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FuelQualityIssuesRaisedbyLowSulfurFuels
CONTENTS
1) GlobalandUS‐ SulfurandCatfine data2) HSFOV/SLSFOProblems3) ProblemswithLSFObunkers4) NewmethodtoidentifyFilterChoking4)Solutions5)FutureScenario6)Conclusion
GLOBAL BUNKERFUELSULFUR&CATFINECONTENT
PreAugust2012 PostAugust2012
FuelType Sulfur Catfines Sulfur Catfines
HighSulfurFuels 2.72 22.2 2.67 22.3
LowSulfurFuels 0.91 28 0.92 28.1
DistillateFuels 0.36 0.6 0.37 0.6
LowSulfurDistillates 0.07 0.6 0.07 0.5
US BUNKERFUELSULFUR&CATFINECONTENT
PreAugust2012 PostAugust2012
FuelType Sulfur Catfines Sulfur Catfines
HighSulfurFuels 2.67 21.4 2.76 23.1
LowSulfurFuels 0.92 28.1 0.97 37.1*
DistillateFuels 0.15 0.1 0.08 0.1
LowSulfurDistillates 0.02 0.1 0.02 0.1
*32%increaseincatfine contentafterUSECA
HSFO V/S LSFO (2013)FuelGrade ProblemCases TypesofProblems
HSFO 52(0.24%ofallsamples)
17‐FilterChoking7– PistonRingBreakage8– PurifierChoking
1– Fuelpumpjamming19–Misc*
LSFO 18(0.45%ofallsamples)9‐FilterChoking5‐PurifierChoking
4–Misc*
* IncreasedExhausttemperatures,Explosion,ProblemswithIgnitionandcombustion,Machinerybreakdownorwearingout,Blackout,Pistonringwear
TwiceasmanybunkerfuelrelatedproblemswithLSFOin2013
INSURANCE COMPANY DATA
• Averagecostofmainenginedamagehasrisen52%fromUSD358,000toUSD545,000since2004
• AveragecostofPistonDamageclaimsis$438,488• AveragecostofCylinderLinerDamageclaimsis$553,998• AveragecostofFuelPumpDamageclaimsis$313,764• AveragecostofMultiplePartDamageclaimsis$684,885
SWEDISHP&ICLUBREPORT– DECEMBER2012
PROBLEMSWITHLowSulfur fuels
1. RapidFilterChoking2. HeavyPurifierSludging3. FuelPumpJamming4. PoorIgnitionandCombustionProperties5. HighWearduetoincreasedcatfines6. HighWearduetoincreasedacidity7. OrganicChloridesinfuelresultingincorrosion8. PistonRingBreakage
FilterChoking/PurifierSludging
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PossibleCauses• ContaminantssuchasDCPD,Styrene,Indeneinfuel• Unstablefuel(ImproperBlending)• Polymericmaterialinfuel• Waste/Offspec Biodiesel(FAME’s)
SuggestedSolutions• Blendingwithbetterfuels• Addingsuitableadditives• Onboardsolutions– Heating/Purificationetc
NEWTECHNOLOGYTOIDENTIFYFILTERCHOKINGFBTN(FilterBlockingTendencyNumber)
• More than 200 cases of Main Engine fuel filters gettingblocked .
• Identified reasons are presence of Polypropylene,Polystyrene, contaminants such as Styrene, DCPD andIndene, high sediment and unstable fuel
Hazards due to this Problem• Complete Filter Choking resulting in Main Enginestoppage, Auxiliary Engine stoppage
• Black Outs and 3 recent cases of Ships Drifting
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HowFBTNcansolveFilterBlockingProblems
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• IfFBTNvalueishighwhileusingsamefiltermeshasthevesselsfiltrationsystem,identifythesubstanceblockingthefilterusingFT‐IR/GCMS
• 3Typesofpolypropylene(polymers)possible• Eachoftheabovehavedifferentmeltingpoints• BymanipulatingFBTNsetuptemperature(limit150
degC),possibletoidentifytypeofpolymer• Inactualengine,temperaturescanbeincreasedto
solvefilterblockingproblem
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DeterminationofFBTNofproblemfuel4samples– 10micronfiltermesh
VesselName AAA BBB CCC DDD
Density(kg/m3) 987.8 974.3 942.3 988.1
Viscosity@50°C(cst) 330.3 310.3 407.1 330
Temperaturetoattain15cst viscosity (°C)
126 124.5 129.7 125.7
Al+Si(ppm) 143 58 43
TSP(%,mass) 0.02 0.06 0.03
Iron(ppm) 10 36 22
Water(%,vol) 0.10 0.10 0.70 0.20
FBTN 1.04(Normalsample)
15.09(Filterchoked)
2.02(Filterchoked)
3.53(Filterchoked)
Testparametersoffueloil
*FBTN‐FilterBlockingTendencyNumber
ApplicationofFBTN
18* FBT-Filter Blocking Tendency
InterpretationofFBTNresults:
FBTN<1.4:NofilterchokingproblemexpectedFBTN>1.4Pa/mL:Seriousfilterchokingproblemexpected
Note – Aboveiswhileusing10micronfilter.Ifthefiltermeshisofadifferentsize,theFBTNwillbedifferent.Testscarriedoutusingsamefiltermeshsizeusedbyship.
