1. ECH-A
Energy-Saving and Carbon-
Reducing Emulsified Heavy
Crude Oil Equipment
VAST CALIBRE TECHNOLOGY INC.
E- mail:VIGIRA@HOTMAIL.COM
TEL:886955111899(Rep) SKYPE: VIGIRA
2. Table of Contents
Use of Heavy Crude Oil and Problems 2
Related technologies 3
Comparison of related technologies 4
ECH-A Emulsification Device 5
ECH-A Performance Test and Comparison 9
Estimation and Comparison of ECH-A and
Related Techniques in Their Oil-efficient
Capacity 25
Water Addition Suggestion for Energy-saving
Heavy Crude Oil. 29
1
3. Use of Heavy Crude Oil and Problems
Characteristics and Use of Heavy Crude Oil
Heavy crude oil is the residues at the bottom of the tower
left over from processing and cracking of crude oil. Its
heating value (8,500 ~ 11,000 Kcal/kg) is high, so are its
bitumen and sulfur content.
Because heavy crude oil has a high heating value and is
relatively cheap, it is widely used.
Problems associated with use of heavy crude oil
Incomplete burning is likely, which will lead to greater air
pollution and higher emission indexes (suspension
particulates SS, SOx, NOx, NO, CO, and tail gas emission
temperature)
Because heavy crude oil has greater viscosity and
repeated heating is thus necessary, bitumen will sediment
and oil silt will clog the nozzle and pipeline. As such, the
frequency of cleaning the burner nozzles and the oil tank is
relatively high, leading to economic losses.
2
4. Related technologies
Additives in the heavy crude oil:
To enhance the burning performance of heavy crude oil, additives can be
pour point depressants, demulsifiers, and bitumen dissipating agents.
Bottleneck problems
Compared with the saved fuels, additives are expensive with limited
benefits.
Without auxiliary equipment, additives cannot be used separately.
Average oil-efficient rate after additives costs are deducted:
8%
With ECH-A, bottleneck problems are solved.
There is no need for any additives and it saves on fuels, with numerous
benefits
There is no need to add auxiliary equipment. Installation is easy.
Ratio of water addition can be as high as 40%, depending on the needs.
With addition of 18.5% of water, the oil-efficient rate is 16.19%.
Emulsifying water can be replaced by organic industrial waste water. It
is more eco-friendly.
3
5. Comparison of related technologies
Related Techniques Use of additives ECH-A
Comparison Items
1. Cost-saving Low (below 8%) High (With addition of 18.5%
(Relatively reduced fuel of water, the oil-efficient rate
expenses) is 16.19%)
2. Air pollution High High
improvement
3.Stability High High
4. Burner and peripheral High Low
equipments
5. Overall economic Low High
benefit
4
6. ECH-A Emulsification Device
ECH-A Design Concepts
Online reconstitution of energy-saving and eco-
friendly emulsified heavy crude oil.
Complete emulsification of heavy crude oil + water to
generate highly-efficient secondary nebulization and
contribute to complete burning for enhanced oil-
efficent rate.
Complete homogenizing emulsification. Storage and
transportation is possible.
Complete homogenizing emulsification with stable
burning conditions.
Optimized reconstitution ratio can be applied with the
burning equipment on-site to reflect actual demand.
5
8. Energy-Saving and Eco-Friendly
Heavy Crude Oil Process of ECH-A
Raw material
heavy crude oil
(60 – 100%) ECH-A energy-
saving and eco- Burning device
friendly heavy
Water or organic crude oil
industrial waste
water
(0-40%)
ECH-A Emulsification Device
7
9. Secondary nebulization of oil mist
in the burning chamber
(Micro-explosion) = The key for
ECH-A to enhance oil-efficient and
reduce emissions of pollutants.
8
10. ECH-A Performance Test and
Comparison
Testing Institution
Research Developments on Combustion, Science
and Technology, Department of Mechanical
Engineering, National Cheng Kung University
Secondary nebulization water drop distribution
and analysis
Comparison of ECH-A and heavy crude oil
Burning test
Air pollution test
9
12. From ECH-A oil mist to secondary nebulization
(micro-explosion)
1. ECH oil mist is heated
2. When the temperature exceeds 100℃, water
in the oil mist starts to gasify and the volume
starts to inflate.
3. When the water gasifying pressure is greater
than the tension on the surface of the oil mist,
the oil mist explodes.
4. The oil mist explodes to several particles with
smaller diameters. Their oxygen-absorbing
capability is enhanced, contributing to the
burning.
11
13. ECH-A Emulsified Heavy Crude Oil –
Water Drop Distribution Analysis
100 amplification factor 200 amplification factor 400 amplification factor 100 amplification factor 200 amplification factor 400 amplification factor
Figure 4 Distribution Map of Water Drop Diameters in Oil No. F03-25-10B (Test No.
