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Enclosure
1693520-5.4
Page 1 (10) Quality of Heavy Fuel Oil (HFO) B 11 00 0
General
Prerequisites Several international specifications for heavy fuel
oils are existing. The most important specifications
MAN Diesel four-stroke engines can be operated are ISO 8217-2005 and CIMAC-2003. These two
on any crude-oil based heavy fuel oil meeting the specifications are more or less equivalent. Table
requirements listed in Table 1, provided the engine 2 CIMAC Recommendations for residual fuels for
and the fuel treatment plant are designed accord- diesel engines (as bunkered) shows the specifi-
ingly. In order to ensure a well-balanced relation cations CIMAC-2003. All qualities of these specifi-
between the costs for fuel, spare parts and mainte- cations up to K700 can be used provided the fuel
nance and repair work, we recommend bearing in treatment system is designed for these fuel grades
mind the following points. e.g. fuels with a maximum density of 1010 kg/m3
can only be used with modern separation.
Heavy fuel oil (HFO)
Important
Provenance/refining process
Fuel oil characteristics as stated in analysis results
The quality of the heavy fuel oil is largely deter- - even if they meet the above mentioned require-
mined by the crude oil grade (provenance) and the ments - may be not sufficient for estimating the
refining process applied. This is the reason why combustion properties and the stability of the fuel
heavy fuel oils of the same viscosity may differ con- oil. This means that service results depend on oil
siderably, depending on the bunker places. Heavy properties which cannot be known beforehand.
fuel oil normally is a mixture of residue oil and distil- This especially applies to the tendency of the oil to
lates. The components of the mixture usually come form deposits in the combustion chamber injection
from state-of-the-art refining processes such as system, gas passages and turbines. It may, there-
visbreaker or catalytic cracking plants. These proc- fore, be necessary to rule out some oils that cause
esses may have a negative effect on the stability of difficulties.
the fuel and on its ignition and combustion proper-
ties. In the essence, these factors also influence the Blends
heavy fuel oil treatment and the operating results of
the engine. The admixing of engine oils (ULO:used lube oil), of
non-mineral oil constituents (such as coal oil) and
Bunker places where heavy fuel oil grades of stand- of residual products from chemical or other proc-
ardised quality are offered should be given prefer- esses (such as solvents, polymers or chemical
ence. If fuels are supplied by independent traders, waste) is not permitted. The reasons are, for ex-
it is to be made sure that these, too, keep to the ample: the abrasive and corrosive effects, the ad-
international specifications. The responsibility for verse combustion properties, a poor compatibility
the choice of appropriate fuels rests with the en- with mineral oils and, last but not least, the nega-
gine operator. tive environmental effects. The order letter for the
fuel should expressly mention what is prohibited,
Specifications as this constraint has not yet been incorporated in
the commonly applied fuel specifications.
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MAN Diesel
General
A fuel shall be considered to be free of used lube The admixing of chemical waste materials (such as
oil (ULO) if one or more of the elements Zn, P and solvents) to the fuel is for reasons of environmen-
Zn are below the specific limits (Zn: 15 ppm; P: tal protection prohibited by resolution of the IMO
15 ppm; Ca: 30 ppm). Marine Environment Protection Committee of 1st
January 1992.
Vanadium mg/kg
600 »Heavy fuel oil treatment«
Water % vol.
1 »Heavy fuel oil treatment«
Sediment % wt.
0.1
(potential)
Supplementary characteristic values
Aluminium mg/kg max.
08028-0D/H5250/94.08.12
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Characteristics Unit Limit CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC Test method
A30 B30 D80 E 180 F 180 G 380 H 380 K 380 H 700 K 700 reference
Table 2
Page 3 (10)
1693520-5.4
Ash % max.
0.10 0.10 0.10 0.15 0.15 0.15 ISO 6245
(m/m)
Water % max.
