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Emulsion Power

Stable Box blender

Animated diagram that describes the simplified operation of a  Stable Emulsion Box by Power

 

The blender series Stable Box is the new reference of this industry since these blenders allow to produce a W/O (water-in-oil) stabilized emulsion of excellent quality with both Diesel and HFO base fuels.

 

We call it Stable Emulsion in order to emphasize that its main characteristic is the stability, higher than the minimum required by the law (in Italy the DM 20 Marzo 2000 e s.m.i. requires 4 months of stability for the stabilized emulsion for automotive, the Stable Emulsion overcome several months). It is the result achievable with the Emulsion Power synergy of mechanics (Stable Box blenders) and chemistry (additives ACL Series).

Two typology of Stable Box exist: the Stable Box D and Stable Box H series, designed to produce stabilized emulsion with Diesel and HFO base fuel respectively. The two series of plants differ in some component selection and sizing, depending on the difference of the fuel to be processed, but they share the same design philosophy: high quality of the components and total monitoring and control of the process.

The production process is cyclic (batch processing). Every cycle is characterized by a predetermined series of phases, each of which is designed in detail to assure repeatability and quality of the final product. The phase timing and the products quantities optimization is carried out at the setting up of the blender in the production site, based on the client specific needs.

The choice of adopting a batch processing logic allows to increase the product’s quality keeping it constant over time. The Stable Box design is carried out with the aim of obtaining the highest control of the material fluxes: in order to reach this goal, the more critical components, as for instance motor pumps and flowmeters, are selected with care.

The Stable Box blenders are turnkey provided, with the possibility of subscribe a full service contract which includes maintenance and technical services.

These plants are very compact, all the equipment is installed inside a standard skid, easily moveable: once the connections to the storage tanks, to the electrical and the water grids and to a computer, it is easy to turn on the blender and produce, simply setting up the quantity needed.
Emulsion Power will help and support the client in each phase of the project of the installation site and successively, at the moment of the start up, in the personnel training.

The production is automatically managed by the Stable Box and it will be sufficient to monitor the state of the process through the software provided with the blender, the tank levels and output batch data to easily manage the supplying of the products (additive and fuel), that is almost the only activity that operators should do periodically.
There are also additional functionalities, provided on request, which can simplify further the production management. For instance, the Stable Box can interact with the site control systems to control external tanks levels.
In any case the maintenance activity required to the operators is minimal.
Emulsion Power can also supply customized solutions which best fit any specific need of the client. Click here to visit the dedicated webpage.

 

 

 

 

Insight on Stable Box and Stable Emulsion

Stable Emulsion

The stabilized emulsion “Stable Emulsion” produced with Emulsion Power blenders Stable Box is an exceptional quality product:

  • Stability over time as required
  • The Diesel based one (water content between 10 – 15 % by weight) can be used both on boilers and engine/generators.
  • Green product, significant pollutant emissions abatement
  • Replaces the original fuel
  • Engines cleaning enhancement
  • Economic benefits (in particolar in Italy and France, due to fiscal relief)

The stabilization is obtained with the use of peculiar surfactant substances which prevent the separation of the two non-miscible liquid phases over a large period (more than 5 months). The water droplets average size is generally lower than 1 µm. Measurements showed a distribution centred in the interval 0,1 – 0,5 µm
Total control: quality and safety first
The production of the Stable Emulsion/On-Demand Emulsion is completely under control in every phase of the process cycle. This is due to the several level transmitters installed within the tanks, the temperature and pressure probes and the flowmeters used to measure the material fluxes. Based on these signals and on the program settings, the PLC system controls automatically the production, assuring both an excellent product quality and safety of the machine. The remote monitoring and control system, which also provides to send messages to predefined telephone numbers when alarms or warnings raise, permits to Emulsion Power support team to act immediately, in order to identify and solve any eventual issue or remotely modify the process parameters on request by the client.
Emulsion Power dynamic mixer
 The core of every blender is without any doubt the mixer. Its characteristics change depending of the viscosity of the base fuel and it is designed to obtain the smallest water droplets size. Actually these units are defined as dynamic mixer, i.e. a moving part (rotor) is driven by an electric motor running at high speed and they can be single or double stage depending on the application. Thanks to the high shear stress they can produce on the fluid and the drastic reduction of the passage opening, these mixers yields to the reduction of the water droplets at a size lower than 1 m. The dynamic mixers are designed and produced by Emulsion Power.
Mass flow meters

