Технічні науки

Pastuh Dmitriy

Specialist in the field of Smart Transportation and

modern engineering approaches to transport system management

Odesa National Polytechnic University 

https://www.doi.org/10.25313/2524-2695-2025-2-07-18

ABOUT NEW DESIGN CONCEPT OF FAD

About new design concept of FAD (Device for activating the fuel mixture)

Summary. New design concept of FAD, include the device security requirements of Dor Chemicals and other companies; The dimensions of the device are extremely small; In the picture, in real scale factor is demonstrated FAD – 30 with maximal fuel flow = 285 liter per hour

Today’s internal and open combustion systems (engines, boilers, turbines, etc.) are only as effective as the fuel used in the process. Today’s fuels are sub-optimal in three ways; they are not homogenous, they are limited in their blending options and they require significant amounts of added oxygen during combustion to complete the process. Turbulent Energy has designed, prototyped and tested technologies, which can be packaged, scaled and integrated with all thermodynamic combustion systems to improve liquid fuel characteristics and therefore improve combustion.

Liquid fuels including distillates and synthetics are often not entirely homogenous at the time of distilling or blending and often loose their homogeneity over a period of time. Clotting and phase separation can occur and the fuels performance characteristics are degraded as a result. This change in the fuel’s composition can also hamper the combustion process and cause damage to fuel system components. Non-chemical methods are needed to ensure fuels are uniform and the combustion process is not compromised.

In addition to ability to homogenize today’s standard fuels (gasoline, diesel, kerosene, etc.), Turbulent Energy can also “blend” those fuels while homogenizing them to create “new” fuel composites (i.e. emulsions). Completely uniform and homogeneous oil-in-water and water-in-oil emulsions are possible with any liquid fuel, including heavy fuel oil.

Key words: Internal combustion engine, Fuel mixture, Fuel mixture activation, Fuel mixture activation device, Fuel emulsion, Methanol, Ethanol, Dynamic homogenization, Simultaneous mixing and homogenization of the fuel mixture, Incompressible fuel mixture, Compressible fuel mixture, Diesel engine fuel line, Internal combustion engine fuel line.

For online stream mixing heavy diesel oil with methanol, a system of dynamic mixing, activation and homogenization, which consists of two parallel connected devices, with a diameter of 25 millimeters worker

In general (at the top level) device mixes the heavy flow of diesel fuel (fuel oil) with methanol – version 1; Mixing with steam in the same configuration – version -2;

Mix Ratio – 40% of heavy diesel fuel (fuel oil), 60% methanol or 80% of HFO with 20% of steam, – version -2

This device has two inputs for heavy diesel fuel (fuel oil), – of which one axial input capacity of 60% of the total number and the integral one radial entrance accommodates 40% of the total amount of heavy diesel fuel supplied to the mixing

The device has an additional integral radial entrance, designed for 100% methanol supplied to the mixing or for 20% of steam;

After mixing and homogenizing simultaneously, it is fed to the nozzle of the boiler, but only part of the stream is injected, and the rest of the mixture returns to a special container

In a special container there is a standard device for re-blending, which supports the quality and uniformity of the mixture at the appropriate level

Special container also has a level sensor and a temperature sensor mix mixture

At the outlet of the pump has a special container with the necessary control and measuring equipment

Upon reaching inside a special container mix level sufficient to start the pump, it is switched on and feeds the mixture into the second device on the integrated input (in the upper level of the input device designed methanol)

The second device, the flow is homogenized and fed into the common summing the pipeline, where the nozzle is fed to the boiler

The system consist of the following inputs- outputs:

• input for 100% flow of the HFO [ divided to two lines for the top FAD- 25 and to the bottom FAD- 25
• input for the 100% of methanol to the top FAD- 25 [ related only for current configuration ]
• input for the 100% of the returned fuel blend flow
• output from the system[ combined the flow of prepared in system fuel blend from 40% of HFO [ Mazut ] mixed and homogenized with 60% of Methanol and returned back flow of the same blend, homogenized in the second [ bottom ] FAD- 25; The proportions of the output between new blend and back flow is adjustable

Characteristics of new design concept of FAD – 25, using in the system:

The device has no moving parts and is therefore highly durable and reliable. All of the internal components are made via standard machines with numerical control without the use of special techniques or cutting tools.

