FuelMag treatment for microbiological contaimination

Transcription

1 FuelMag treatment for microbiological contaimination Filtertechnik Filtration, Purification & Separation Solutions Filtertechnik are experts in fuel and oil health with over 25 years of inovation and industry know-how. All of this experience has gone into creating the FRB Suitable for all oil and fuel treatment applications. Filtertechnik Filtration, Purification & Separation Solutions Freephone in UK: Tel: +44 (0) Web: Fax: +44 (0)

2 Microbial growth in fuels Microbial contamination is most commonly seen as black sludge that forms in the bottom of storage tanks. This sludge affects engine operations in several ways; it blocks filters, it causes poor fuel combustion that results in significant fuel inefficiencies, it causes incorrect fuel gauge storage readings and it contributes to poor emissions resulting in black smoke. Additionally, bacteria are both aerobic and anaerobic, which, as a result of being present and living, feeding and reproducing in the oil produce organic acids, including sulphurous and sulphuric. These corrosive chemicals cause severe degradation of storage tank coatings and corrosion of both metal tank surfaces and fuel injection equipment. The reason for growth of microbes is the presence of moisture in the fuel. All fuel contains some water and therefore, under normal storage and handling methods, inevitably, microbes are present in varying quantities. These microbes or bugs flourish at the oil/water interface, using the oil as a source of food. Warm temperatures (30 to 40 C) frequently exist in engine rooms or exposed tank environments and provide ideal breeding conditions. The only treatment to date is by using (adding) liquid biocides regularly. Biocides are highly toxic chemicals hazardous to handle and dispose of. Not all microbes are eliminated with biocides and any waste materials remain toxic. Adding biocides is an on-going operational maintenance expense. It does not solves the original problem. It is merely a short term localised fix. Installation of FuelMag is the natural way of protecting fuel systems from microbial contamination. Unlike biocides, it is a permanent, non-toxic, maintenance free solution suitable for any type of engine or fuel storage systems. Advantages over Biocides Biocides bring economic, operational, environmental and potential health issues that call into question their long term suitability. Our units are maintenance free and carry a 10 year warranty so offer an excellent long term solution. FuelMag is the effective modern alternative to treat and control microbiogical contamination of fuel system. Advantages and benefits include: Low initial capital expenditure with no ongoing costs. Ease of installation No toxic chemicals or toxic sludge waste to be concerned about. No maintenance requirements Long operational life Affects all types and level of microbiological growth 2.

3 The Technology The main concept behind the FuelMag is that as fuel passes through the device the microorganisms are plasolyzed by the magnets, allowing for them to be small enough to pass through the fuel filter, and be destroyed in the combustion process. The science When microorganisms are subjected to a strong magnetic flux field, the ability of the protein channels to maintain the electrical and chemical potentials across the cell s membrane is disrupted. In brief, the ion channels open up to allow osmosis to happen, leaving the cell in a plasmolyzed state. Once this process has been achieved the cells will stay in this form for around 15 to 30 days, after this time the cell will begin to duplicate themselves again; if left untreated the fuel will become highly contaminated and could cause your engine to fail. Proof Scientific experimentation conducted by The School Of Ocean Sciences at The University of Wales on our behalf, resulted in a clear endorsement of our own research and fuel testing programmes, which also resulted from on-going work with marine underwriters and classification societies. Through the activities of the scientics at The University of Wales, we have gained greater understanding of how FuelMag works and how it can best be utilised to give it s most effective performance. More recently, investigations were carried out by CABI, the largest UK Government Research Institute. They were commissioned to measure the effect on bacteria, yeast and fungus within contaminated fuel after passing through a FuelMag Unit in a circulating system for up to 10 days. These results were directly compared with a circulating system on the same fuel without the FuelMag unit in the system. The result of the test showed that there was a dramatic fall in the level of contamination found in the water once it has been passed through a FuelMag unit, as expressed below in CABI s test results. Fungus Bacteria Yeast 3.