(V/V) 0.5 0.5 0.5 0.5 0.5 ISO 3733
CIMAC Recommendations for residual fuels for diesel engines (as bunkered)
or IP 501
Total sediment % max. ISO
potential (m/m) 0.10 0.10 0.10 0.10 0.10
Quality of Heavy Fuel Oil (HFO)
103072
Aluminium plus mg/kg max.
silicon 80 80 80 80 80 ISO 10478
Used lubricating The fuel shall be free of ULO. A fuel shall be considered to be free of ULO if one ore more of the elementsl Zinc,
oil (ULO) Phosphorus and Calcium are below or at the specified limits. All three elements must exceed the same limits
before a fuel shall be deemed to contain ULO.
1) 1 mm2/s = 1cSt
2) Fuels with density close to the maximum, but with very low viscosity, may exhibit poor ignition quality.
3) A sulphur limit of 1,5% mm will apply in SOx Emission Control Areas designated by the IMO, when its relevant Protocol comes into force. There may be local variations.
General
B 11 00 0
MAN Diesel
General
Leaked oil collectors The specified injection viscosity of 12-14mm2/s (for
GenSets 16/24, 21/31, 23/30H, 27/38 and 28/32H:
Leaked oil collectors into which leaked oil and resi- 12 - 18 cSt) and/or fuel oil temperature upstream
due pipes as well as overflow pipes of the lube oil of the engine should be adhered to. Only then will
system, in particular, must not have any connection an appropriate atomisation and proper mixing,
to fuel tanks. Leaked oil collectors should empty and hence a low-residue combustion be possible.
into sludge tanks. Besides, mechanical overloading of the injection
system will be prevented. The specified injection
Supplementary remarks viscosity and/or the necessary fuel oil temperature
upstream of the engine can be seen from the vis-
The following remarks are thought to outline the re- cosity/temperature diagram.
lations between heavy fuel oil grade, heavy fuel oil
treatment, engine operation and operating results. Heavy fuel oil treatment
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MAN Diesel
1693520-5.4
Page 5 (10) Quality of Heavy Fuel Oil (HFO) B 11 00 0
General
• Separators pable of separating water up to a heavy fuel oil density
of 1.01 g/ml at 15° C.
A centrifugal separator is a suitable device for ex-
tracting material of higher specific gravity, such as Table 3, shows the demands made on the separa-
water, foreign particles and sludge. The separators tor. These limit values which the manufacturers of
must be of the self-cleaning type (i.e. with automati- these separators take as a basis and which they
cally induced cleaning intervals). also guarantee.
Separators of the new generation are to be used ex- The manufacturer’ specifications have to be ad-
clusively; they are fully efficient over a large density hered to in order to achieve an optimum cleaning
range without requiring any switchover, and are ca- effect.
1 separator for
100% throughput
Layout of the separators is to be in accordance with lected, it can be expected that the results given in
the latest recommendations of the separator manu- Table 3, for water and inorganic foreign particles in
facturers, Alfa Laval and Westfalia. In particular, the the heavy fuel oil are reached at the entry into the
density and viscosity of the heavy fuel oil are to be engine.
taken into consideration. Consulting MAN Diesel is
required if other makes of separators come up for The results obtained in practical operation reveal
discussion. that adherence to these values helps to particularly
keep abrasive wear in the injection system and in
If the cleaning treatment prescribed by MAN Die- the engine within acceptable limits. Besides, opti-
sel is applied, and if the correct separators are se- mal lube oil treatment must be ensured.
08028-0D/H5250/94.08.12
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MAN Diesel
General
• Water • Ash
Attention is to be paid to very thorough water sep- Heavy fuel oils with a high ash content in the form
aration, since the water is not a finely distributed of foreign particles such as sand, corrosion and
emulsion but in the form of adversely large droplets. catalyst residues, promote the mechanical wear in
Water in this form promotes corrosion and sludge the engine. There may be catalyst fines (catfines)
formation also in the fuel system, which has an ad- in heavy fuel oils coming from catalytic cracking
verse effect on the delivery and atomisation and processes. In most cases, these catfines will be
thus also on the combustion of the heavy fuel oil. aluminium silicate, which causes high wear in the
If the water involved is sea water, harmful sodium injection system and in the engine. The aluminium
chloride and other salts dissolved in the water will content found multiplied by 5 - 8 (depending on
enter the engine. the catalyst composition) will approximately cor-
respond to the content of catalyst materials in the
The water-containing sludge must be removed from heavy fuel oil.
the settling tank prior to each separating process,
and at regular intervals from the service tank. The • Homogeniser
venting system of the tanks must be designed in
such a way that condensate cannot flow back into If a homogeniser is used, it must not be installed
the tanks. between the settling tank and the separator on any
account, since in that case, harmful contaminants,
• Vanadium/sodium and in particular seawater, cannot be separated out
sufficiently.
