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
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
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.
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.
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.
The R&D branch (Additive Chemicals Ltd) has developed two series of additives suitable for the production of stabilized emulsions.
For further information and insights please visit the dedicated webpage: Additives ACL series
Negli ultimi anni c’è stata un evoluzione normativa riguardo alle emulsioni stabili, qui di seguito un rapida panoramica:
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.
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:
*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).
Download here the specific Stable Box D series documentation
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:
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: firstname.lastname@example.org
Download here the specific Stable Box H series documentation