4 Why Microorganisms Hate Magnets Microorganisms are single-celled organisms surrounded by a phospholipids membrane. The membrane: Contains the cell s organelles and the other cellular machinery (proteins) needed for survival Maintains a separation between the intracellular and extracellular salt solutions in which the cell exists (Plate No. 1). This separation of the ions across the bacterial cell wall and the maintenance of the impermeable phospholipids membrane are essential for cell life. The membrane contains protein channels that transport different ions across the membrane to control both electrical and chemical potential that exists across it (Plate No. 2). When microorganisms are subjected to a strong magnetic flux field, the ability of the protein channels to maintain the electrical and chemical potentials across the cell s membrane is disrupted. In brief, the ion channels open up to allow osmosis to happen, leaving the cell in a plasmolyzed state. 4.

5 The biofuels threat In 2008 the UK Government committed to the European Community Directive requiring a minimum of 2.5% of all sales of fuel by volume to be biofuel. This has created the need to include a biofuel blend withing everyday fuel supplies. This is due to increase to 5% by 2010 and beyond that depending upon the industries ability to meet the biofuel supply requirements. This means that the fuel you purchase at the pumps will have a varying level of biofuel content; currently 5% is a common blend but even at this level will lead to your fuel supply becoming more prone to microbial contamination. Water content You wouldn t necessarily expect fuel to contain water but it naturally absorbs moisture from the atmosphere. Unfortunately microbes live in water and when added to fuel you have given the microbes somewhere nice to live in water and a huge amount to eat. Hence you will get a massive population boom of microbes at the water/fuel interface which will continue to expand as long as the conditions persists. Treatment Additives have been used extensively but they have potential health, handling and environmental issues which has led to many being banned from sale. When additives are used to try and combat fuel contamination they leave a toxic sludge behind which can be very hard to dispose of without causing any negative health or environmental problems. Bio-fuel Under certain conditions, biodiesel is a perfect growth media for microorganisms - the organic material present in the fuel provides an excellent substrate for microorganism metabolism under anaerobic fermentation conditions. When biodiesel leaves the manufacturing plant it is generally expected to be commercially sterile, the onset of microbial degradation only occurring during transportation, blending and subsequent storage. With the majority of fuel having to be transported before it can be purchased or used, it begins to pose a problem, as microbial contamination soon begins to effect the quality of the fuel. Interesting Points Bacteria To date over 100 different types of bacteria have been identified that feed on fuel. How can I tell? Contamination is not visible to the naked eye at less than 8 million ppml (parts per millilitre). So you can t tell by visual inspection. Why is my fuel tank pitted? A by-product of the microbes is the production of acid that will attack the tank lining over time and lead to expensive repairs. Sulphur reducing bacteria These also contribute to corrosion, eating steel and reducing ferrite to an oxide through a chemical reaction. The manufacturer must therefore ensure a quality assurance system is in place to mitigate the onset of microbial degradation and hence the development of a non specification product. 5.

6 Magnet options & installation guide 6.

7 Fuel mag product overview FMX RANGE Suitable for 8 mm to 12 mm flexible fuel lines. Uses include road transport, power generators and engines with higher capacity. FM ISO 08 For small water crafts, class 4-7 road vehicles, power generators with hard fuel lines. Compatible with 1/4 fuel lines. FM ISO 10 The unit has been designed to allow for variable angles on the entry or exit fuel lines instead of straight line connections. Compatible with 3/8 or 10mm fuel lines. FM ISO 15, 20 & 25 Designed to connect to fuel line with limited flexibility. Compatible with 1/2, 3/4 or 1 fuel lines. FM ISO 40 and 50 Designed to connect into a fuel line with limited flexibility. Compatible with 1 1/2, or 2 fuel lines. FM 100 This product has been recently developed to solve a bespoke client need for a fuel delivery system FM32FX For tug boats, barges, fishing vessels, fuel storages and dispensers, yachts, medium size water crafts and small ships, class 8 heavy duty vehicles, power generators; suitable for hard fuel lines. 7.

