Fuel Treatments
Combustion Catalysts
Several metals catalyze combustion of petroleum fuels. These include iron, manganese, copper, barium and cerium. Iron is the best choice for combustion turbine applications. SFA International manufactures FuelSpec® 116 series ferric carboxylate salt available in up to 9% Fe concentration. We also have FuelSpec® 118 series oil-miscible colloidal dispersion of iron with up to 18% Fe concentration. Both of these products meet combustion turbine manufacturer contaminant metal requirements.
SFA manufactures a patented iron and magnesium catalyst system with unusual activity. This material will reduce carbon matter in combustion turbine exhaust streams by up to 90%. It also yields improved fuel efficiency commensurate with the reduction of particulate matter and unburned hydrocarbon in the exhaust..
SFA International has had experience in the application of the iron combustion catalyst in several applications ranging from control of smoke during turbine start up to base load applications in fuels from high aliphatic waxy residual to high asphaltenic residual oil.
Application of this product has enabled combustion turbine operators to continue operating engines in sites where tightened environmental regulations would require discontinuation of power production. For examples of application of our catalyst technology in combustion turbine engines, request our experience list. For more information on the mechanism of this process, go to the Research page.
Diesel Engine Products
Diesel Engine Fuel Treatment
There are three basic types of Diesel engines: low speed (150 – 450 rpm), medium speed (450 – 1,000 rpm) and high speed (> 1,000 rpm). Low speed engines are commonly used on ships and for generation of electricity. Medium speed engines are used for a wide range of purposes including generation of electricity, railroads, tug boats and pipeline pumps. High-speed engines are used in trucks and automobiles as well as agriculture and construction equipment.
Low speed engines have been used for many years with low quality fuels ranging from vacuum distillates to residual oils. The poorest quality fuels contain 300 or more ppm vanadium, high levels of sodium and 3-4% sulfur. Because of relatively low temperatures in the engine, deposits and corrosion on piston crowns and exhaust valves are minimized compared with combustion turbines operated on similar fuels.
In recent years, considerable interest has developed in running medium speed engines on residual oils. Because of higher operating temperatures, piston crown and exhaust valve deposits and corrosion are a significant problem. There are also problems with deposits and corrosion on turbocharger blades.
Another problem with Diesel engines is emissions. These include smoke (unburned carbon particles), nitrogen oxides and sulfur oxides.
Fuel Borne Catalysts
FuelSpec® 110 Series fuel borne combustion catalysts effectively reduce smoke (carbon particles) and NOx in Diesel engine exhausts and reduce fuel consumption. We have measured up to 90% reduction in particulate matter in exhausts and 75% reduction in NOx. Reductions in fuel consumption depend on engine design and sulfur content in the fuel and can range from 2% to 12%. These products are currently available for off-road use in the United States.
SFA’s FuelSpec® 110 Series are oil-soluble liquid organo-metallic catalysts based on SFA’s patented iron – magnesium technology.
Diesel Engine Fuel Additives
FuelSpec® 113 and 114 are fuel borne catalysts with EPA registration for on-road use in the United States. They are recommended for industrial customers requiring EPA registration for products they use.
Additives used in off-road Diesel engines include FuelSpec® 116, 117 and 119 Series Diesel fuel borne catalysts and smoke inhibitors, and FuelSpec® 130 Series ash modifiers for high temperature corrosion and deposit control.
FuelSpec® 116 Series catalysts are designed for use in fuels containing >1,000 ppm sulfur.
FuelSpec® 117 Series catalysts are designed for use in fuel with <1,000 ppm sulfur. Removal of sulfur by dehydrodesulfurization in the refining process results in reduced lubricating properties of the fuel. Our FuelSpec® 117 Series catalysts include a lubricity agent to compensate for this loss in lubricating property.
FuelSpec® 119 Series catalysts are designed for use in large, low-speed engines operating on heavy fuel oil (HFO) or residual oil (RO).
Gasoline Engine Fuel Additives
FuelSpec® 114 is EPA registered and can be used in gasoline engines in on-road use. This product reduces fuel consumption by 4 to 8% with a substantial (30%) reduction in NOx.
FuelSpec® 117 Series fuel borne catalysts substantially lower fuel consumption by 6 to 10% in off-road gasoline fueled spark-ignited engines and reduce NOx by 75%.
Natural Gas Fuel Additives
FuelSpec® 114 is EPA registered and can be used in natural gas fuel engines for on or off-road use.
FuelSpec® 115 is for use in off-road natural gas fuel engines. This product was designed specifically for injection into the intake manifolds of natural gas reciprocating engines. It will immediately evaporate into the air-fuel mixture. The product will allow full power from the engine under extreme lean-burn conditions where NOx is reduced by 75% or more.
Boiler and Process Heater Fuel Additives
Additives utilized in various types of Boilers and Process Heaters for steam and industrial uses, including units operating on coal and petroleum fuels. SFA’s FuelSpec® 140 Series organo-metallic oil-soluble magnesium carboxylates with up to 35% magnesium concentration reduce deposits on fire walls, water walls and super heater tubes. Magnesium containing fuel additives also reduce sulfuric acid formation and acid rain in the exhaust from fuels containing high levels of sulfur.
In large boilers, including coal applications, we recommend our FuelSpec® 118 series colloidal dispersion combustion catalyst to reduce particulate matter and NOx in the exhaust.
Product Testing
These products have been extensively tested by government and private research laboratories, including Automotive Research Association of India, Southwest Research Institute in San Antonio, TX, University of Houston and Jerry Lang Combustion Consultants in Lindale, TX. These results are presented in papers in the Research page of this site.
Spark-Ignited Reciprocating Engine Products
Gasoline Fuel Treatment
SFA International’s FuelSpec® 117 Series combustion catalysts have demonstrated fuel savings and NOx reduction in spark-ignited reciprocating engines using ASTM No. 1 grade naphtha based or gasoline fuel. Fuel savings are in the 5% to 10% range in test engines and field tests in vehicles on the road. Reductions in nitrogen oxide emissions in the exhausts in test engines have been measured in the 75% range. Extensive testing in fuel compatibility tests have demonstrated that the catalyst does not affect fuel stability.
The low level of ash contribution from the catalyst does not materially affect fuel quality. Therefore, addition of the catalyst will not negate engine warranties because of ash specifications.
Key Benefits from these SFA Products
Longer Turbine Blade Life
Less Downtime for Maintenance & Repair
Reduced Smoking & Pollution
More Efficient Heat Generation & Better Fuel Economy
Catalyst Mechanism
For more information on the mechanism of this process, go to our Research page.
Technical Service
Our engineers provide technical service to aid customers in achieving optimum results from use of boiler fuel additives. Before a recommendation is made, a survey of the plant is made. From this information, a proposal is prepared outlining the additive application, dosage rate, function and expected benefits.
All technical information and research reports are copyright of SFA International.
Used with permission.