EFFECTIVENESS OF HOMOGENIZATION EQUIPMENT ON VERY LARGE

CRUDE CARRIER VESSEL

HARIS FADILLA BIN NORDIN

UNIVERSITI TEKNOLOGI MALAYSIA

EFFECTIVENESS OF HOMOGENIZATION EQUIPMENT ON VERY LARGE

CRUDE CARRIER VESSEL

HARIS FADILLA BIN NORDIN

A thesis submitted in fulfilment of the

requirements for the award of the degree of

Master of Engineering (Marine Technology)

Faculty of Mechanical Engineering

Universiti Teknologi Malaysia

JANUARY 2014

iii

To

Beloved parents;

Nordin Lot & Alawiah Arshad

Beloved wife & children

Noordiana, Danish, Dania, Darwish & Dhani

For all of their patience and understanding

In the past, presence and future

iv

ACKNOWLEDGEMENT

All praises be to Allah S.W.T, The Al Mighty, The Most Gracious and The

Most Merciful

First and foremost, my utmost gratitude to Ir. Nordin Mat Yusoff, Vice

President of Group Technical Services, MISC Berhad for offering and encouraging

me to take up this challenge.

I would like to express my sincere thanks and deepest appreciation to my

project supervisor, Ir. Dr. Faizul Amri Adnan for their generous advice, guidance,

comments, patience and encouragement given to me in preparing and completing this

Master project research. Special thanks to the distinguished Panel Supervisors of the

program: Prof. Dr. Roslan Abdul Rahman and all panel supervisors for their support,

patience, encouragement, and useful suggestions.

My thanks go to AET Ship Management Sdn. Bhd., Master and Chief

Engineer Bunga Kasturi Lima which provided assistance, co-operation and provision

to carry out the measurement onboard Bunga Kasturi Lima.

I would like also to extend my gratitude to all my classmates for encouraging

each other to complete this study and providing wonderful thoughts and suggestions

during ups and downs as I pursued my Master degree.

And last but not least, special thanks to my wife, Noordiana Yaacob, my

children and family for their good-natured forbearance with the process and for their

pride in this accomplishment.

May all the good deeds that were done will be blessed by Allah. Wassalam…

v

ABSTRACT

The use of homogenizer in fuel treatment of heavy fuel oilonboard merchant

vessel is arguable; it will reduce separation efficiency of fuel contaminants and fuel

properties. Therefore this research analyses the effectiveness of homogenizer

operated in Very Large Crude Carrier (VLCC) vessel, MT Bunga Kasturi Lima. The

aim of this research is to compare operational effects on the application of

homogenizer against those without the use of homogenizer. The common method for

fuel treatment onboard the vessel is by using purifier. The separation of impurities

and water from heavy fuel oil is essential for good combustion. Actual measurement

was captured onboard for sludge production, fuel oil sampling for purifier efficiency

and fuel properties analyses and main engine exhaust gas sampling while the vessel

was sailing from Singapore to Port of Sikka, India and then to Cape Town, South

Africa. The range of sludge production reduction is between 17% to 23% compared

to without homogenizer in operation. Purifier efficiency gives a result between 63%

to 70% reduction of Aluminum and Silicon for untreated fuel (without homogenizer)

and 42% to 50% for homogenized fuel (with homogenizer). The saving calculated

from the operational data such as valuable fuel oil and less handling fees for sludge

disposal were used for Net Present Value (NPV) analysis. The negative NPV was

obtained and showed that the installation of homogenizer did not provide economic

advantages. Furthermore it could be concluded that the effect from bunker fuel type,

homogenizer positioning onboard fuel treatment, vessel fuel consumption and sea

state condition gave various impact on the effectiveness of homogenizer.

vi

ABSTRAK

Penggunaan homogenizer dipersoalkan di dalam rawatan dan penggunaan

bahan api bagi sesebuah enjin kapal dagang, dimana akan menyebabkan penurunan

kecekapan dalam pemisahan bahan-bahan yang tercemar dan air yang terdapat di

dalam minyak. Oleh sebab itu kajian ini bertujuan untuk menganalisis keberkesanan

homogenizer yang beroperasi di atas kapal MT Bunga Kasturi Lima.Tujuan kajian

ini adalah untuk membandingkan kesan yang terhasil dari pengunaan homogenizer

keatas rawatan minyak dan kesannya terhadap pembakaran di dalam enjin kapal.