8 Product specification FMX series Fuel Line Size /Typical Application Max Operating Pressure Fuel Flow Rate (Litres/Hour) Horsepower Guide BHP FM08 08mm Tail: Small water Craft, Class 1-3 vehicles 4 bar up to FM10 FM12 10mm Tail: Small water Craft, Class 4-7 vehicles 12mm Tail: Small water Craft, Class 8 vehicles Weight: 12oz / 230g Size: OD 32mm Length: 185 mm Material: t6 Aluminium FM ISO 08 Fuel Line Size (inches) Max Operating Pressure Fuel Flow Rate (Litres/Hour) Horsepower Guide BHP FM08 ¼ 4 bar up to Weight: 12oz / 270g Size: OD 32mm Length: 185 mm Material: t6 Aluminium 8.

9 Product specification FM ISO 10 Fuel Line Size (inches) Max Operating Pressure Fuel Flow Rate (Litres/Hour) Horsepower Guide BHP 3/8 6.9 bar up to Weight: 12oz / 370g Material: Pressure Die Cast Marine Grade Aluminum LM6 Suitable for Yachts, Medium size Water Craft, Class 6-8 Vehicles; Power Generators with hard fuel lines. FM ISO 08 Fuel Line Size (inches) Max Operating Pressure Fuel Flow Rate (Litres/Hour) Horsepower Guide BHP FM ISO 15 ½ 6.9 bar up to FM ISO 20 ½ 6.9 bar up to FM ISO bar up to Weight: 2.5lb / 1.3kg Material: t6 Aluminium Suitable for Fishing Vessels, Fuel Dispensers, Yachts, Medium size Water Craft, Class 8 to 12 heavy duty Vehicles; Power Generators, Fuel Dispensing Systems, Locomotives 9.

10 Product specification FM ISO 08 Fuel Line Size (inches) Max Operating Pressure Fuel Flow Rate (Litres/Hour) Horsepower Guide BHP FM ISO 40 1 ½ 10 bar up to FM ISO bar up to Weight: 1. 30lb / 14kg 2. 43lb / 20kg Material: Pressure Die Cast Marine Grade Aluminum 6068-t6 Suitable for Tug boats, Barges, Fishing Vessels, Fuel Dispensers 10.

11 Product specification FM 40 TS Fuel Line Size (inches) Max Operating Pressure Fuel Flow Rate (Litres/Hour) Horsepower Guide BHP bar up to 100m 3 /h Weight: 10.2 kg Material: Carbon Steel ISO 40mm (1.5 inch BSP) THREADED INLET AND OUTLET Fabrication specification Approval: IACS/LR/ABS etc Body: ASTM A 106/B Sockets: BS 3799 ANSI B Welding: ASME IX Magnets: St Ferrite Finish Internal: SA2.5 Oil Coated Finish External: Zinc Phosphate/White Enamel Operational specifications Design pressure: 10 bar Test pressure (Components): 3000 psi / 207 bar Operating pressure: 10 bar Pressure differential: 1.0 bar Certificates Weld procedure: ASA B16.5 Welder qualifications: ASME IX Visual inspection: Yes NDT finished welds: No Manufacturer's Certificate of Compliance: If Required 11.

12 Product specification FM 50 TS Fuel Line Size (inches) Max Operating Pressure Fuel Flow Rate (Litres/Hour) Horsepower Guide BHP bar up to 100m 3 /h Weight: 10.2 kg Material: Carbon Steel ISO 50mm (2 inch BSP) THREADED INLET AND OUTLET Fabrication specification Approval: IACS/LR/ABS etc Body: ASTM A 106/B Sockets: BS 3799 ANSI B Welding: ASME IX Magnets: St Ferrite Finish Internal: SA2.5 Oil Coated Finish External: Zinc Phosphate/White Enamel Operational specifications Design pressure: 10 bar Test pressure (Components): 3000 psi / 207 bar Operating pressure:10 bar Pressure differential: 1.0 bar Certificates Weld procedure: ASA B16.5 Welder qualifications: ASME IX Visual inspection: Yes NDT finished welds: No Manufacturer's Certificate of Compliance: If Required 12.

