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Peyton Ondeo-Nalco Fuel Field Manual

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Contents

Introduction ...................................................................

vii

1. A Problem Solving Technique ...............................

1

Observations from Distribution Terminal Tank Records ........

3

Cause of the Problem ...........................................................

4

2. Refining Processes Used in Fuel Production ......

5

A. Distillation ........................................................................

5

B. Thermal Cracking .............................................................

9

C. Visbreaking ......................................................................

10

D. Fluid Catalytic Cracking (FCC) .........................................

10

E. Hydrotreating or Hydroprocessing ....................................

17

F. Catalytic Hydrocracking ...................................................

18

G. Isomerization ...................................................................

19

H. Catalytic Polymerization ...................................................

19

I. Catalytic Reforming ..........................................................

20

J. Alkylatlon .........................................................................

22

K. Coking .............................................................................

23

L. Finishing Processes .........................................................

25

3. Critical Properties of Crude Oil and Common

 

Hydrocarbon Fuels .................................................

31

A. Crude Oil .........................................................................

31

B. Automotive Gasoline ........................................................

39

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v

vi Contents

 

C. Aviation Gasoline .............................................................

47

D. Jet Fuel or Aviation Turbine Fuel .....................................

50

E. Diesel Fuel and Fuel Oil ...................................................

54

F. Marine Fuels ....................................................................

61

G. Burner Fuels ....................................................................

64

H. Residual Fuel Oil ..............................................................

66

4. Common Sources of Fuel Performance

 

Problems .................................................................

71

A. Environmental Sources ....................................................

71

B. Wax in Petroleum Products ..............................................

85

C. Low Volatility ....................................................................

94

D. Diesel Fuel Cetane Number and Cetane Index

 

Determinations .................................................................

96

E. Hydroperoxides and Olefins .............................................

101

F. Microorganisms, Sediment, and Water ............................

105

5.Utilizing Physical and Chemical Property Measurements to Identify Sources of Fuel

Problems .................................................................

111

A. High Viscosity ..................................................................

111

B. Low Viscosity ...................................................................

114

C. High Sulfur Content ..........................................................

116

D. High Aromatic Content .....................................................

120

E. High Paraffin Content .......................................................

125

F. Low Flash Point ...............................................................

130

G. High Carbon Values for Micro Method, Conradson,

 

and Ramsbottom Carbon Number Determinations ...........

131

H. Distillation Profile .............................................................

133

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Contents

vii

6. Solving Fuel Problems by Using Chemical

 

Additives .................................................................

137

A. Antioxidants .....................................................................

137

B. Distillate Fuel Stabilizers ..................................................

140

C. Demulsifiers and Dehazers ..............................................

143

D. Microbiocides ...................................................................

146

E. Wax Crystal Modifiers ......................................................

149

F. Corrosion Inhibitors ..........................................................

152

G. Fuel Sweetening Additives ...............................................

160

H. Cetane Improver ..............................................................

160

I. Detergents and Dispersants .............................................

161

J. Lubricity Improver ............................................................

165

K. Problems Related to Fuel Additives .................................

168

7. Test Methods Used to Identify and Solve Fuel

 

Problems .................................................................

175

A. Common Test Methods Used to Determine the

 

Oxidative Stability of Fuel .................................................

175

B. Testing the Copper Corrosion Properties of Fuel .............

181

C. Common Test Methods Used to Determine the

 

Ferrous Metal Corrosion Properties of Fuel ......................

182

D. Common Test Methods Used to Determine the

 

Emulsion Tendencies of Fuel ...........................................

183

E. Common Test Methods Used to Determine the Low-

 

Temperature Performance of Fuel ...................................

188

F. Fuel Cetane Engine Number Testing ...............................

195

G. Hydrogen Sulfide Determination in Fuel ...........................

196

H. Additional Analytical Tests Used to Solve Fuel

 

Problems .........................................................................

198

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viii Contents

 

8. Identifying and Solving Specific Fuel

 

Problems .................................................................

201

Problem: Difficulty in Pumping Diesel Fuel at Low

 

Temperatures / Fuel Filter Plugging ......................

201

Problem: Increase in Pour Point of Residual Fuel Oil or

 

Crude Oil After Heating or Shearing .....................

203

Problem: Reversion and Actual Increase in the Pour

 

Point of a Crude Oil or Residual Fuel Oil ..............

204

Problem: Poor Combustion Quality / Fuel Economy /

 

Power of Diesel Fuel .............................................

205

Problem: Poor Flame Quality of Kerosene ...........................

206

Problem: Diesel Fuel Darkens in Color and Sediment

 

Forms ...................................................................

207

Problem: Rusting Is Identified on Metal Components ...........

209

Problem: Ferrous Metal Corrosion Inhibitor Fails to

 

Prevent Rusting of Metal Components .................

210

Problem: Haze or Emulsion Is Found in Fuel .......................

212

Problem: Jet Fuel Fails “WSIM” Test ...................................

213

Problem: Jet Fuel Fails “JFTOT” ..........................................

214

Problem: Jet Fuel Fails Particulate Contamination Test .......

215

Problem: Fuel Corrodes Copper, Bronze, or Brass

 

Components .........................................................

216

Problem: Hydrogen Sulfide in Fuel ......................................

217

9. Components of Fuel and Fuel Additive

 

Storage and Injection Systems .............................

219

A. Metals ..............................................................................

219

B. Plastics and Elastomers ...................................................

229

C. Chemical Storage and Injection Equipment ......................

230

D. Vehicle Fuel Tanks ..........................................................

237

E. Diesel Fuel Filters ............................................................

237

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Contents

ix

F. Diesel Fuel Injection Pumps .............................................

238

10. Safe Shipping and Hazard Information for

 

Common Fuels, Oils, and Solvents .......................

241

A. Hazardous Material Shipping Guidelines .........................

241

B. Hazard Information for Common Fuels and Refined

 

Products ..........................................................................

246

C. Hazard Class Descriptions ...............................................

250

11. Fuel Performance Property and Problem

 

Solving Guide .........................................................

253

1. High Viscosity ..................................................................

253

2. Deposit Analysis ..............................................................

262

12. Synthetic and Alternative Fuels ............................

271

A. Coal .................................................................................

271

B. Biomass ...........................................................................

277

C. Synthesis Gas to Methanol ..............................................

287

D. Oil Shale ..........................................................................

289

E. Tar Sands or Oil Sands ....................................................

291

F. Properties and Performance of Alternative Fuels .............

295

References ....................................................................

309

Appendices ...................................................................

321

Appendix 1. Heat of Combustion of Fuels -

 

Approximate BTU-Gravity Relation ..................

321

Appendix 2. Factors for Converting Volumes to 60°F ...........

322

Appendix 3. Reduction of Observed API Gravity to API

 

Gravity at 60°F .................................................

327

Appendix 4. Galvanic Series of Metals and Metal

 

Alloys ...............................................................

333

Appendix 5. Composition of Synthetic Sea Water

 

Utilized in ASTM D-665-B ................................

334

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