Cavitation
Area of application - Industrial oil processing

Industrial oil processing

One of RAPTECH's particular areas of expertise is the homogenization of heavy fuel oil and the production of water-in-oil mixtures. The hydrodynamic UADA cavitation technology with the CaviFlow® inline module achieves outstanding results with the smallest particles. Fast, uncomplicated and cost-efficient. The quality of the treated oil increases significantly through homogenization.

By homogenizing heavy fuel oil (HFO) with the CaviFlow® inline module , the oil is treated in such a way that the components are evenly distributed in ultra-fine droplets. HFO homogenization brings advantages such as clean combustion and less paraffinic contamination in the systems. It can be used profitably in industries such as refineries and petrochemicals, also to produce alternative fuels .

Advantages of HFO homogenization with CaviFlow®

Optimized viscosity

Improved consistency

Increased stability

More flexible processability

Cleaner combustion

+100%

Effectiveness with
CaviFlow® inline module

-25%

Reduction of
emissions

Areas of application

Preparation of drilling fluids
Extraction of oil residues
Reduction of asphalt-resin-wax deposits
Improvement of crude oil stabilization
Light distillates through pre-cracking
Residual oil processing
Hydraulic oil production
Waste oil treatment
Used oil extraction
Recycling of oily sludge
Recycling of bilge water
Homogenization of HFO
Oil-water dispersions
Water-wax dispersions
Reduction of paraffin-wax deposits
Optimization of rheological properties
Pour point and viscosity reduction
Breaking molecular bonds of asphalt-resin-paraffin

Immediate use

CaviFlow®

The CaviFlow® inline modules can be adapted to flow rates of up to 100 m³/h. Thanks to the threaded or flanged connection, they can be integrated into existing systems plug & play.

There are no moving parts inside the module. This guarantees low maintenance and very low susceptibility to faults. Quality made in Germany.

Use CaviFlow® now

Reliable flowability

Viscosity

Homogenization with the CaviFlow® inline module reduces the viscosity of the oil. The positive consequences range from improved handling to environmental benefits. A heavy oil with optimized viscosity:

Can be pumped and transported more easily
Burns more effectively in engines and machines
Reduces wear on machine parts as it creates less friction
Remains free-flowing even at low temperatures
Burns with fewer emissions

Greater compatibility

Consistency

Homogenization with the CaviFlow® inline module ensures that the oil has a uniform consistency. This leads to advantages such as better processability or higher quality end products. A heavy oil with improved consistency:

Can be processed more easily, which facilitates the production of heating oil, diesel, lubricants, etc.
Is less susceptible to changes in pressure or temperature
Forms less sediment, making it easier to clean and maintain equipment and machinery
Is more compatible with additives, fuels or lubricants, which facilitates new product developments
Leads to a higher quality of end products

Increased security

Stability

Homogenization with the CaviFlow® inline module improves the stability of the oil. This produces positive effects, from reduced oxidation to increased safety. A heavy oil with increased stability:

Is less susceptible to oxidation, which reduces the formation of contaminants and deposits
Tolerates prolonged storage without loss of quality
Can reduce corrosion of metals and other materials
Reduces the risk of accidents and explosions as it is less susceptible to spontaneous combustion

Lower energy costs

Workability

Homogenization with the CaviFlow® inline module facilitates the processing of the oil, as it is easier to mix, filter and process. A heavy oil with a more flexible processability:

Can be processed faster and at lower temperatures and pressures, which reduces energy costs
Increases product quality as desired properties and specifications are more easily achieved
Easier to adapt to different applications

Cleaner combustion

Less kerosene deposits

Heavy fuel oil or oil-in-water mixtures homogenized with the CaviFlow® inline module achieve a particle size of 5-10 micrometres and can be burned more evenly due to the homogeneous particle distribution and better flame geometry and temperature. Valves and pumps are protected from contamination and more environmentally friendly combustion is guaranteed.

Reduced smoke development
Less soiling
Cleaner plants
Fewer emissions

The figures show the results after a 30-minute combustion test with untreated and homogenized heavy fuel oil (HFO) with a viscosity of 380 mm³/s and a fuel oil/water emulsion of 15%. The homogenized heavy fuel oil burns significantly cleaner, as does the oil-in-water mixture.

HFO 380 heavy fuel oil | untreated

HFO 380 Heavy fuel oil | homogenized

HFO water emulsion | 15 %

Homogenized HFO

Combustion of fuel droplets

Under ideal conditions, the combustion of fuel droplets follows the following pattern:

Vaporization of all hydrocarbon molecules in the injected fuel droplets
Mixing with oxygen
Complete combustion within a fraction of a second
Without residues or unwanted by-products

The degree of deposition due to incomplete combustion is strongly influenced by the size of the fuel droplets. The figure illustrates the process.

Droplet enters the combustion zone | 100 microns

Evaporation | Steam combustion | Rapid mixing

Broken up hydrocarbon molecules | Steam combustion

Zenosphere | Spongy carbon | Slow diffusion | 20-50 microns

Ash residue | complete combustion | 2-5 microns

Particle size

Ultrafine fluids through homogenization of HFO

The patented RAPTECH UADA cavitation technology guarantees the highest product quality in the inline homogenization of heavy fuel oil.

Particle sizes < 5 micrometers
Excellent viscosity
Stability and temperature resistance
Long shelf life
Improved transportability

Best rheological properties
Ideal pour and flash point

The illustration (microscope view) shows ultra-fine homogenized heavy fuel oil (HFO) with a viscosity of 380 mm³/s and a fuel oil/water emulsion of 15%. The homogenized heavy fuel oil burns significantly cleaner, as does the oil-in-water mixture.