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Heavy Oil Heater (OH Series)

heavy oil heater

For appropriate spraying and combustion of fuel oil, it is necessary to reduce its viscosity sufficiently. Viscosity is a variable quantity and decreases with increasing fluid temperature. For instance, the appropriate viscosity for fuel oil combustion in high-energy burners is 5-10 cSt. Reduction in viscosity occurs for fuel with an initial viscosity of 180 to 380 centistokes at a temperature of 100 to 140 degrees Celsius. Since fuel oil sometimes includes impurities and foreign materials, it is necessary to maintain and repair the combustion equipment that works with this fuel type carefully and continuously. Due to the importance of this part of the production line, the main equipment of the combustion system is usually considered dual (including a coarse filter to protect the fuel pump, fuel pump, heat exchangers for fuel preheating, fine filters to protect the nozzle fuel injector). If one fails, the other will continue to work and prevent the complete stop of the production process.

Heat is transferred to all parts of the liquid fuel line (including the heat exchanger of the fuel preparation part for entering the burner, pipelines, and fuel exit from the storage tank), which can be done by water vapor, oil bath, electric current, and Radiation from the flame.

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Nox Reduction Methods

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Heavy Oil Heater (OH Series)

heavy Oil Heater
A diesel burner is one of the burners used in industries that require a large volume of hot water and hot steam, such as refineries and powerhouses, to provide heating for boilers and furnaces.

Preparation of liquid fuel for use in the furnace

For the combustion of fuel oil, its viscosity must be between 12 and 20 centistokes when entering the burner, and in no case should it exceed 20 centistokes. This way, proper fuel injection and distribution of fuel droplets are ensured. Considering the quality of crude oil available in the market, it is necessary to carefully measure and control the viscosity changes of this fuel with temperature. Furthermore, it is necessary to keep the temperature changes of the heated fuel oil as low as possible to achieve a flame with a uniform behavior and a stable shape.

The use of liquid fuel as a burner fuel can be divided into the following steps:

  • Fuel transfer to the storage tank
  • Storing fuel in the tank and extracting it.
  • Preparation, measurement, and regulation of fuel properties for use in furnaces
  • Preheating and fuel injection using an atomizer and finally fuel combustion

For appropriate spraying and combustion of fuel oil, it is necessary to reduce its viscosity sufficiently. Viscosity is a variable quantity and decreases with increasing fluid temperature. For instance, the appropriate viscosity for fuel oil combustion in high-energy burners is 5-10 cSt. Reduction in viscosity occurs for fuel with an initial viscosity of 180 to 380 centistokes at a temperature of 100 to 140 degrees Celsius. Since fuel oil sometimes includes impurities and foreign materials, it is necessary to maintain and repair the combustion equipment that works with this fuel type carefully and continuously. Due to the importance of this part of the production line, the main equipment of the combustion system is usually considered dual (including a coarse filter to protect the fuel pump, fuel pump, heat exchangers for fuel preheating, fine filters to protect the nozzle fuel injector). If one fails, the other will continue to work and prevent the complete stop of the production process.

Heat is transferred to all parts of the liquid fuel line (including the heat exchanger of the fuel preparation part for entering the burner, pipelines, and fuel exit from the storage tank), which can be done by water vapor, oil bath, electric current, and Radiation from the flame.

1. Liquid fuel Heating by steam

Using water vapor is the most common method of heat transfer to fuel oil for preheating. The following methods can be used to prepare steam:

  • Oil-burning steam generator
  • Pressure tanks heated with floating electric coil
  • Steam generators using heat recovered from the exhaust gases from the furnace

The significant defects of heating fuel oil with steam are included:

  • The need to reduce water salts used in steam production (Water hardness)
  • Returning unused steam
  • Condensed vapor collection problems
  • Working in high-pressure conditions
  • The possibility of freezing the system in cold seasons and during the stoppage of the production line

It is worth bearing in mind that in using the boiler burners, using part of the steam or hot water produced by the boiler to preheat the fuel oil is not associated with the mentioned problems and is a suitable method.

2. Heating of liquid fuel using an oil bath

The oil used for heat transfer must be of a synthetic type with a low flammability limit. The required heat of such systems can be provided in the following ways:

  • Oil heaters
  • Heating heaters with floating electric coil
  • Use of recycled heat from exhaust gases from the furnace

Advantages of using this method:

  • Maintaining the liquid state in a wide temperature range
  • Remaining at low pressure even at operating temperatures up to 300°C
  • No freezing problems

The efficiency of the used oil decreases over time, so its quality should be monitored regularly, and the oil should be changed at 5-year intervals

3. Direct heating of liquid fuel with an electric system

This method has a high operating cost, so it can only be used as a fuel oil heating system in low-capacity production lines. However, the electric heater is used as an auxiliary system along with other heaters, especially during the start-up of the production line. In this method, in addition to using electric coils, the electric current can be directly connected to the fuel oil pipeline so that the passing fuel is heated due to the pipes’ electric resistance and heating. The electricity used must have high current intensity and low voltage.

4. Radiant heating of liquid fuel

In this method, fuel oil flame is directly used for heating, but in this way, the temperature of fuel oil may rise too much and cause its decomposition and separation of light hydrocarbons. For this reason, it is necessary to maintain the temperature of heated fuel oil at 120 degrees Celsius.