Advances in the generation of a new emulsified fuel

The development of a new emulsified fuel is described, from the conceptual idea to the semi-industrial tests of the final product. The starting point was the necessity to lower the particulate matter (PM) emissions produced by the combustion of more than 200 MBD of heavy fuel oil (HFO) used for electric power conversion. The major component of HFO is a vacuum residue of the oil refining process mixed with light cycle oils to make it pumpable. An alternative to handle and burn the high viscosity residue (solid at room temperature) is by converting it in an oil-in-water emulsion. The best emulsions resulted of 70% residue in 30% water, Sauter Mean Diameter of 10–20 μm and a stability of more than 90 days. Spray burning tests of the emulsion against HFO in a semi-industrial 500 kW furnace showed a reduction in PM emissions of 24–36%.