8-10% FUEL (F.O.

) SAVINGS
AT A VERY LOW CAPITAL COST

A NEW GENERATION FUEL EFFICIENCY ENHANCER

Almost complete fuel combustion

Reduced Carbon deposition
BENEFITS Reduced black smoke
Less air requirement
Reduced SO3, CO & NOx
 A NEW GENERATION FUEL EFFICIENCY ENHANCER

INTRODUCTION ATOMIZATION PROCESS COMPLETE COMBUSTION

OF FURNACE OIL WITH ZYCRYL-15

ZYCRYL-15 (patented) improves
fuel efficiency of Furnace Oil (FO./
Bunker oil no 6) by 8 - 10%; by
addition of 4% water in it, using low
pressure emulsification technique
and low shear, at low capital
investment. A furnace or a boiler
utilizes the energy generated by
combustion of fuel. The efficiency of
a furnace/ boiler; depends on the
combustion system and utilization
of the heat generated during the
combustion of fuel.
A typical 6-20 bar pressure pumping
to burner atomizer, produces a
spray of fuel droplets of 100 to 200
microns, (depending on fuel quality,
temperature & atomizer design).
Typically, the larger fuel droplets do
not burn completely and leave
unburnt carbon, which collects on
heat transfer surfaces. These
carbon particles can also escape as
particulate matter in exhaust gases.
Poor quality burning also leads to
higher percentage of Carbon
Monoxide in flue gases.
The fuel droplets are further divided
as a result of the explosive
vaporization caused by the rapid
heating of the water droplets
dispersed within the individual fuel
droplet. The vaporization of water, in
turn, produces a rapid expansion of
the surrounding F.O., fragmenting
the FO into a vast number of smaller
fuel droplets. This process ensures
almost complete combustion of FO.
due to the higher surface area to
volume ratio of droplet.
(Refer to diagram (b) below)

CONVENTIONAL COMBUSTION A

Exhaust Gases

Carbon particles

B
COMPLETE COMBUSTION WITH ZYCRYL-15

Oil droplet size

100 microns Oil droplet size 15-20 microns

Water droplet

Water in oil emulsion below 1000 C

Heat Water in oil emulsion 100 - 2500 C

APPLICATION PROCEDURE
Zycryl-15 emulsion technology can be utilized by using following steps:

STEP-1 EMULSION PREPARATION

First prepare an emulsion of Fuel Oil with water in presence of Zycryl-15 in a separate vessel (Emulsion preparation Tank)

STEP-2- MIXING EMULSION WITH FUEL OIL

Prepare Emulsified Fuel oil (ready for use) by mixing above emulsion with main Fuel Oil.

RECIPE FOR EMULSION

INGREDIENTS PARTS BY WEIGHT (%) PARTS BY VOLUME (%)

(for 1000 parts fuel) (for 1000 galons fuel)
STEP 1.
EMULSION PREPARATION FURNACE OIL 49 % 50 gallon
(in Emulsion Preparation Tank) Zycryl 15 2 gallon
49 %

Water 2% 39.2 gallon

Total 100 % 100 gallon

PROCEDURE
Take 49 parts of F.O. and 2 parts of Zycryl-15 in the emulsion preparation tank.
Mix it thoroughly for 5 minutes under high speed pumping.
Slowly (over a period of 90 minutes) add 49 parts of water at room temperature along the same pumping line.
Continue pumping (mixing) for 60 minutes.
The emulsion is now ready for mixing in the main fuel.

RECIPE For 1000 gallon mix EMULSIFIED FUEL

ACTUAL WEIGHT
STEP 2. INGREDIENTS PARTS BY WEIGHT (%) (for 1000 galons fuel)
MIXING EMULSION WITH FUEL OIL Emulsion as per step A 8 - 12 % 80-1200 gallon
(in main storage tank)
Fuel oil 8 - 92 % 880 - 920 gallon

Total 100 % 1000 gallon

PROCEDURE
Mix 8 part this above emulsion in 88 - 92 part of fuel oil (Furnace oil/HFO/Bunker oil) in the Day Tank / Main storage tank.
Mix properly by giving 2 turns for homogenous mixing. This emulsified fuel oil is now ready to be used in boilers/furnaces.

ADVANTAGES

FEATURES BENEFITS

Reduced fuel consumptionI Improved efficiency by 8-10 %

Shorter and hotter flame Larger radiant cooling zone

Less air requirement
Increased CO2 concentration
Reduced Fire side additive
SPECIFICATIONS
Appearance : Pale yellow viscous liquid
Reduced air pollution (less Sox, Nox )
pH : Neutral
Less SPM, Carbon (Soot) & CO generation
Solid content : 98 + 2 %
Better thermal efficiency at reduced cost

Better combustion Reduced Carbon particles

STORAGE
Zycryl-15 should be stored at ambient temperature. At lower temperatures it can have freezing tendencies. This will not have any
adverse effect on performance or emulsion preparation. Zycryl-15 has a shelf life of 24 month.
 ZYCRYL-15

Water Tank

2-3 feet Emulsion

Preparation
Tank

V4

V2

Main V6
Storage
Tank
To
Day
V3 Tank

(Furnace Oil) V5

Main Pump

V1
Line from F.O. Storage tank

STANDARD OPERATING PROCEDURE

STEP-1 Close valve V-6, V-4, V-3, V-5. Open valves V-1 & V-2.
Pump 49% F.O. to emulsion preparation tank.
Close valve V-1. Open valve V-4.
Add 2% Zycryl-15 and start circulation in the tank.
Circulate for 5 minutes.

STEP-2 Open valve V-3 and slowly add 49% water within 90 minutes.
Close V-3 and continue circulation for 15-20 minutes to ensure homogenization.

STEP-3 Mix 8% of the above prepared emulsion with your regular F.O.

Now follow either step-4 or step-5

STEP-4 For adding the emulsion in the main storage tank, close valve V-2 and open V-6 & V-1.
When the emulsion tank is empty, close V-4 and continue circulation for allowing 2-3 turns

STEP-5 For adding F.O. + Emulsion to the day tank, close V-2 and open V-1, V-5, ensure that the
emulsion tank is empty before day tank is full, to ensure uniform emulsion mixing.

Disclaimer
the information in this leaflet is given in good faith but without warranty. We recommend that before using our products, the customer should make his own tests to determine the
suitability of products for his own purpose under his operating conditions. As the circumstances under which our products are stored, handled and used; are beyond our control, we can not
assume any responsibility for their use by the customer.

ZYDEX INDUSTRIES Asia-Pacific:

25-A, Gandhi Oil Mill Compound, Mr. Manish Shah, Grace & Sachi
Gorwa, Vadodara - 390 016 (Gujarat) India #06-15, No. 1 Bukit batok street 25, Singapore 658882
Phones: + 91 265 2280120, 2283386, 2280865, 2283742 Phone/Fax : +65 96702884
Fax: + 91 265 2280872 Email : sachis@singnet.com.sg
E-mail: info@zydexonline.com manish@gracensachi.com
Website www.zydexindustries.com Website : www.gracensachi.com