Emulsified Heavy Fuel Oil (Furnace Oil) is the perfect solution for reducing Fuel Bills, decreasing Burning Losses, Oxide formations, Carbon Build-up and Waste Heat generation. It will also clean up your Stack Emissions and prolong Refractory and Boiler Fire-tube life span.
Heavy Fuel Oil emulsified by our Hydrolyzer 5-stage batch process enjoys Complete Combustion and provides Maximum Thermal Yield first through the process of Homogenization, then Secondary Atomization and lastly by the formation of a highly combustion enriching Syn-Gas through a Gas-Shift reaction during the combustion process. Usage of Emulsified HFO can effectively reduce Oil-fired Boiler and Furnace Fuel consumption by 5% - 10%.
Our HYDROLYZER Furnace Oil Emulsification Technology is a one-stop Plug & Play system that can be easily assembled on site and retrofitted to most Oil burning Furnaces and Boilers without modifying oil pipelines, circuit or burners to achieve phenomenal fuel savings and reduction in emission.
Utilizing a combination of Hydrodynamic Cavitation, Static and Dynamic mixing it generates a water-in- oil emulsified Fuel having up-to 20 % water, embedded in 5-10 micron sized droplets. The all new HYDROLYZER design has a 5-stage process to insure the complete emulsification of Water in Furnace Oil into a uniform Water-in-Oil Fuel Emulsion.
This is a microscope image of an Emulsified HFO droplet created in our 5-stage batch emulsifying process. Each dark speck is a microscopic droplet of water and the yellow background is oil. The image is under 100X magnification and each segment on the scale is 10 microns.
When Heavy Fuel Oil / Furnace Oil is combusted, the burners first atomize it into droplets of 100 to 200 microns in size, but as combustion takes place only on the exposed surface of the droplet and the larger droplets do not burn completely, leaving behind unburned carbon deposits in the combustion chamber or as particulate matter in flue gases.
But when the burner or an injector atomizes Emulsified Fuel, its highly homogenized nature produces droplets much finer in size than that of normal H.F.O. But more importantly, once fired into the Furnace or the Combustion chamber, the embedded water in the Emulsified Fuel explodes into steam in a series of tiny micro-explosions due to the sudden exposure to extreme heat. This rapid transformation shatters the host petroleum droplet into a microscopic mist having 10-fold more surface area and contact with air. It burns down completely leaving no unburned carbon or soot thus releasing all the calories trapped in the Fuel. This unique combustion characteristic of emulsified fuels is known as "Secondary Atomization."
Emulsified HFO Combustion uses 15%-20% less oxygen than normal HFO. This is due to the complete combustion and lower excess air requirement, as a result it also produces 20-30% less waste-heat.
Emulsified HFO Combustion releases up-to 30% less NOx, almost 60% less SOx and 20% less PM(particulate matter) in flue gases which is comparable with Diesel Burners. NOx is reduced due to the reduced peak combustion temperature while Sulfur is reduced by a combination of a chemical as well as by the cavitation process.
The completely homogenized nature of the Emulsified Fuel ensures that there is no sludge or any other impurities in the Fuel Tanks, so no periodic sludge removal and disposal is needed which itself reduces soil and groundwater contamination.
We had been pioneers in successfully introducing Fuel Emulsification to the Steel sector in India. Unlike vendors who offer "Emulsifying chemicals" or Emulsifying Mixer promising huge fuel savings , but often with zero or negative impact , we first designed and ran two HFO Emulsifying units in Steel Plants for over 5 year before we commercially offered our HYDROLYZER technology to others.