Figure 3 Distribution Map of Water Drop Diameters in Oil No. F03-25-10B (Test No. M06-21-10B)
M05-15-10B)
Test No. M05-15-10B M06-21-10B
Measured water drop quantity 200 200
Manufactured Date 03/25/2010 Location: Sanxia, Taipei
Test 1, 05/15/2010 Location: Guiren Campus, National Average diameter (μm) 4.96 5.3
Cheng Kung University Standard deviation (μm) 3.09 2.6
Test 2, 06/21/2010 Location: Guiren Campus, National Maximum diameter (μm) 19.25 18.3
Cheng Kung University Minimum diameter (μm) 1.16 2.2
Distribution Map of Water Drop Fig. 3 Fig. 4
Diameters
12
14. Heavy Crude Oil VS. ECH-A Emulsified
Heavy Crude Oil
Burning Temperature Test – Testing
Platform
Figure 2 Photographs of Multiple-Fuel Burning Test Equipment
Figure 3 Configuration Layout of Temperature Measurements for Horizontal Burners.
13
15. Heavy Oil VS. ECH-A Emulsified Heavy Crude Oil
Comparison Table and Statistics of Burning
Temperatures
Fuel oil Content % Water Minimum Maximum
addition ratio flame flame
% temperature temperature
℃(R7) ℃(R7)
Heavy crude 100% 0% 1104 1136
oil
ECH-A 81.5 % 18.5 % 1057 1095
Emulsified oil
14
16. Heavy Crude Oil VS. ECH-A Emulsified Heavy Crude Oil
Comparison Table of Burning Temperatures – Actual
Measurement Record Sheet
Heavy crude oil Burning Performance (Oil No. F06-07-10A; Test No.: B06-16-10A)
Time*(minute )
Original Data
6％O2 Modification
Original Data
6％O2 Modification
ECH-A Burning Performance (Oil No. F06-07-10B; Test No.: B06-16-10B)
Time*(minute )
Original Data
6％O2 Modification
Original Data
6％O2 Modification
*Timing starts after the oil has gone through the pre-burn test for 1 hour.
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17. Heavy Crude Oil VS ECH-A Emulsified
Heavy Crude Oil
Comparison Table of Secondary Air Supply
Fuel oil Content % Water Consumption Secondary air
addition ratio L/Hr supply
% M3/hr
Heavy crude 100% 0% 20 210
oil
ECH-A 81.5 % 18.5 % 20 195
Emulsified oil
16
18. Heavy Crude Oil VS ECH-A Emulsified
Heavy Crude Oil
Comparison of Secondary Air Supply – Actual
Measurement Record Sheet
Heavy crude oil ECH-A
17
19. Heavy Crude Oil VS ECH-A Emulsified
Heavy Crude Oil
Comparison Table of Burning Efficiency
Fuel oil Content % Water Minimum Maximum
addition ratio efficiency % efficiency %
%
Heavy crude 100% 0% 84 85
oil
ECH-A 81.5 % 18.5 % 85 86
Emulsified oil
18
20. Heavy Crude Oil VS ECH-A Emulsified Heavy
Crude Oil
Comparison Table of Efficiency and Stability –
Actual Measurement Record Sheet
Heavy crude oil ECH-A
19
21. Heavy Crude Oil VS ECH-A Emulsified
Heavy Crude Oil
Comparison Table of Heating Values
Fuel oil Heavy crude Water Net heating
oil content % addition ratio value
% cal/g
Heavy crude 100% 0% 9711
oil
ECH-A 81.5 % 18.5 % 9440
Emulsified oil
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22. Heavy Crude Oil VS ECH-A Emulsified Heavy
Crude Oil
Comparison Table and Statistics of Heating Values
Oil No. Heavy crude oil ECH-A Test method
Density＠60℉, g/mL
Flash point, ℃
Sulfur content, %
Flow, ℃
Dynamic
viscosity cSt
Total aromatic hydrocarbons, wt%
Water content, vol%
Carbon content, wt%
Hydrogen content, wt%
Nitrogen content, μg%
Net heating value, cal/g
Total heating value, cal/g
Note: “-" in the table means that the analysis was not performed. 21
23. #6 Heavy Crude Oil VS ECH-A Emulsified
Heavy Crude Oil
Comparison of Air Pollution Emissions
Air Pollution Emissions Testing Equipment
22
24. Heavy Crude Oil VS ECH-A Emulsified
Heavy Crude Oil
Comparison Table of Air Pollution Emissions
Fuel oil O2 % max CO2 % max CO (ppm) NOx (ppm) Sox (ppm)
min max max
Heavy 6.2 10.9 0 369 199.5
crude oil
ECH-A 6.15 10.5 0 286.6 180.6
Emulsified
oil
Water
Content
18.5%
23
25. Heavy Crude Oil VS ECH-A Emulsified Heavy Crude Oil
Comparison Table and Statistics of Air Pollution
Emissions
Burning Performance (Oil No. F06-07-10A; Test No.: B06-16-10A) Heavy crude oil
Time*(minute )
Original Data
6％O2
Modification
Original Data
6％O2
Modification
Burning Performance (Oil No. F06-07-10B; Test No.: B06-16-10B) ECH-A
Time*(minute )
Original Data
6％O2
Modification
Original Data
6％O2
Modification
24
*Timing starts after the oil has gone through the pre-burn test for 1 hour.
