REPORT

ON

Performance Trials OF Fuel Additive PROMAX 21

Client : M/S Universal Chemicals Ambernath.

Assignment Executed By M/S ENERGYTECH PRODUCTS DOMBIVLI DOMBIVLI

INDEX

1. Background 2. Methodology 3. Equipment Calibration 4. Data Logging 5. SFR Calculation Procedure 6 Important Facts 7 Data Summary 8 Data Analysis 9 Conclusion & Recommondations 10 Annexure 1 11 Annexure 2 12 Annexure 3

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Report of Fuel Additive Trials

Client : Additive Used: Fuel Used: Persons Involved: M/S Universal Chemicals Ambernath PROMAX 21 of M/s Energytech Products Dombivli Furnace Oil 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 used for 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.In order 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 after addition 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 per decrease/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 with necessary 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 pump running hours and flow rate of pump, amount of water pumped to boiler was calculated. By subtracting quantity of blowdown water, net generation of steam was found out.

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 satisfactorily 2) Fuel Oil Day tank: Calibration for this was available. It was 18.5 lit/cm 3) 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 again reconfirmed 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 hour 2) 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 tank 2) 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 total blowdown 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)

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 parameters of 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 days July: 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 days August: 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 15 August to 6 September. Total 18 readings are obtained in this period.

6) Post Additive Stabilized Phase: Once internal cleaning of the system is over, performance of additive starts stabilizing. This phase covers readings from 7 September to 22 September. Total 12 readings are obtained in this phase. 7) Results from Annexure 2: a) Average SFR: Pre additive: Post Additive (Transition Phase) Post Additive (Stabilized Phase) Post Additive (Cumulative) b) Improvement in SFR: Post Additive (Transition Phase) Post Additive (Stabilized Phase) Post Additive (Cumulative) 8) Results from Annexure 3: Category wise distribution of data is given S No Category Pre additive Trials 00 30 09 13 26 17 04 Post additive Post additive Post additive Transition Stabilized Cumulative Phase Phase 00 00 00 00 00 00 11 00 07 06 08 07 61 25 47 11 42 23 11 25 17

SFR: SFR : SFR : SFR:

12.16 12.86 13.14 12.97

Improvement: 5.77 % Improvement: 8.06 % Improvement: 6.69 %

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Below 10.5 Between 10.5 &11.5 Between 11.5 &12.0 Between 12.0 &12.5 Between 12.5 &13.0 Between 13.0 &13.5 Above 13.5

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 the sludge formed in system. So depending on cleanliness of tank and system this period 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 has further increased to 13.14 in stabilized phase. This is further confirmed by data in Annexure 3. 6

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. In stabilized 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 to cleaning 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 to 13.14 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 this figure 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 brings uniformity 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 Pre additive 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.

Annexure 1

Annexure 2

Annexure 3

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