FBTNCONCLUSION
19* Patented
1. FBTNtestisapracticalandeasytest2. Clearresultsthatwillreflectactualconditions3. Resultsobtainedinquicktimebeforestartingto
usethefuel4. Byidentifyingcontaminant,itispossibletosolve
blockageproblembymanipulatingthefuelheatingtemperature
5. ApaperhasbeenpresentedatCIMACShanghai2013onViswaFBTN– Paper140
ViswaLabisveryproudtohavedevelopedandpioneeredthisinstrument
FuelPumpJamming
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PossibleCauses• ContaminantssuchasDCPD,Styrene,Indeneinfuel• Unstablefuel(ImproperBlending)• OrganicChlorideinFuel
SuggestedSolutions• Blendingwithbetterfuels• Addingsuitableadditives• Onboardsolutions– Heating/Purificationetc
HighCatfinesinLowSulfurFuel
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LSFOcatfine contentincreasedby32% sinceAug2012• CatfinesHardestsubstancesafterdiamond• Catfinesgetembeddedinlinerandpistonringsurfaces– Portionsstickingoutwilldigintotherubbingsurface– 15to25micronstilltheywearout
• In7‐8hoursthelinerandpistonringscanberuined!
SuggestedSolutions• TestOnboardPurificationsystemefficiencyregularly
SEMimageofparticlefoundonmetalmesh(scalebaris20micron)
SEM/EDSofCatfine Particletrappedinfilter
ElementalanalysisofcatalystfinesshowspresenceofAl,Si
WearduetoIncreasedAcidity
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PossibleSourcesofIncreaseAcidity• OrganicChloridesinFuel• Waste/OffSpecBiodieselinfuel• ShaleOil(Phenol)usedascutterstock
SuggestedSolutions• Blendingwithbetterfuels• Someadditivescanreducetheacidity
BlendingwithShaleOil
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Shaleoilisfrequentlyusedascutterstock• ShaleOilislowcost($100/MT)• ShaleOilhaslowsulfur(under1%)• ShaleOilhashighdensityandlowviscosity
ShaleOilcontainsPhenol.Phenols:• HavepoorIgnitionandCombustionProperty(ECN1.5)• HavehighAcidity(AcidNumberaround1mgKOH/g)• Stabilityoffuelswithphenolsgoesdownovertime
IncreasedpresenceofOrganicChlorides
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• In2013VLhashad7casesoffuelsfoundwithorganicchlorides.
• OrganicChloridescanbefromcleaningagentsorchemicalwaste
Problemscausedbyorganicchloridesinclude• Totalwearoutofrubbingparts,fuelvalves,fuelpump,cylinderliners,pistonrings
WHATTODOIFCONTAMINANTSAREFOUNDINFUELS?
• Quantifycontaminants,findiflevelslikelytocauseproblems
• Useempiricaldataavailablewithtestinglabtodeterminedamagepotential
• Blendingwithbetterqualityfuel(compatible)willreducethecontaminantlevels
• Additivetreatmentchemicalsworkinsomecases• Lastresortde‐bunkering
FUTURESCENARIO• In2015,ECAarea(rapidlyexpanding)callfor0.1%sulfurcontent
• From2020,HSFOgloballyis0.5%andECAisstill0.1%• RefineriesnotplanningtoproduceLSHFO• Someresearch‐PeroxidesandSulfones• Optionsare:‐ LowSulfurfuelatexorbitantcost($300moreperMT)‐ LNG(Smallpercentage)‐ Scrubber
“ Out Of Clutter, Find Simplicity.From Discord, Find Harmony.Realize That In The Middle Of Difficulty, Lies Opportunity”.—ALBERT EINSTEIN
Conclusions
Testingincludingadditionaltestingislikealockonthedoor(PeaceofMind)
OnboardFuelTreatmentatmaximumefficiency.Tryblending.Useadditives
Knowledgeisthenameofthegame.Themoreyouknow,themoreyougain.
VISWALABPHILOSOPHY
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Thereare3kindsoflabs.• Firstisthosethattestandgiveresults.• The2ndlevellabstestandtellthecustomeraboutpotentialproblems.
• VLbelongstothe3rdcategoryWetest,identifypotentialproblemsandalsoPROVIDESOLUTIONS.SolutionsarebasedonpastexperienceinproblemsolvingandR&Defforts.
VISWA LAB WE MAKE IT EASIER FOR YOU
ONE STOP SHOP FOR ALL FUELS, LUBES AND MACHINERY PROBLEMS
EMPOWERMENT THROUGH KNOWLEDGE
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Phone – 65 67787975singapore@viswalab.com
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Phone – 1 713 842 1985customerhelp@viswalab.com
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