13 Large Volume Flanged Units Welded Steel Construction Material: ASTM A 106-9A Gr. B/F316L Welding Specification: ASME 1X Flange Type: Standard 150 lb. table NSI class ISO Flow Rate: Consistent with an unrestricted flow path for fuel systems as required by ABS Ship Construction Rules for fuel piping systems with a maximum working pressure of 25 bar. Size guide for flanged units Size Flange OD Body ND Length between Weight (kg) flanges ND=nominal diameter 13.

14 Installation There is no restriction of flow through the FuelMag unit and blocking is highly unlikely to occur. However, in cases of heavy infestation, blockages may occur when the unit is first installed. In this case, the unit may be cleaned out with compressed air. In order to get the best results, the unit should be mounted either horizontally or vertically with the fuel connections at the lowest level. There is no dedicated inlet or outlet. General Installation Procedure for the FM Range 1. FuelMag should be installed on the (suction) hard / soft line between fuel tank and pressure pump. 2. Threaded nozzles should be locked using Anabond or Loctite. 3. Care must be taken not to exert undue pressure whilst tightening nozzles as this may damage threads 4. Teflon tape should not be used on threads as restricted fuel flow could result from incorrect fitting. 5. After installation, any airlock in fuel line should be released prior to starting the engine. This can be accomplished by loosening the breather grub-screw (if any) at the top of the unit. 6. Finally, check for leaks on any joints Installing FuelMag on hard lines (Metal Fuel Lines) from Fuel Tank to Pressure Pump 1. On hard fuel line (metal pipe) an appropriate length of pipe should be cut to install FuelMag. 2. On certain models, a mounting hole has been drilled in the FuelMag body allowing attachment to the vehicle body at a convenient place. Ties or clips of suitable size may be used for attachment of the cylindrical units to a suitable mounting place located close to the existing fuel line route. 3. Ensure the mounting location is sturdy and not subject to frequent jerking or extreme vibrations. 4. Check the FuelMag unit and joints for any leaks. Installing FuelMag on soft lines (Rubber or Nylon fuel lines) before the Pressure Pump 1. On Soft line before pressure pump, use new rubber or nylon hose (an extended hose may be used depending on place of fitment). 2. Ensure the hose does not kink when fixing FuelMag in a soft line. Using a new hose will ensure air lock does not occur at a later date. 14.

15 Typical installation Typical Vehicle Installation Typical Marine Installation Typical Storage Tank Installation 15.

16 Installation information Installing FuelMag on storage tanks Installing FuelMag on storage tanks where the fuel is stored for longer than three weeks at a time without any circulation or movement puts the fuel out of contact with the FuelMag unit. This enables microbes to grow and multiply once again. It is therefore recommended to install a circulation system with FuelMag unit. The pump must be of appropriate size that enables all of the maximum fuel tank volume to be circulated through the FuelMag unit within days, ensuring no substantial re-growth of microbes is possible. The preferred option is to fit a pump between the outlet and the inlet or breather, with the FuelMag unit fitted to this line. Such an installation will prevent the build-up of sludge at the bottom of the tank and keep all microbial growth dormant. Fuel Circulation Systems Installation: Tank System without Fuel Circulation The effect of the FuelMag is twofold: To break down the size of microbial matter to less than one micron, sufficient to pass through the filter. Fuel returning to the tank has viable but dormant microbial material which is less than 1 micron. With Circulation, eventually all microbial material in the tank will have passed through the FuelMag and the microbial content of the tank will be in a plasmodia and fragmented dormant state. The result is that, as fuel is consumed, the microbial content becomes depleted. Every time the tank is filled (through fuel topup/re-fueling), new microbial material is introduced which in turn will be treated. A balance will be reached when the amount of microbial matter being drawn from the tank equals the amount that is either generated or added to the tank. Even after passing through the FuelMag the microbial material, whilst dormant, is still viable. Experiments have shown periodical increases in microbial growth in controlled systems. This is to be expected as some of the dormant life-forms will remain in storage long enough to revive and begin growing again, only later to be passed through the circulating system. 16.