Proses rawatan minyak di atas kapal biasanya mengunakan purifier. Perbandingan

seperti kadar pengeluar enapcemar minyak, sampel minyak dan pengukuran

kandungan ekzos gas dilakukan terhadap kesan yang sama tanpa mengunakan

homogenizer. Pengumpulan data dan ujian itu dilakukan di atas kapal semasa dalam

pelayaran dari Singapura ke Pelabuhan Sikka, India dan kemudianya ke Cape Town,

Afrika Selatan. Kecekapan purifier memberi keputusan antara 63% hingga 70%

pengurangan Aluminium dan Silicon apabila homogenizer tidak digunakan.

Walaubagaimanapun bagi penggunaan homogenizer ia memberikan keputusan antara

42% hingga 50%. Seterusnya penjimatan yang diperolehi dari penggunaan

homogenizer berdasarkan data pengoperasian seperti nilai lebih minyak yang

berharga dan penjimatan dari kos pengendalian enapcemar minyak telah dikira dan

seterusnya dianalisis mengunakan kaedah NPV. Nilai negatif NPV telah diperolehi

dan menunjukkan bahawa pemasangan homogenizer tidak memberikan kelebihan

dari segi keberkesanan ekonomi. Kesimpulan yang boleh dibuat ialah keberkesanan

penggunaan homogenizer bergantung kepada jenis bahanapi, kedudukan

homogenizer di dalam system rawatan minyak kapal, kuantiti penggunaan bahan api

kapal dan juga keadaan laut.