27. ECH-A Average Oil-efficient Rate Estimate Table * Based on Test
Report on 07/09/2010
Example: Water Content of 20%
I. Oil-efficient rate
1. #6 Heavy crude oil total heating value: 10,260 cal/g = 10,260,000 kcal/MT
2. Total heating value of ECH-A (including 18.5% of water) emulsified heavy crude oil
3. For ECH-A emulsified heavy crude oil to reach the total heating value 10,260,000
kcal/MT, the fuels that need to be used are 10,260,000 kcal/MT /9,986,000 kcal/MT =
1.027MT = 1,027kg. In other words, to maintain the same heating value when ECH-A
is used, additional 1,027 – 1,000 kg = 27kg of ECH-A fuel oil that contains 18.5% of
water needs to be used.
4. Therefore, the oil-saving rate when ECH-A emulsified heavy crude oil is used is 1,000
kg – (815.0 kg + 27 kg)=158.0kg. In other words, the oil-efficient rate is
158.0kg/1,000kg=15.8%.
II. Saved expenditure
Suppose the cost for each ton of #6 heavy crude oil is NT 19,528 / MT
5. The cost for each ton of ECH-A emulsified heavy oil is NT 19,528 /MT*0.815(fuel oil) +
(NT65*0.1850)(Water)+ (NT 2.74kw-h*2.2kw- h)(electricity cost)= NT15,915 + 12.0 +
7.0 = NT 15,934
6. When ECH-A with an equivalent heating value is used, it is NT 15,934/MT*1.027 MT =
NT 16365.
7. Saved fuel cost with ECH-A = NT 19,528 –NT 16365 = NT3,163
8. Saved expenditure with ECH-A = NT3,163 / NT 19,528 = 16.19%
Saved expenditure with water addition ratio of 18.5%= 16.19%.
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28. Estimate Table of Average Oil-efficient Rates
for Related Technologies (GFXP)
Example: Water content of 12.85% and emulsifying agent of 0.65%
I. Oil-efficient rate
#6 Heavy crude oil total heating value: 10,260 cal/g = 10,260,000 kcal/MT
2. Total heating value of GFXP (including 18.5% of water) emulsified heavy crude oil =
10,162 cal/g =10,162,000kcal/MT
3. For GFXP emulsified heavy crude oil to reach the total heating value 10,627,000
kcal/MT, the fuels that need to be used are 10, 627,000 kcal/MT / 10,162,000
kcal/MT = 1.046MT = 1,046kg. In other words, to maintain the same heating value,
additional 1,046 – 1,000 kg = 46kg of GFXP fuel oil that contains 12.85% of water
and 0.65% of emulsifying agent needs to be used.
4. Therefore, the oil-saving rate when GFXP emulsified heavy crude oil is used is 1,000
kg – (865.5 kg + 46 kg)=88.5kg. In other words, the oil-efficient rate is
88.5kg/1,000kg=8.85%.
II. Saved expenditure
Suppose the cost for each ton of #6 heavy crude oil is NT 19,528 / MT
5. Cost for each ton of GFXP emulsified heavy crude oil= = NT 19,528 /MT*0.8655 (fuel
oil) + (NT65*0.1280)(Water)+ (NT29,100*0.0065)(emulsifying agent)(NT 2.74kw-
h*7.6kw- h)(electricity cost)= NT16,901 + 8.32 + 189.15 + 20.824 = NT 17,119
6. When GFXP with an equivalent heating value is used, it is NT 17,119/MT*1.046 MT =
NT 17,907.
7. Saved fuel cost with GFXP = NT 19,528 –NT 17,907 = NT1,621
8. Saved expenditure with GFXP = NT1,621 / NT 19,528 = 8.3%
Saved expenditure with water addition ratio of 18.5%= 8.3%.
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29. Comparison Table of ECH-A and Related
Technologies (GFXP) in Energy-Saving
Energy-saving technology Oil-efficient rate Saved expenditure
ECH-A 15.8% 16.19%
(Water content of 18.5%)
GFXP 8.85% 8.3%
(Water content of 12.85% and
emulsifying additives of
0.65%)
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30. Recommended water addition rates for
ECH-A emulsified heavy crude oil used
in different industries
Industry Application Water addition
rates
Glass fiber manufacturers, glass
industries, ceramics industries, Furnaces, ~20%
cement industries, metallurgical melting pots,
industries, mining industries, baking ovens
asphalt factories, power plants
Pharmaceutical industries,
petrochemical industries, dyeing Steam boilers ~30%
and finishing industries, printing
and dyeing industries, textiles, dairy
industries, chemical industries, dye
industries
Food industry, hospitals, hotels, Steam boilers,
swimming pools, public architecture, Hot water boilers ~40%
general industries
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