• In the shown emboddiment, the device is made of stainless steel, which allows the installation of systems in harsh environments in terms of temperatures or corresive elements such as marine vessels. Depending upon the operating enviroment and flow requirements others materials could be used.
• The device is extremely compact and has dimensions which allow it to be packaged in almost any internal combustion engine such as a stationary engine (e.g. marine engine, generators) as well as in engines installed in vehicles (e.g. automobiles or trucks). The device should be integrated into the fuel system between the fuel storage tank and the engines fuel injection system. All standard attachment methods are possible on the input or output side of the device.
• The device can be made via serial production equipment with digital program management for the manufacture and assembly. Quality control does not require special technologies, materials and tools

Homogeneous process description

To homogenize the liquid fuel, the process simply requires the liquid fuel supply line to be connected with a standard fitting to the input of the device. The liquid enters the device in the first accelerating hydrodynamic section; the liquid then passes through a coaxial second section with an integrated vortex generator. These internal geometries create an amplified level of hydrodynamic turbulence.

Devices specifics

An industrial installation for the homogenization of liquid fuel i.e. diesel fuel number 6 (Heavy Fuel Oil) and diesel fuel number 2 (Light Fuel Oil), as well as for micro-miniaturization and optimization of dispersion during injection of bio-fuel, methanol, ethanol and also kerosene obtained from waste plastics and automobile and other tires; Capacity of the device, despite its small size [ for example FAD – 40 ], – 1000 liters per hour under pressure of 7-10 bar.

Description to the general installation diagram

• For installation and mounting in an industrial boiler fuel line for on-line mixing of the flow of heavy diesel fuel and methanol, provides a system of dynamic mixing, activation and homogenization, which consists of two parallel connected devices, with a diameter of 25 millimeters worker
• In general, the boiler itself and all equipment included in its fuel cells are arranged as follows:
• Scheme 1 shows a boiler which is connected from the output 11 of the dynamic mixing and activation homogenization consisting of two parallel-connected devices having a working diameter of 25 mm each;
• The tank 2 (includes all associated equipment) contain heavy fuel oil (mazut), which through the heating system is fed to the input 15 of the dynamic mixing, activation and homogenization
• Methanol contained in the tank 3 with all necessary equipment from where it is fed to the input 14 of the system
• The system methanol is mixed with fuel oil in the ratio – 40% oil to 60% methanol and 11 through the outlet nozzle is fed to the boiler 1
• Part of the flow of the fuel mixture is returned to the tank 4 where a special pump 5 through a valve 6, a pressure gauge and a flowmeter 7, 8, through the heater 12 is routed to input 13 of
• The principle provides for the installation of the line heater 12
• The return flow of the fuel mixture is introduced into the second device, wherein homogenized and connects to a new stream of the fuel mixture produced in the first device
• Joint flow of the fuel mixture is then introduced into the boiler 1 and the injection process is repeated
• To eliminate the pulsations in the system at each branch conduit has the check valves, – 16, 17, 18, 19, 20, 21;
• Backup unit 22 for installation in an industrial boiler is used only for inputting and return homogenizing the mixture; Return the mixture is injected and distributed through the Manifold 26;
• Methanol is injected and distributed through the Manifold 25;
• Putting oil in the radial input through Manifold 27;
• Manifold 28 for this version of the installation, – closed
• 16 – check valve
• 17 – check valve
• 18 – check valve
• 19 – check valve
• 20 – check valve
• 21 – check valve
• 22 – bottom FAD – 25
• 23 – top FAD – 25
• 24 – main HFO input [ ~ 60 % of the HFO flow ]
• 25 – top methanol manifold
• 26 – bottom manifold for blend back flow / bottom methanol manifold
• 27 – main HFO manifold [ 40% of total HFO flow ]
• 28 – bottom HFO manifold of the system [ optional ]

Additional opportunities of FAD in in-line homogenization process:

Today’s internal and open combustion systems (engines, boilers, turbines, etc.) are only as effective as the fuel used in the process. Today’s fuels are sub-optimal in three ways; they are not homogenous, they are limited in their blending options and they require significant amounts of added oxygen during combustion to complete the process. Turbulent Energy has designed, prototyped and tested technologies, which can be packaged, scaled and integrated with all thermodynamic combustion systems to improve liquid fuel characteristics and therefore improve combustion.

Liquid fuels including distillates and synthetics are often not entirely homogenous at the time of distilling or blending and often loose their homogeneity over a period of time. Clotting and phase separation can occur and the fuels performance characteristics are degraded as a result. This change in the fuel’s composition can also hamper the combustion process and cause damage to fuel system components. Non-chemical methods are needed to ensure fuels are uniform and the combustion process is not compromised.

