ICHEM the speed of chemical reaction without taking part in

the reaction is called catalysis.

Petroleum (L. petroleum, from Latin: petra rock +
oleum oil or crude oil is a naturally occurring, toxic, •Over 80% of industrial processes involve catalysts.
flammable liquid consisting of a complex mixture of
hydrocarbons of various molecular weights, and other
organic compounds, that are found in geologic
formations beneath the Earth's surface.

Petroleum is recovered mostly through oil drilling.

It is refined and separated, most easily by boiling

point, into a large number of consumer products, from
gasoline and kerosene to asphalt and chemical
reagents used to make plastics and pharmaceuticals.
FUEL OIL Properties

• Fuel oil is a fraction obtained from petroleum

distillation, either as a distillate or a residue
• Fuel oil is any liquid petroleum product that is
burned in a furnace to generate heat.
• Fuel oil is also the heaviest commercial fuel that is
produced from crude oil.

PETROLEUM RECOVERY PROCESS There are two basic types of fuel oil: Distillate fuel oil
(lighter, thinner, better for cold-start) and Residual fuel
oil (heavier, thicker. more powerful, better
lubrication). Often some distillate is added to residual
fuel oil to get a desired viscosity. They are only' used
for industrial and marine applications because.
although fuel oil is cheaper than diesel oil. it is more
difficult to handle (must be settled preheated and
filtered and leave a sludge at the bottom of the tanks).

In the maritime field another type of classification is

used for fuel oils:

• MGO (Marine gas oil) – roughly equivalent to

No. 2 fuel oil, made from distillate only
• MDO (Marine diesel oil) – A blend of heavy
gasoil that may contain very small amounts of
black refinery feed stocks, but has a low
viscosity up to 12 cSt so it need not be heated
for use in internal combustion engines
• IFO (Intermediate fuel oil) A blend of gasoil and
heavy fuel oil, with less gasoil than marine
Catalysis: diesel oil
• HFO (Heavy fuel oil) – Pure or nearly pure
Definition: Catalysts are substances that help to
residual oil, roughly equivalent to No. 6 fuel oil
speed up the process of chemical reactions without
• MFO (Marine fuel oil) – same as HFO (just
taking part in the reaction. This process of speeding up
another “naming”)
Number 1 fuel oil is volatile distillate oil intended for
vaporizing pot-type burners. It is the kerosene refinery
cut that boils off right after the heavy naphtha cut used
for gasoline. Older names include coal oil, stove oil
and range oil.
Number 2 fuel oil is distillate home heating oil. Trucks
and some cars use similar diesel fuel with a certain
number limit describing the ignition quality of the fuel.
Both are typically obtained from the light gas oil cut.
Gas oil refers to the original use of this fraction in the
late 19th and early 20th centuries - the gas oil cut was
used as an enriching agent for carbureted water gas
manufacture.
Number 3 fuel oil was distillate oil for burners
requiring low-viscosity fuel. ASTM merged this grade
into the number 2 specification, and the term has
been rarely used since the mid-20th century.
Number 4 fuel oil is commercial heating oil for burner
installations not equipped with preheaters. It may be
obtained from the heavy gas oil cut.
Number 5 fuel oil is a residual-type industrial heating
oil requiring preheating to 170 – 220 °F (77 – 104 °C) for
proper atomization at the burners] This fuel is
sometimes known as Bunker B. It may be obtained
from the heavy gas oil cut, or it may be a blend of
residual oil with enough number 2 oil to adjust
viscosity until it can be pumped without preheating.
Number 6 fuel oil is a high-viscosity residual oil
requiring preheating to 220 – 260 °F (104 – 127 °C).
Residual means the material remaining after the more
valuable cuts of crude oil have boiled off. The residue
may contain various undesirable impurities including
2 percent water and one-half percent mineral soil.
This fuel may be known as residual fuel oil (RFO), by
the Navy specification of Bunker C, or by the Pacific
Specification of PS-400.
Density
• Ratio of the fuel's mass to its volume at 15 deg C
• kg/m3
• Useful for determining fuel quantity and quality.
Specific gravity
• Ratio of weight of oil volume to weight of same
water volume at a given temperature
• Specific gravity of water is 1.
• no unit (ratio)
Viscosity
• Measure of fuel's resistance to flow
• Most important characteristic for storage and use
• Decreases as temperature increases
• Centistokes (cSt)
Pour Point
• Lowest temperature at which fuel will flow.
• Indication of temperature at which fuel can be
pumped.
Flash Point
• Lowest temperature at which a fuel can be heated
so that the vapor gives off flashes when an open
flame is passes over it.
Water Content
• Free or emulsified form
• Can damage furnace surface and impact flame
Sulphur content
• Depends on source of crude oil and less on the
refining process.
• Sulphuric Acid causes corrosion.
Ash content
• Inorganic material or salts in fuel
• (Salts — compounds: sodium, vanadium,
calcium, magnesium, silicon, iron, aluminum,
nickel, etc.
• Corrosion of burner tips and damage to materials
and equipment at high temperatures
Carbon Residue
• Tendency of oil to deposit a carbonaceous solid
residue on a hot surface.
Calorific value Fuel Oil Viscosity