 

Metering the incoming product and the produced Stable Emulsion is a very important feature for fiscal depots. For this
reason, on the Stable Box blenders, the choice has been to Coriolis mass flowmeters. They can measure indeed the flowrate, the density and the temperature of the fluid with the highest precision and accuracy, independently by the external ambient conditions

 

 

 

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PLC
The PLC system manages the automatic operation mode and the signals to and from outer sources. The operator has to set the number of cycles (batch) to be produced. Then the product quality is assured by PLC control system which, on the bases of the process parameters already optimized by the Emulsion Power technical team during the start-up operations, can produce Stable Emulsion/On-Demand Emulsion with a constant over time quality.
Also eventual anomalies are managed by the system. The several signals from the measuring probes and instrumentation (or other safety devices as the high/low level probes) are constantly monitored by the PLC which can immediately identify a failure. In that case the PLC can suddenly interrupt the production and generate alarm signals (visual alarm, SMS to predetermined numbers).
Even if the machinery is conceived for stand alone operation, some of the signals can be derived to be integrated with the on-site already existing control systems (as for instance a DCS). Besides the system can receive additional signals from external sources (for instance a level probe of an underground tank).
Remote control

The PLC can be remotely monitored and controlled with a GSM connection. The Emulsion Power technical team can act and modify or correct the process parameters, based on the client need or for adapting to a change of the boundary conditions (for the winter production, for instance).
Nobody can modify the process parameters but Emulsion Power, since it is password protected with several level of security.

Synoptic software

Emulsion Power provides a software for monitoring the production from a remote position. This functionality can be used by the operator to verify in real time from different positions which is the process phase running at that time, how many cycles have been completed, the produced and used products quantities, the level of the various tanks and the physical main properties of the product (Stable Emulsion). On the basis of these information the operator will be able to plan the products supplying and the very few programmed maintenance operations.
The Synoptic software provides also the possibility to download the data of about the last 200 cycles. Among these data, extrapolated and processed from measurements of the mass flowmeters, there are the quantity of base fuel used (Diesel or Fuel Oil) and of the Stable Emulsion produced, referred to base conditions (15° C). Thanks to this functionality the operator has a very useful tool for the stock management of the fiscal depot.

Deionized water

In order to produce law compliant stabilized emulsions is necessary to use deionized water, with electric conductivity lower than 30 µS/cm.
For this reason, the Stable Box blenders by Emulsion Power are equipped with inverse osmosis demineralizers, specifically selected to support each blender size. This means that is not required any additional equipment to be installed on site. The Stable Box requires the connection to the water grid only.

 

Additives ACD e ACH

The R&D branch (Additive Chemicals Ltd) has developed two series of additives suitable for the production of stabilized emulsions.

  • ACD series: emulsifying additives for Diesel based Stable Emulsion
  • ACH series: emulsifying additives for Fuel Oil based Stable Emulsion

For further information and insights please visit the dedicated webpage: Additives ACL series

Law

Negli ultimi anni c’è stata un evoluzione normativa riguardo alle emulsioni stabili, qui di seguito un rapida panoramica:

  • Europa: Sviluppo di uno standard europeo per emulsione stabile con diesel CE CWA 15145:2004
  • Francia: specifica ANFOR NF M15 – 021 Feb 202 – Caracteristique des emulsion d’eau dans le  gazoile (EEG)
  • Francia: Normativa di agevolazione accise in Francia per emulsioni stabili disel ad uso autotrazione e riscaldamento
  • Italia: “caratteristiche tecniche delle emulsioni stabilizzate” tramite D.M 20 Marzo 2000
  • Italia: agevolazione fiscale tramite accise dedicaate per emulsioni stabili ( diesel ed olio denso)
  • Italia: standard tecnico per composizione e metodo di analisi CUNA NC 637-01 12 2003
  • Israele: standard caratteristiche tecniche SI 5937

Gli uffici Emulsion Power S.r.l. sono a vostra disposizione per consulenze e vi seguiranno in tutte le fasi di richiesta start-up tecnico e burocratico.

 

 

Stable box Diesel series

The Stable Box D series is specifically developed and designed to produce Stable Emulsion with Diesel as base fuel.

The Stable Emulsion is white colored, latescent, and its chemical-physical characteristics are very similar to the Diesel used to produce it. It can be used to substitute the Diesel itself in all the applications, from internal combustion engines to boiler burners.