vii

TABLE OF CONTENTS

CHAPTER TITLES PAGE

DECLARATION ii

DEDICATION iii

ACKNOWLEDEGEMENTS iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES xii

LIST OF FIGURES xiv

LIST OF ABBREVIATION xvi

LIST OF SYMBOLS xvii

LIST OF APPENDICES x

1 INTRODUCTION 1

1.1 Background 1

1.2 Problem statement 2

1.3 Objective of research 2

1.4 Scope of research 3

2 LITERATURE 4

2.1 Introduction 4

2.2 Crude oil 5

viii

2.3 Refinery Process 5

2.3.1 Heavy crude oil / Residual oil 6

2.3.2 The Quality of Heavy Fuel Oil 8

2.4 The Fuel Oil Treatment 9

2.4.1 Existing Fuel Treatment Onboard Fuel

Purifier and Filter 10

2.5 Nature of Heavy Fuel/Residual Fuel Combustibility 11

2.6 What is Sludge? 11

2.6.1 MARPOL Guidelines for Handling

Oily Wastes on Ships 13

2.6.2 Remarks to MARPOL Annex I

Regulation 17 Amount of Sludge 13

2.6.3 Sludge On Board Ships 14

2.7 Fuel Homogenizer 15

2.7.1 Background 15

2.7.2 Application of Fuel Homogenizer 16

2.7.3 Type of Homogenizer 16

2.7.4 Functional Principle of a Rotor Stator

Homogenizer 17

2.8 Effect for Fuel Homogenization 18

2.8.1 Sludge Reduction 19

2.8.2 Combustion Improvement 19

2.9 Fuel Quality Characteristic and Their Importance 20

2.9.1 Viscosity 20

2.9.2 Specific Gravity 21

2.9.3 Carbon Residue/Asphalts 21

2.9.4 Sulfur 22

2.9.5 Ash/Sediment 22

2.10 Factors of Marine Fuel Oil Contaminants 23

2.10.1 Water 24

2.10.2 Sediment 24

2.10.3 Alumina/Silica 25

2.10.4 Sludge 26

2.11 Exhaust Gas Emission 26

ix

2.12 Economic Analysis 28

2.12.1 Alternative 29

2.12.2 Cash Flow 29

2.12.3 Alternative selection 29

2.12.4 Evaluation Criteria 30

2.12.5 Time Value of Money 30

2.12.6 Cash Flow Estimation 30

2.12.7 Capital Budgeting Decision Rules 31

2.13 Research Area 33

2.13.1 General 33

2.13.2 Ship’s Particulars 34

2.13.3 Equipment specification 34

2.13.4 Arrangement of Homogenizer Onboard 35

Vessel

2.14 Summary of Literature Review 36

3 RESEARCH METHODOLOGY 37

3.1 Research Methodology Flowchart 37

3.2 Identification of Research variable 38

3.3 Algorithm / Data Processing 39

3.3.1 Operational Data 39

3.3.2 Economic Data 42

3.4 Collection of Data 44

3.4.1 Vessel Condition 46

3.4.2 Collection of Purifier Efficiency Data 46

3.4.3 Collection of Fuel Sample for Analyzing

Fuel Oil Properties 49

3.4.4 Collection of Sludge Production Data 50

3.4.5 Specific Fuel Consumption Measurement 52

3.4.6 Collection of Exhaust Gas Emission Data 52

3.4.7 Collection of Main Engine Data 53

x

3.5 Analyzing of Data 54

3.5.1 Calculation of Purifier Efficiency

(Removal Particle Expectation) 54

3.5.2 Calculation of Sludge Production 55

3.5.3 Calculating Specific Fuel Consumption 57

3.5.4 Calculating Cost Estimation for

Economic Analysis 58

3.5.5 Inferential Statistic 64

3.6 Concluding Remarks 65

4 RESULT AND DISCUSSION 66

4.1 Introduction 66

4.2 Purifier Particle Removal Expectation

(Purifier Efficiency) 67

4.3 Sludge Production 71

4.4 Fuel Oil Properties 78

4.4.1 Density 79

4.4.2 Water 79

4.4.3 Micro Carbon Residue 80

4.4.4 Vanadium 81

4.4.5 Aluminum and Silicon 82

4.4.6 Nickel and Iron 83

4.4.7 Fuel oil Properties – ISO 8217 Standard 86

4.5 Specific Fuel Oil Consumption 87

4.6 Exhaust Emission Result 93

4.6.1 NOx Emission 93

4.6.2 CO Emission 95

4.6.3 Exhaust Emission Effect 96

4.7 Overall Operational Effect 97

4.8 Economic Analysis – NPV 98

4.9 Discussion on Fuel Quality in the Current Market 100

4.10 Discussion on 1% Clause of Sludge in Marine

Industries Standard 102

xi

5 CONCLUSIONS AND RECOMMENDATIONS 104

5.1 Conclusion 104

5.1.1 Purifier Efficiency – Particle Removal

Expectation 104

5.1.2 Sludge Production 105

5.1.3 Fuel Oil properties 106

5.1.4 Specific Fuel oil consumption 107

5.1.5 Exhaust gas emission 107

5.1.6 Economic Analysis – NPV 108

5.1.7 Fuel quality in current market 109

5.1.8 1% clause of sludge in Marine standards 109

5.2 Overall conclusion 109

5.3 Recommendation 110

REFERENCES 111

APPENDICES A-I 113 - 194

xii

LIST OF TABLES

TABLE NO. TITLES PAGE

2.1 Typical characteristic of a poor quality fuel and the

resulting problems 9

2.2 Characteristic Properties and Contaminants Effects 23

2.3 Bunga Kasturi Lima’s Principal Dimension 34

2.4 Fuel Oil Homogenizer’s Specification 34

2.5 Fuel Oil Purifier’s Specification 35

3.1 VLCC Bunga Kasturi Lima Vessel Condition 46

3.2 Fuel oil Properties Data Sampling 49

3.3 Sludge Volume Measurement Record 51

3.4 Others Data Collection 54

3.5 Fuel Oil Treatment with Homogenizer 55

3.6 Fuel Oil Treatment without Homogenizer 55

3.7 Sludge Production Record 56

3.8 Calculation of Specific Fuel Oil Consumption for

Los Angeles Heavy Fuel Oil 57

3.9 Calculation of Specific Fuel Oil Consumption for

Singapore Heavy Fuel Oil 58

3.10 NPV Analysis with Homogenizer 61

3.11 NPV Analysis without Homogenizer 63

4.1 Separation efficiency analysis 67

4.2 Result Volume of Actual Sludge Production per day

Compare with Theoretical sludge Volume and Equipment

Maker’s expectation 71

4.3 Fuel quality record – result from bunker analysis 76

4.4 Sludge properties result 76

4.5 Sludge production (T-test analysis) 78

xiii

4.6 Density of fuel 79

4.7 Water content in fuel oil 80

4.8 Carbon residue content in fuel oil 81

4.9 Vanadium contents of fuel oil 81

4.10 Aluminum and silicon content in fuel oil 82

4.11 Nickel content in fuel oil 84

4.12 Iron content in fuel oil 84

4.13 Results from analysis of fuel sample with homogenized

Fuel and untreated fuel 85

4.14 ISO 8217 fuel standard with & without homogenizer 86

4.15 Result of Main Engine Fuel Oil Consumption Measurement 88

4.16 Main Engine SFOC (T-test analysis) 89

4.17 NOx Emission (T-test analysis) 94

4.18 Average quality characteristic of 380cSt heavy fuel in the

years 1996 and 2001 in the major bunkering port 101

4.19 Bunker report for Bunga Kasturi Lima in year 2009 101

xiv

LIST OF FIGURES

FIGURE NO. TITLES PAGE

2.1 Refinery Process 6

2.2 Sludge (Asphalt) Composition 12

2.3 Principle of Fuel Homogenizer 18

2.4 Typical exhaust emission from a modern low speed

engine 27

2.5 Arrangement of Homogenizer Onboard Vessel 35

3.1 Research Methodology 37

3.2 Fuel oil Sampling Position 47

3.3 Sample bottle and labeling 48

3.4 P&ID for Fuel Oil Sludge Tank 50

3.5 Exhaust Sampling Point area 52

3.6 Flue Gas Analyzer 53

4.1 Purifier removal expectation result with Homogenizer in

operation and without operation, a) Water, b) Vanadium 68

4.2 Purifier removal expectation result with Homogenizer in

operation and without operation, Aluminum and Silicon 68

4.3 Purifier removal expectation result for fuel properties

a) by purifier only, R b) by Homogenizer, H1+H2 69

4.4 Volume of Sludge production per day 72

4.5 Sludge Production vs. Operation Mode 72

4.6 Sludge production basis on 1% clause of MARPOL

Regulation, a) With Homogenizer, b) Without

Homogenizer 73

4.7 Sludge production basis Maker expectation a) With

Homogenizer, b) Without Homogenizer 73

xv

4.8 Sludge production basis on Actual measurement onboard

Bunga Kasturi Lima, a) With Homogenizer, b) Without

Homogenizer 74

4.9 Sludge production versus operating condition onboard

Bunga Kasturi Lima 74

4.10 Fuel oil consumption per day while homogenizer with

and without operation 88

4.11 Specific fuel oil consumption comparing with main engine

load while homogenizer with and without operation 90

4.12 Average specific fuel oil consumption from MT Bunga

Kasturi Lima, operation mode on homogenized (H1+H2),

untreated fuel (R) for vessel in laden and ballast voyage 91

4.13 Main engine mean effective pressure for each cylinder unit 92

4.14 Main engine average exhaust temperature comparing to

operation mode 92

4.15 NOx emissions from operation on various forms on fuel

pre-treatment 95

4.16 CO emission from operation on various forms on fuel

pre-treatment 96

4.17 Comparison of Exhaust Emission 97

4.18 Comparison of Operational Effect 98

4.19 NPV Analysis 99

xvi

LIST OF ABBREVIATIONS

VLCC - Very Large Crude Carrier

MGO - Marine Gas Oil

MDO - Marine Diesel Oil

HFO - Heavy Fuel Oil

MARPOL - Marine Pollution

PSC - Port State Control

NOx - Nitrogen Oxide

SOx - Sulfur Oxide

HC - Hydrocarbon

CO - Carbon monoxide

DN - Do nothing

NPV - Net Present Value

IRR - Internal Rate of Return

DMCO - De-ratted Maximum Continuous Output

DSCO - De-ratted Service Continuous Output

DNVPS - Det Norske Veritas Petroleum Services

SFOC - Specific Fuel Oil Consumption

MT - Motor Tanker

CCAI - Calculated Carbon Aromaticity Index

PPM - Part per million

NCF - Net cash flow

NPV - Net present value

PSC - Port State Control

DNVPS - DET NORSKE VERITAS Petroleum Services

xvii

LIST OF SYMBOLS

V1 - sludge tank capacity

K1 - 1% clause of sludge

C - Daily fuel oil consumption

D - Period of voyage

np - payback period

P - Initial investment

P - Principal of investment

I - Cash flow

r - discount rate/inflation rate

t - Number of year

kW - Kilowatt

𝑣 (%) - Purifier efficiency

𝑣𝑜 - Amount contaminant outlet flow

𝑣𝑖 - Amount contaminant incoming flow

𝑉1 - Theoretical value

𝑉2 - Maker’s expectation

𝑉𝑎 - Actual sludge production

𝐺𝑟𝑜 - Specific gravity (15/4°C),

𝑃𝑒 - Engine power obtain by Main Engine operating data

𝐶𝑜 - Fuel consumption for one (1) hour by Flow Meter

𝑡1 - Inlet temperature at Flow meter

SI - saving generates from valuable burnable fuel oil in t year

OS - Operator reduction cost (Less sludge handling) in t year

SV - Resale value in t year

OC - Operating cost in t year

MC - Maintenance cost in t year

FO - Fuel oil

xviii

m3 - cubic meter

mt - metric ton

𝐸𝑃 - Electric motor and feed pump power consumption

𝐺𝑃 - Total power consumption at normal sea going,

𝐺𝑓𝑜 - Fuel oil consumption for Generator engine,

Dt - depreciation charge for year t

B - First cost

S - Estimated salvage value

N - Recovery period

D - Depreciation rate 1/n

R - Without Homogenizer / Untreated fuel

H1+H2 - With homogenizer / Homogenized fuel

M/E - Main engine

Kt - knots

Kg/m3 - kilogram per cubic meter

mm/s2 - millimeter per second

cSt - centistokes

% v/v - percentage of volume

% m/m - percentage of content

Mg/kg - Milligram per kilogram

° C - Degree Celsius

MJ/kg - Mega joule per kilogram

xix

LIST OF APPENDICES

APPENDIX TITLE PAGE

A MT Bunga Kasturi Engine Log Book 114

B Data records on Daily Basis 131

C MT Bunga Kasturi Main Engine Performance Sheet 162

D Sludge Production Record 168

E Fuel Oil Properties Record 170

F Fuel Oil & Sludge Oil Samples Record 175

G Exhaust Emission Record 178

H Main Engine –Mean Effective Pressure 180

I Fuel Oil Samples Delivery Form 183

CHAPTER 1

INTRODUCTION

1.1 Background

Today the world’s fleet includes approximately 55% slow speed diesel, 40%

medium speed diesel and 5% other engine types (Rischmann, 2005). Prior to 1970

marine fuel quality was fairly predictable and did not seem to be a major cause for

concern. Residual fuels were purchased for boiler and slow speed diesel engine

consumption both for marine and shore installations, where they were a viable

alternative to solid fuels or gas. At that time residual fuels may found under the titles

or short names as ‘Burner Fuel’, ‘Heavy Oil’, ‘Boiler Oil’, and ‘Bunker C’ which

still exist.

Today the efficiency of the oil refinery processes is good and now the

residual fuel is produced using different refinery processes. The heavy fuel oil use

for Marine fuel oil is expensive due to high light crude oil prices (Rischmann, 2005).

Marine fuel oil quality is influenced by the worldwide refinery mix, the variation in

crude oil quality available, and the demand patterns for middle distillate and residual

fuels (American Bureau Shipping, 1984). Implementation of good fuel oil treatment

is essential in order to operate vessel without problems.

2

If new homogenizer system is positioned in the right place of fuel treatment

system, the homogenizer can help to solve operational problems, which may occur

during the use of heavy fuel oil onboard of the vessels.

The research will be based on the installation of Homogenizer onboard

VLCC Bunga Kasturi Lima and to investigate the effectiveness of the homogenizer

equipment onboard fuel oil system.

1.2 Problem Statement

The use of homogenizers in pre-treatment of heavy fuels is controversial, the

major manufacturers of fuel purifier advocate against installation of homogenizer

upstream separators, arguing that it will strongly reduce separation efficiency (Lien

and Kolle, 2002). Previous researcher found that there no significant changes in

separation efficiency between untreated and homogenized fuel could be detected

(Lien and Kolle, 2002).

It is important to investigate to what extent the fuel oil homogenizer system

affects the purifier efficiency, fuel oil consumption, sludge performance and

equipments maintenance.

In MISC Berhad context, the installation of fuel oil homogenizer will be

significant in order to reduce and recover Fuel oil sludge as valuable operative fuel

oil. This research compares the advantages and disadvantages of using homogenizer

and the cost involved. The results are certainly useful to major shipping companies in

term of significant effect, environmental effect and cost to the overall vessel

operation.

3

1.3 Objective of the Research

i. To compare the operational effects on the application of Homogenizer

equipment onboard vessel against without the use of homogenizer

ii. To determine the effectiveness of homogenizer equipment installed on

Very Large Crude Carrier (VLCC) vessel.

1.4 Scope of Research

The scope of the research covers the application of Homogenizer equipment

onboard M.T Bunga Kasturi Lima. The target route of vessel sailing is from

Singapore to Fujairah. Fuel bunkering will be expected in Singapore. Operating

condition such as vessel’s speed, Main Engine output and fuel consumption, will be

monitored.

This study will concentrate on the comparative study with and without the

use of homogenizer on the operational effect for following;

i. Purifier Efficiency ηp

ii. Sludge Reduction νr

iii. Fuel oil properties Fp

iv. Specific fuel oil consumption

v. Exhaust Gas Analysis

The above operational data will be used for economic analysis by using Net

Present Value.

112

REFERENCES

1. Lien, S.I., and Kolle, L.(2002). Project Green Efforts for Existing

Ship.Norwegian Marine Technology Research Institute.

2. Rischmann, J., (2005).Lloyd’s Register Technical Association, Paper No. VII.

Session 2005-2006.

3. American Bureau Shipping (1984).Notes on Heavy Fuel Oil. American

Bureau Shipping.

4. Fisher, C., and Lux, J. (2004).Bunkers-An Analysis of the Practical Technical

and Legal Issue.England: Petro Spot Limited.

5. S.I.T (2007). The Technology of Conditioning Device.[Brochure]

6. Lin, C.Y. and Chen, L.W. (2007).Comparison of Fuel Properties and

Emission Characteristic of Two and Three Phase Emulsion.National Taiwan

University.

7. Burak, S.R.Improving Fuel Oil Usage by Homogenization.Ashland Specialty

Chemical Company: Drew Marine Division

8. Environmental Protection Agency (2009).In use Marine Diesel Fuel.

Environmental Protection Agency. United States of America.

9. Marine Environment Protection Committee (2003).MEPC 103 (49),Guidelines

for onboard NOx Verification Procedure – Direct Measurement and

Monitoring Method. Marine Environment Protection Committee

10. Zainuddin, N.S. (2007).Effectiveness of Sediment Basin and Silt Traps at Oil

Palm Plantations. Master Thesis. University Technology Malaysia.

11. DetNorske Veritas (2009).Engine Damage Working Group Meeting,

Singapore

12. Blanchard, B.S. and Fabrycky, W.J. (2006). System Engineering and Analysis.

Prentice Hall.

13. Blank, L. and Tarquin, A. (2008).Basics of Engineering Economy, McGraw-

Hill Higher Education.

14. Chapter 4, Economic Measures, Page 39

113

15. DetNorske VeritasPetroleum Services (2009).Fuel System Check,

16. Universal Shipbuilding Corporation (2005). Bunga Kasturi Lima - Piping

Diagram of All Systems in Engine Room. Universal Shipbuilding Corporation

Kumamoto Japan.