• Heat or energy produced. • Measure of fuel’s resistance to flow / Centistokes

• Gross calorific value (GCV): vapour is fully (cSt)
condensed. • Most important characteristic for storage and use
• Net calorific value (NCV): water is not fully • Decreases as temperature increases.
condensed.
Most important characteristic of fuel oil

• storage
Explain the significance why two different grades of • use
bunker fuel oil may not be mixed onboard:
Influence
HFO Compatibility
• pre-heating
Fuel compatibility: The tendency of fuels to produce • handling
deposits when mixed.
• storage
Problems of incompatibility between residual fuels • atomization
are rare but when those happen the results are severe.
Too viscous FO
Typical problems are:
• difficult to be pumped
• sludging • hard to light the burner
• blockage of bunker • difficult to handle
o service tanks
PROBLEMS IN VISCOSITY
o pipe runs
o filters • Poor atomization may result in the formation of
o centrifuge bowls carbon deposits on the burner tips or on the walls.
In extreme circumstances, the only remedy is manual CORRECTIVE ACTION
removal of the sludge build up.
• Therefore, pre-heating is necessary for proper
It is impossible to give precise advice on the atomization.
probability of compatibility problems between two
fuels, but the risk of incompatibility can be ranked. Sulphur content (High and Low) effect on engine
operations
Residual Fuel Stability
SULPHUR - An element which is chemically bonded
Stability of residual fuel the ability of a fuel to remain within the molecules that constitute crude oil. It
in an unchanged condition the resistance of an oil to cannot be economically removed from fuel oil at the
breakdown. refining state, but may be blended to acceptable
levels. Sulphur can lead to low temperature corrosion
Unstable of residual fuel will: produce a deposit of
through the formation of sulphuric acid and therefore
asphaltic sludge time and/or temperature.
affects the cylinder wear rate. Its effects in an engine
Fuel is manufactured as stable will not produce can be reduced by the use of appropriate cylinder
asphaltic sludge it does not necessarily mean that two lubricants.
(2) stable fuels are compatible when mixed together.
Internal Combustion Engines Types of lubrication REGIME

Working Principle Fluid Film Lubrication (Hydrodynamic Lubrication):

• (thick film lubrication)

• Example: lubrication in journal bearings

Mixed Film Lubrication:

• Example: lubrication in ball bearings and roller

bearings

Boundary Lubrication:

• (thin film lubrication)

• Example: lubrication between gears

What is meant by Fluid Film Lubrication

Hydrodynamic Lubrication?

• Moving surfaces are separated completely by the

Lubricating Oils – LO pressure of a continuous unbroken film or a layer
of lubricant, generated by the movement of the
• is responsible for Lubrication and Cooling of the two surfaces relative to each other.
parts which are operating relative to each other.
• Essential requirement is formation of a wedge of
• enables the formation of a film of oil between the lubricants between surfaces.
moving parts, which reduces friction and wear.
• Thickness of film 0.025 — 0.10 mm.
Types of lubricating oil • Happens in lubrication for Journal Bearing,
Bottom End Bearing, Tilting Pad Thrust Bearing
Mineral Oils – are obtained
from the processing of crude
oil

Synthetic Oils – are created

by the combination of
mineral and artificially-made
additives to make the
products suitable for high-
performance engines.
 Viscosity index

• The rate of change of viscosity of an oil with

respect to change in temperature.
• An oil with low viscosity index has greater change
of viscosity with change in temperature.