The Emulsion Power technology reached a really high quality level: the following image shows a microscope picture of a sample of Stable Emulsion produced by one of our blenders.

 

 

The Stable Box D blenders (standard versions*) are available in the following sizes:

  • STABLE BOX D 1500 – 1500 L/h
  • STABLE BOX D 2500 – 2500 L/h
  • STABLE BOX D 5000 – 5000 L/h

*Emulsion Power provides the best support to its clients offering customized solutions as well. For further information click here.

The plant layout and the dimensions of each container in which the blender is installed vary with the size, however, all the models are built following the same design approach, summarized in the next scheme:

Schema PFD Stable Box D series semplificato

 

The internal tanks are sized to meet the target of hourly emulsion production and in order not to stop the production during minor operators activities, as for instance the additive supplying or the programmed maintenance of the demineralizer.
Every component has been studied or selected to optimize the process. The deionized water is for instance injected through a nozzle that has been specifically designed to distribute it uniformly within the stream, even before it enters the mixer. Also the main tank, which contains the product processed at every cycle, is specifically designed to assure that no stagnant region can form and all the fluid is always in motion. Besides, all the pumps installed are positive displacement type to assure higher steadiness of the flowrate and higher reliability.

The Stable Box D models are equipped with one or two dynamic, double head, mixers for the use with Diesel: this mixer has been designed to produce specifically W/O stable emulsions. The main characteristic of this component is to create very high shear stresses on the circulating fluid, in order to reduce the water droplets to a very thin size to assure the quality of the emulsion, with an high energy efficiency. Consequently, the mechanical internal parts have been designed and optimized for the use with Diesel specifically.
The measurement of the Diesel to be processed and of the produced Stable Emulsion must be highly precise, in particular for those countries as Italy in which the production has to be carried out in a fiscal depot, so in conditions of excise suspension. For this reason we provide a measurement system that is compliant to the MID directive. So, our Stable Box D blenders are equipped with Coriolis mass flowmeters, which assure very high precision independently by the fluid to be measured. Emulsion Power supplements the output data available from the electronic transmitters of the measuring system with additional elaborated data, integrated with the provided software, as for instance the quantities referred to base conditions (liters and density at 15°C). This functionality supports the operators daily work since they can easily survey the production or the stored quantities.

The Stable Box D series are also equipped with an automatic sampling system in order to carry out periodic quality controls and to allow eventual controls from agencies in charge. For instance, in Italy, the “Ufficio Tecnico di Finanza” (technical department of the Customs) periodically controls the emulsion in order to verify its compliance to the law (DM 20 Marzo 2000).

 

 


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Download here the specific Stable Box D series documentation

  • Brochure Stable Box D series
  • Additives ACD series
  • Technical Sheet Stable Emulsion Diesel – Automotive
  • Technical Sheet Stable Emulsion Diesel – Heating

 

 

Stable box HFO series

The Stable Box H models are specifically developed to produce the Stable Emulsion with fuel oils as base fuel.

The Stable Box H series blenders are available in the following sizes:

  • STABLE BOX H 1500 – 1500 L/h
  • STABLE BOX H 2500 – 2500 L/h
  • STABLE BOX H 5000 – 5000 L/h
  • *Emulsion Power provides the best support to its clients offering customized solutions as well. For further information click here.

Compared to the models developed to produce emulsions with Diesel as base fuel, there are few but substantial differences. Even if they follow the same design approach, the process management becomes more complex and this is reflected on the controlling and monitoring software which are designed on purpose for these models.

Simplified Stable Box H PFD.

To assure the quality of the emulsion produced indeed is necessary to equip the main tank with an heating system and the mixing circuit, the fuel oil feeding line and the main tank itself have to be insulated.

Also in this case, one or two units of dynamic mixer for the production of the stabilized emulsion are installed. The mixer is designed on purpose for this type of application, so the mechanical internal components are designed on the basis of the fuel oil physical characteristics, which differ from the Diesel case.
Emulsion Power owns the technology to produce O/W emulsions with HFO. For more information please contact: info@emulsionpower.com

Download here the specific Stable Box H series documentation

 

  • Brochure Stable Box H series
  • Additives ACH series
  • Technical Sheet Stable Emulsion HFO

 

 

 

Emulsion Power
The mission of EMULSION POWER S.r.l. it's to optimize energetic efficiency in the name of the economy (rationalization) while respecting the environment, in perfect harmony with the existing and future directives .
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