17 Applications & FAQ s 17.

18 Application examples Fuel transfer points: Contamination of fuel often occurs at points of transfer and in the delivery process itself. Terminals Barges Rail Cars Pipelines Tank Farms Diesel Farms Retail and Fleet applications: Commercial locations that serve the general public. Petrol forecourts Supermarkets Bus stations Airports Subways Rail locomotives Biodiesel depots Marine applications: On board Marinas Off-shore drilling Industrial applications: Mining equipment Construction equipment Other applications: Agriculture Military Refineries Power plants Back-up Power Generation: Fuel stored for stand-by generators must be clean and dry when needed. Hospitals Universities Laboratories Banks Bakeries Software companies Embassies Web Farms Communication centers 18.

19 Application examples Fuel transfer points: Contamination of fuel often occurs at points of transfer and in the delivery process itself. Terminals Barges Rail Cars Pipelines Tank Farms Diesel Farms 19.

20 Frequently asked questions Where do organisms come from? The microbes usually enter through the fuel distribution network as well as through airborne contamination. What is the ideal breeding ground for microbes? Microbes like still fuel between temperatures of 5-70 C. Around 30 C is ideal temperature at which growth significantly increases. What can be done to prevent fuel contamination? Eliminate the water from the tanks and fuel lines! In addition to promoting growth of microbes, the presence of water in fuel will result in damage to internal combustion engines. What is a fuel bug? Fuel that is contaminated with living micro-organisms such as bacteria, fungus, mold and algae. These can be either water or airborne and may double in size every 20 minutes. What do microbes feed on? The micro-organisms feed on water, hydrocarbons and nutrients in the fuel. In addition to this, appropriate temperature and low-light levels will determine the rate of microbial growth. How much water is required to allow for microbial growth? Water content as low as 100 ppm in the fuel will allow for bacterial growth to occur. How does the water get into the fuel? Water ingresses the tank from newly delivered fuel, the environment and from condensation within the tank. As water is heavier than fuel, it will settle to the base of the storage tanks creating the perfect breeding ground for microbes. What problems do diesel bugs cause? Obvious signs of microbial activity is the formation sticky, slimy polymers that form strings and films. This slime can block fuel filters, fuel lines, block injectors resulting in system failure. How can these microbes cause corrosion? The by-products of the bacterial action are often acidic and when this settles into the water phase at the bottom of the tank, corrosion of steel, brass and copper is inevitable. Is the a problem with BioFuels? Yes, this is more of a problem than ever before. Biofuels are not only hygroscopic (absorb moisture from the environment) but that also add more nutrients to the fuel mix, thereby increasing the problem. Why are magnets so effective at removing bacteria in fuels? Microbes are vulnerable to magnetic waves. Exposing the microbes to a strong, changing magnetic field disrupts the flow of ions, leading to the destruction of the cells. When the microbe-contaminated fuel passes though the magnet, the microbe cells experience intense levels of magnetic flux density from different angles. This disrupts the cell immediately which kills some cells immediately while the rest die off over time. The treated particles then pass through the diesel filter and burn up in the combustion process. 20.

21 If you are experiencing fuel related problems, please contact us for advice and assistance. Filtertechnik Filtration, Purification & Separation Solutions Filtertechnik Ltd, Central Park, Lenton Lane, Nottingham, NG7 2NR Tel: +44 (0) Fax: +44 (0) Free Phone: