Optimise Combustion Efficiency Reduce Engine Fouling
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1 Power plant optimisation made in Germany PENTOMAG 4400 Diesel Engine Additive Optimise Combustion Efficiency Reduce Engine Fouling
2 PENTOMAG 4400 Diesel Engine Additive PentoMag 4400 keeps fuel oil fired diesel engines clean from deposits. We faced serious problems in our Diesel Engines, leading to shutdowns every few weeks to clean the injection nozzles in the engine and the turbochargers. Manuel Gonzales, Service Engineer After an extensive trial period in 2010, PentoMag 4400 is continuously used and deployed to all our diesel power plants. In addition to the reduction of maintenance works, we save approx. 3.5 g/kw of fuel oil using PentoMag
3 PentoMag 4400 is an additive for both stationary and mobile diesel engines to Reduce fuel oil consumption Reduce corrosion in the engine and Reduce cleaning cycles. As per 2012, this additive is in permanent application on more than 300 engines. What is PentoMAG 4400? PentoMag 4400 is a combination of powerful surfaceactive solvents, sludge dispersants, water emulsifiers, combustion catalysts and organometallic salts. The product is liquid and is injected by means of a dosing pump into the transfer line from the unloading pump to the storage tank. PentoMag 4400 is delivered in IBC containers of 1000 kg each. Benefits Improved combustion - reduced soot deposits Allows use of low quality heavy fuel oils Reduced down time for cleaning and repair of liners, piston rings, valves and turbo Reduced corrosion Overall improved efficiency 3
4 Which problems can be addressed with PentoMag 4400? PRE-combustion ProblEMS Sedimentation and Sludge formation can occur in oil storage tanks, oil preheaters, strainers and fuel lines. The main cause of sediment and sludge in oil tanks and fuel oil lines is due to separation of the water content from the fuel oil and when asphaltenes, waxes and other materials flocculate and settle. A certain amount of water is always found in fuel oil and additional water can come from condensation in the storage tank and during tank filling. The water normally separates out and remains at the bottom of the tank and under the right conditions micro- organisms can grow at the water/oil interface, which contributes, to an increased amount of sediment in the tank. Asphaltenes, the most polar and heaviest compounds of heavy fuel oil, associates themselves in solution to form complex colloidal structures which cause serious problems in diesel engines, fuel systems and oil fuel lines. The sludge build up caused by asphaltenes occurs not only from the natural oxidation and aging of the fuel, but also as the result of mixing oils from different crude sources and blending in the storage tank. Asphaltene solubility is also affected by the aromaticity and the type/concentration of resins in the blended components, which may cause them to precipitate. EffECts of Sulphur VanADIum & SoDIum The formation of sulphur trioxide during combustion due to the sulphur in the fuel oil can cause serious corrosion and deposits in the diesel engine cylinder. The complex Na/V/S compounds formed during combustion can form molten deposits which in a diesel engine can cause problems on the exhaust valve seats, in the nozzle ring and on the blades of the turbo charger. 4
5 How does PentoMag 4400 work? A combustion catalyst functions by reducing the Activation Energy and therefore reducing the amount of excess air required to drive the reaction to completion, thus saving oil, improving combustion and producing less smoke. The Activation Energy is the minimum amount of energy that must be provided by a molecular collision for the reaction to occur. The effect of metal catalysts can be characterised into three different stages. 1. SolID PhASE Reaction The most credited way of reaction is that the metals can absorb large quantities of oxygen, apparently by incorporating it in the metallic lattice as oxygen atoms, thus receiving activation energy, which is then released to the metal when reacting with organic hydrocarbons constituting the fuel oil. These reactions take place at surface and, therefore it is very important that the catalyst has a wide surface area. In effect the metals provide a new reaction path of low activation energy for the combustion (oxidation) reactions. That is, the presence of metals permits a new mechanism or reaction path, whereby the single slow molecular process is replaced by two or three faster reactions. An outstanding feature of PentoMag 4400 catalysts is their specificity: i.e. catalysts particularly effective for the oxidation of carbon and carbon monoxide, which have little or no effect on the rate of sulphur dioxide oxidation. 2. LiquID PhASE Reaction In this process the metal catalyst acts as a cracking catalyst producing lighter fractions of the fuel oil which readily volatilise. 3. GAS PhASE Reaction In the gas phase reaction the volatilised fuel oil is catalysed by the ionised and particulate metal catalysts. 5
6 TechnICAl Evaluation PentoMag 4400 was developed to increase the efficiency of heavy fuel oil fired diesel engines. This goal is achieved in 6 steps: 1. Clean the complete fuel system, including sludge absorber, injection pumps, injector and nozzles. Existing deposits become friable and can easily be removed without water. 2. Disperse heavy fractions of the fuel oil. Instead of separating and disposing of heavy fractions, they are dispersed in the fuel and burnt, increasing the net calorific value of the fuel used and reducing the amount of waste disposed of. 3. Reduce Corrosion Ashes of salts are formed during combustion that contain sulphur, vanadium, sodium, potassium and other metals. These residuals adhere to the surfaces forming deposits and causing corrosion. Hot corrosion in engines is mainly happening in escape valves and in the turbo charger and is provoked by two principal causes: - Formation of sodium vanadates of low fusion point. - Formation of sodium sulphate. PentoMag 4400 increases the fusion point of these combustion residuals. Therefore these salts cannot stick to the surfaces. Ash ph is increased from 4 to > Optimize Combustion PentoMag 4400 contains a combustion catalyst reducing the activation energy and therefore reducing excess air. 5. Reduce Emission Thanks to the optimized combustion, the fuel is burned more complete, therefore producing less smoke. 6. Reduce Maintenance time. Cleaning intervals can be greatly extended. State of the fixed nozzles State of the mobile nozzles without treatment with treatment without treatment with treatment 6
7 Economic ConSIDERAtions Intensive testing has been conducted on diesel engines for electricity generation BAZAN 40/45, built under MAN license. This engine, with 6 cylinders in line, was developed with a capacity of 3,45 MW. The test has been extended to Hyundai engines, operating with the following fuel: ParametERs Units Value Viscosity cst 418,02 ±42,00 % of water v/v 0,19 ±0,06 % de Carbon m/m 10,0 ±0,95 Gravity ºAPI 13,72 ±0,87 CCai 834,61 ±6,81 Ash m/m 0,04 ±0,01 HCV Kcal/Kg 10243,73 ±9,40 Asphaltenes m/m 6,87 ±1,08 Sulphur m/m 2,52 ±0,24 During a 3 month period the fuel consumed by the engines was treated with PentoMag 4400 with an average dosing rate of 360 ppm. An overall picture of the trial on this engine revealed that there has been an improvement of 3.5 gr/ Kw reduction of fuel oil consumption. The profitability of the use of PentoMag 4400 is explained by: 1. The increase of the useful life of the valves, 2. The reduction of the Turbo fouling allows to deliver more power and requires less cleaning cycles. 3. the reduction of fuel consumption due to the disintegration of the organic sludge and it s use as fuel. 4. The reduction of maintenance time. 5. Better efficiency of the steam boiler due to exit gases from the engine being cleaner and thus not causing any blockage or corrosion. 6.Less oil changes. Acidic deposits do not accumulate in the engine oil. 7. Water consumption for centrifuge cleaning reduced by 75%. 7
8 PENTOMAG 4400 For Diesel Engines Reduce emission Protect recovery boiler Dosing pump Clean injectors Clean turbo Reduce sludge and water consumption Increase efficiency PE NT OL GmbH Degussaweg 1 / P.O. Box 206 D Grenzach-Wyhlen Tel. +49(0) Fax: +49(0) sales@pentol.net PENTOL - ENVIRO POLSKA Sp. z o.o. Osiedle Piastów 21B, Kraków Tel , fax pentol@pentol.pl
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