Detergency

• Obtained by adding metallic based additives to

prevent the buildup of small deposits in the metal
surface
• It removes the deposits from the ring pack area
and keeps the combustion space as clean as
possible

Dispersancy

• Prevents impurities to mix up with itself and keeps

What is meant by Boundary Lubrication? them suspended on the surface
• It exists when a full-fluid film lubrication is not • This makes it easy for the separator to remove it
possible. from the oil
• The sliding surfaces are separated by only a thin Load Carrying Capacity
film of lubricant.
• High friction between the surfaces and some • Must be enough to withstand the pressure of the
degree of metal to metal contact occurs load which are subjected to different internal parts
• Lubricant oil film decreases, until asperities of of the Marine Engine
mating surfaces touch Oxidation Resistance
What is meant by Mixed Film Lubrication (Elasto- • LO is always in contact with air and thus oxygen
Hydrodynamic Lubrication)? presence in oil is inevitable
• Applies to line contact or nominal point between • At high temperature of the oil, the oxidation
rolling or sliding surfaces, such as rolling contact increases leading to sludge formation, acid
bearings. production, and bearing corrosion
• Thin film or squeeze film lubrication limits metal to TOTAL BASE NUMBER (TBN)
metal contact.
• Elastic deformation of the metals occurs, and • Controls the acidic corrosion caused by Sulphuric
there is an effect of high pressure on the lubricant. Acid from burning of FO
• In Two-Stroke engines, separate grade of LO is
Lubricating Oil Properties used as Cylinder Oil and its Alkalinity depends on
• Viscosity / Viscosity Grade / Viscosity Index the Engine Fuel grade
• Detergency Thermal Conductivity
• Dispersancy
• Load Carrying Capacity • The internal parts of the engine are always in
• Oxidation Resistance movement producing heat energy
• (TBN) Total Base Number • The LO must cool down the internal parts to avoid
• Thermal Conductivity wear down due to thermal stresses
• Flash Point
• Demulsification Number
• Oiliness
Flash Point

• Should be higher so that in case of increase in

temperature, fire hazard can be avoided.
• Normally, flash point of LO is higher than 220 C.

Demulsification Number

• Contamination of water in oil is difficult to be

avoided
• The demulsification number is the degree of
separation of water from the oil in the separator or
when stored in the settling tank

Oiliness

• The property of the oil to stick around to the

surface.
The branch pipe for a particular cylinder may feed the
• Useful in situations such as those involving journal
main bearing, for instance.
bearings.
Some of this oil will pass along a drilled passage in the
LUBRICATING OIL SYSTEM
crankshaft to the bottom end bearing and then up a
drilled passage in the connecting rod to the gudgeon
pin or crosshead bearing.

After use in the engine the lubricating oil drains back

to the sump or drain tank for re-use.

LUBE OIL STORAGE TANK

Clean oil can be provided from a storage tank.

SUMP TANK

Lubricating oil for an engine is stored in the bottom of

the crankcase, known as the sump, or in a drain tank
located beneath the engine.

STRAINER, PUMPS, FILTERS

Oil is drawn from sump tank through a strainer, by of a

pair of pumps, into one of a pair of fine filters.

COOLER, DISTRIBUTION MANIFOLD

It is then passed through a cooler before entering the
engine and being distributed to the various branch
pipes.
DISTRUBITION MANIFOLD
The branch pipe for a particular cylinder may feed the
main bearing, for instance.
Large slow-speed diesel engines are provided with a
separate lubrication system for the cylinder liners.
Lubricators
Oil is injected between the liner and the piston by
lubricators which supply their individual cylinder.
Cylinder Oil FUEL OIL SYSTEM

• is a special type of oil

• is not recovered, upon use
• in between liner and piston:
o lubricates
o assists in forming a gas seal
o contains additives which clean the
cylinder liner

LUBE OIL CONTAMINANTS

• WATER
• Sources: Condensation, Combustion By-
products, Leakages
• Effects: Rust and Corrosion, Reduced
Lubricating Characteristics – Reduced
Viscosity, Reduced Oil Film, Causes Wear
• COMBUSTION BY-PRODUCT
• Soot, Particulates, Unburnt Fuel
• Effects: Soot – Carbon, Burned Cylinder Oil.
Particulates – Abrasive Wear, L.O. Thickening,
Clogging. Unburnt Fuel – Lowered Viscosity,
Wear
• DUST
• Effects – Highly Abrasive, Can plow/Ridge
Surfaces

Filters and Strainers

Mechanical separation of solid contaminants from oil

systems (fuel and lubricating) is achieved by the use
of filters and strainers. A strainer is usually a coarse
filter to remove the larger contaminating particles.
Both are arranged as full flow units, usually mounted
in pairs (duplex) with one as a standby,

Fuel Oil System Preparation (Pre-Departure)

Check Boiler fuel oil

Check for oil leakages
pump

Check A/E fuel oil

supply unit, Drain HFO settling tanks &
circulating & supply check levels and temperature
pump.

Check M/E HFO

Drain HFO service tanks &
supply & circulating
check levels and temperature
pump.

Drain MDO settling tanks &

Check HFO purifiers
check levels and temperature

Drain MDO service tanks &

Check bilge wells.
check levels and temperature