Should the vanadium/sodium ratio be unfavour-
able, the melting temperature of the heavy fuel oil Flash point (ASTMD-93)
ash may drop into the range of the exhaust valve
temperature which will result in high-temperature National and international regulations for transport,
corrosion. By precleaning the heavy fuel oil in the storage and application of fuels must be adhered to
settling tank and in the centrifugal separators, the in respect of the flash point. Generally, a flash point
water, and with it the water-soluble sodium com- of above 60° C is specified for fuels used in Diesel
pounds can be largely removed. engines.
If the sodium content is lower than 1/3 of the vadi- Low temperature behaviour (ASTM D-97)
um content, the risk of high-temperature corrosion
will be small. It must also be prevented that sodium • Pourpoint
in the form of sea water enters the engine together
with the intake air. The pour point is the temperature at which the fuel
is no longer fluid (pumplike). Since many of the low-
If the sodium content is higher than 100 mg/kg, an viscosity heavy fuel oils have a pour point greater
increase of salt deposits is to be expected in the than 0° C, too, the bunkering system has to be pre-
combustion space and in the exhaust system. This heated unless fuel in accordance with CIMAC A30
08028-0D/H5250/94.08.12
condition will have an adverse effect on engine op- is used. The entire bunkering system should be de-
eration (among others, due to surging of the turbo- signed so as to permit preheating of the heavy fuel
charger). oil to approx. 10° C above the pour point.
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MAN Diesel
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Page 7 (10) Quality of Heavy Fuel Oil (HFO) B 11 00 0
General
Pump ability Preheating of the charge-air in the part-load range
and output reduction for a limited period of time
Difficulties will be experienced with pumping if the are possible measures to reduce detrimental influ-
fuel oil has a viscosity higher than 1,000mm2/s (cSt) ences of fuel of poor ignition qualities. More effec-
or a temperature less than approx. 10° C above the tive, however, are a high compression ratio and the
pour point. Please also refer to “Low temperature in-service matching of the injection system to the
behaviour (ASTM D-97)”. ignition qualities of the fuel oil used, as is the case
in MAN Diesel trunk piston engines.
Combustion properties
The ignition quality is a key property of the fuel. The
An asphalt content higher than 2/3 of the carbon reason why it does not appear in the international
residue (Conradson) may lead to delayed combus- specifications is the absence of a standardised
tion, which involves increased residue formation, testing method. Therefore, parameters such as the
such as deposits on and in the injection nozzles, Calculated Carbon Aromaticity Index (CCAI) are
increased smoke formation, reduced power and in- resorted to as an aid, which are derived from de-
creased fuel consumption, as well as a rapid rise of terminable fuel properties. We have found this to
the ignition pressure and combustion close to the be an appropriate method of roughly assessing the
cylinder wall (thermal overloading of the lube oil ignition quality of the heavy fuel oil used.
film). If the ratio of asphaltenes to carbon residues
reaches the limit value 0.66, and the asphaltene A test instrument utilising a constant-volume
content also exceeds 8 %, additional analyses of combustion technology (FIA fuel ignition analy-
the heavy fuel oil by means of thermogravimetric ser) has been developed and is currently be-
analysis (TGA) must be performed by MAN Diesel ing evaluated at a number of testing laboratories.
to evaluate the usability. This tendency will also be The ignition quality of a fuel is determined as an ig-
promoted by the blend constituents of the heavy nition delay in the instrument that is converted to an
fuel oil being incompatible, or by different and in- instrument-related cetan number (FIA-CN or ECN).
compatible bunkering being mixed together. As a It has been observed that fuels with a low FIA ce-
result, there is an increased separation of asphalt tan number or ECN could, in some cases, lead to
(also see “Compatibility”). operational problems.
Ignition quality As the fluid constituent in the heavy fuel oil is the
determining factor for its ignition quality and the vis-
Cracked products which nowadays are preferred as cous constituent is decisive for the combustion qual-
low-viscosity blend constituents of the heavy fuel ity, it is the responsibility of the bunkering company
oil in order to achieve the specified reference vis- to supply a heavy fuel oil grade of quality matched
cosity may have poor ignition qualities. The cetane to the Diesel engine. Please refer to Figure 2.
number of these constituents should be > 35. An in-
creased aromatics content (above 35 %) also leads
to a decrease in ignition quality.
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MAN Diesel
General
16/24 1
20/27
21/31 32/44CR
V D CCAI 23/30 32/36 40/54
1 800 800 25/30 32/40 48/60
27/38 40/45 52/55B
28/32 52/55A 58/64
820
810
840
820
2
860
830
3 880 A
840
4 900
5 850
920
940 860
10 2
960 870 B
20
980 880
30
50 1000 890
100 1020
900
200 C
1040
400 910
1000
920
5000
930
20000
50000
Figure 2 Nomogram for the determination of CCAI assignment of CCAI ranges to engine types
CCAI can also be calculated with the aid of the following formula:
CCAI = D - 141 log log (V+0.85) - 81
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MAN Diesel
1693520-5.4
Page 9 (10) Quality of Heavy Fuel Oil (HFO) B 11 00 0
General
Sulphuric acid corrosion The use of fuel additives during the guarantee pe-
riod is rejected as a matter of principle.
The engine should be operated at the cooling water
temperatures specified in the operating manual for Additives currently in use for Diesel engines are
the respective load. If the temperature of the com- listed in Table 4, together with their supposed ef-
ponent surface exposed to the acidic combustion fect on engine operation.
gases is below the acid dew point, acid corrosion
can no longer be sufficiently prevented even by an
alcaline lubricating oil. Precombustion • Dispersants/stabilisers
• Emulsion breakers
If the lube oil quality and engine cooling meet the • Biocides
respective requirements, the BN values (see “Qual-
ity of lube oil (SAE40) for heavy fuel oil operation Combustion • Combustion catalysts (fuel
(HFO)”) will be adequate, depending on the sulphur economy, emissions)
concentration in the heavy fuel oil. Postcombustion • Ash modifier (hot corrosion)
• Carbon remover (exhaust
Compatibility
system)
The supplier has to guarantee that the heavy fuel Table 4 Additives to heavy fuels Classification/
oil remains homogenous and stable even after effects
the usual period of storage. If different bunker oils
are mixed, separation may occur which results in
sludge formation in the fuel system, large quantities Low sulphur HFO
of sludge in the separator, clogging of filters, insuf-
ficient atomisation and high–residue combustion. From an engine manufacturer‘s point of view there
is no lower limit for the sulphur content of HFO. We
In such cases, one refers to incompatibility or insta- have not experienced any trouble with the currently
bility. The heavy fuel oil storage tanks should there- available low sulphur HFO, that are related to the
fore be emptied as far as possible prior to rebunker- sulphur content or specific to low sulphur HFO.
ing in order to preclude incompatibility. This may change in the future if new methods are
applied for the production of low sulphur HFO (de-
Blending heavy fuel oil sulphurization, uncommon blending components).
MAN Diesel will monitor developments and inform
If, for instance, heavy fuel for the main engine and our customers if necessary.
gas oil (MGO) are blended to achieve the heavy
fuel oil quality or viscosity specified for the auxil- If the engine is not operated permanently on low
iary engines, it is essential that the constituents are sulphur HFO, then the lubricating oil should be se-
compatible (refer to “Compatibility above). lected according to the highest sulphur content of
the fuels in operation.
Additives to heavy fuel oils
08028-0D/H5250/94.08.12
Safety/environmental protection
MAN Diesel engines can be economically operated
without additives. It is up to the customer to decide Wrong handling of operating media may cause
whether or not the use of an additive would be ad- harm to health, safety and environment. Respec-
vantageous. The additive supplier must warrant tive instructions of the manufacturer have to be fol-
that the product use will have no harmful effects on lowed.
engine operation.
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MAN Diesel
General
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