Cavitation
Area of application - Industrial oil processing
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) using ultrasonic cavitation, 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.
By homogenizing heavy fuel oil (HFO) using ultrasonic cavitation, 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.
Advantages of HFO homogenization
+50%
More effective
Processes
-30%
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
Reliable flowability
Viscosity
Homogenization reduces the viscosity of the oil. The positive consequences range from improved handling to environmental benefits. A heavy fuel 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 generates less friction
- Remains free-flowing even at low temperatures
- Burns with fewer emissions
Greater compatibility
Consistency
Homogenization ensures that the oil has a uniform consistency. This leads to advantages such as better processability or the higher quality of 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 plant 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 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 longer storage without loss of quality
- Can reduce corrosion of metals and other materials
- Reduces the risk of accidents and explosions as it is less prone to spontaneous combustion
Lower energy costs
Workability
Homogenization 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
CaviFlow® |
Immediate use
Immediate use
The low-maintenance RAPTECH CaviFlow® inline modules can be quickly implemented in existing process systems.
- Plug & play solution
- Customizable flow rates
- Low investment costs
Cavitation | Products
RAPTECH offers services and financing options for every product.
- CaviFlow® modules
- Individual processes
- Complete system installations
Cleaner combustion
Less kerosene deposits
Heavy fuel oil or oil-in-water mixtures homogenized with UADA cavitation technology 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.
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.
- Reduced smoke development
- Less soiling
- Cleaner systems
- Less 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:
The degree of deposition due to incomplete combustion is strongly influenced by the size of the fuel droplets. The figure illustrates the process.
- 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.
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.
- 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.
Inline module
CaviFlow®
CaviFlow® modules impress with their durable technical design. Made of black or stainless steel, they are equipped with a functional threaded or flanged connection.
There are no moving parts inside the module. This guarantees low maintenance and very low susceptibility to faults. Quality made in Germany.
Innovative cavitation technology for your business?
RAPTECH offers customized processes for oil processing.
- Simply send us a short message. We look forward to your requirements.
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Areas of application - Industrial oil processing
