive is added, initially part of additive is

used for internal cleaning up of the system. Due to this gradual increase in SFR is seen.

This is called as Transition phase. This phase lasts for 3 weeks. This covers period of 15August to 6 September. Total 18 readings are obtained in this period.


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6) Post Additive Stabilized Phase: Once internal cleaning of the system is over,

performance of additive starts stabilizing. This phase covers readings from 7 Septemberto 22 September. Total 12 readings are obtained in this phase.

7) Results from Annexure 2:

a) Average SFR:Pre additive: SFR: 12.16

Post Additive (Transition Phase) SFR : 12.86Post Additive (Stabilized Phase) SFR : 13.14

Post Additive (Cumulative) SFR: 12.97

b) Improvement in SFR:

Post Additive (Transition Phase) Improvement: 5.77 %

Post Additive (Stabilized Phase) Improvement: 8.06 %

Post Additive (Cumulative) Improvement: 6.69 %

8) Results from Annexure 3:Category wise distribution of data is given

S No Category Pre additiveTrials

Post additiveTransition

Phase

Post additiveStabilized

Phase

Post additiveCumulative

1 Below 10.5 00 00 00 00

2 Between 10.5 &11.5 30 00 00 00

3 Between 11.5 &12.0 09 11 00 07

4 Between 12.0 &12.5 13 06 08 07

5 Between 12.5 &13.0 26 61 25 47

6 Between 13.0 &13.5 17 11 42 237 Above 13.5 04 11 25 17

Data Analysis:

1) Gradual Improvement in SFR:Addition of Promax 21 helps to improve combustion efficiency. Promax 21

not only helps to improve fuel oil atomization but also help to disperse

asphaltenes (sludge) in fuel oil in fine particles. Due to this property,improvement is seen gradually. In initial period, part of Promax added is

utilised for dispersing sludge accumulated in tank and cleaning coating of thesludge formed in system. So depending on cleanliness of tank and system thisperiod lasts for 2 to 3 weeks.

This can be seen from annexure 2. Here gradual rise in SFR is seen.

Pre additive SFR is 12.16. In transition phase it has increased to 12.86.It hasfurther increased to 13.14 in stabilized phase.

This is further confirmed by data in Annexure 3.


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Let us look at SFR range of 12 to 13. Here 39 % readings fall in this range in

pre additive trials, which has increased to 67% in Transition phase. Instabilized phase it has reduced to 33 %.

Also look at SFR values above 13.Here in Pre additive trials 21 % readings

are seen. This is 22 % in Transition phase, which is practically same. However

in stabilized zone this has grown to 67 %. Surely this growth is due tocleaning up of the system.

2) Percentage Improvement in SFR:When we observe average SFR during trials, a remarkable improvement is

seen. Average SFR in Pre additive trials is 12.16, which has increased to13.14 in stabilized phase. It means that Percentage improvement in SFR is

5.77 % in Transition phase while it is 8.06 % in stabilized phase. Taking on

cumulative basis improvement is 6.69%.

This is further validated from data in Annexure 3. Here we see that in Pre

additive trials 47 % SFR readings are above 12.5%. In transition phase thisfigure is 83 % while in stabilized zone it has grown to 92 %

3) Uniformity in combustion:Promax 21 disperses well in fuel oil. Owing to its unique formulation it bringsuniformity in fuel oil. So Promax not only improves fuel economy but brings

uniformity in combustion also. This can be seen from Annexure 3.

During Pre additive trials wide fluctuations in SFR were observed. Data in Preadditive trials is spread over a wide range of 10.5 to 13.5 plus.

After addition of additive these fluctuations have come down. The data is

concentrated over narrow range 12.5 to 13.5 plus

Conclusion & Recommendations:

From the data it is seen that there is substantial savings can be achieved with use of

Promax 21. Also uniformity in combustion can be achieved.

It is recommended to add Promax 21 to furnace oil on regular basis.


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Annexure 1


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Annexure 2


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Annexure 3

promax trials at universal chemicals

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