In addition to ability to homogenize today’s standard fuels (gasoline, diesel, kerosene, etc.), Turbulent Energy can also “blend” those fuels while homogenizing them to create “new” fuel composites (i.e. emulsions). Completely uniform and homogeneous oil-in-water and water-in-oil emulsions are possible with any liquid fuel, including heavy fuel oil.

Fuel blends are complimentary to the traditional fuel supply chain in that they improve combustion performance, add no additional cost to the fuel, contain no added chemicals and can be made in-line on-site at the required flow rate of the combustion system. The new fuel composites can be assembled at any point in the supply chain and be transported to the final combustion point with the existing logistics infrastructure.

The improved combustion performance, results in reduced operating cost and emission reductions. The adoption of technology can improve the overall performance of existing combustion systems and be easily integrated with most installations.

Overview of the Technology

The device used to improve the fuel characteristics can be sized and scaled based on fuel flow requirements and is easily manufactured with existing methods. Depending upon the pressure and temperature requirements, a variety of material options are available. Below are photos of a device with a 40 mm diameter that has been used in internal and open combustion environments where the fuel flow requirements is less than 1000 liters/hour and pressures are between 7 and 10 bar.

Patent protection of the technology – 1:

Method of dynamic mixing of fluids

Foaming of liquids

Fluid composite, device for producing thereof and system of use

General diagram of the installation of the system in boiler environment

The in- line mixing system of heavy diesel fuel (fuel oil) with methanol in a proportion – 40% of heavy diesel fuel and 60% of methanol for simultaneous homogenization before injection into the combustion chamber, it is a functionally complete unit with parallel sub-system for re-blending, regeneration and return the balance of the fuel return flow of fuel mixture

The system connected to present HFO tank of the boiler – 101 and present methanol tank – 102;

The system including an original re-blending multifunctional tank – 103

In the system, according to required optimal fuel blend flow is in specific functional use two parallel Dynamic Fuel Activation and in-line homogenization devices with working internal diameter 25 mm, – the top device – 104 and the bottom device – 105

The top device – 104 in the system used for preparation, in-line mixing and homogenization of “ new “ fuel blend with direct input to boilers injection system of the combustion chamber

The bottom device – 105 used for re-blending, regeneration and secondary homogenization of the fuel blende back flow and re-sending it to boiler combustion chamber

The boiler – 106 require the maximal fuel flow – 50 kg per hour and create back flow of the fuel blend

The combined flow of the fuel blend – 107 is injected to the boiler – 106, combustion chamber and is divided for big part of the stream – direct injected to the combustion chamber and small part of the stream – creating the back flow – 108, sent to tank – 103

The fuel lines of the second bottom device – 105, central – 109 and back integrated – 110 is closed

The top device – 104, connected to the HFO pipe-line with manifold – divider – 111 and central input – 112

The local methanol supply line including local control system – 113 , controlled and calibrated all necessary parameters of the methanol flow

The main HFO flow is under control of control system 115 and heating system – 115

The back flow of the blend – 108 entranced to tank – 103 where is re-blended with re-blending agitator -116, – a main part of local re-blending system 119

The re-blended blend from tank – 103, with pump -118, under control and calibration and on-line adjustment of control system – 117, send to bottom device – 105, which output flow is combined with output from top device – 104 and from this two flows is combined flow – 107

On the tank 103 is mounted central control-analytic box – 120

Installation is as follows:

Inputs to the system are connected to the outputs of existing capacities for the HFO – 101 and methanol – 102. A controlled fuel pump control systems – 113, 114, 115 and fed HFO methanol in the proportions necessary to the upper device – 104, where these components are dynamically mixed and homogenized and then fed at the input – to the boiler 107

Part of this stream (excess) is returned along line – in the tank 108 – 103.

The tank 103 system 119 by means of the activator – foam generator – 116 regenerates the blend after dynamic homogenization connects with the flow of the new blend – 107

This process is repeated continuously during operation of the boiler

Patent protection of the technology – 2:

Fluid composite, device for producing thereof and system of use

Abstract

The current disclosure relates to a new fluid composite, a device for producing the fluid composite, and a method of production therewith, and more specifically a fluid composite made of a fuel and its oxidant for burning as part of different systems such as fuel burners, where the fluid composite after a stage of intense molecular between a controlled flow of a liquid such as fuel and a faster flow of compressed highly directional gas such as air results in the creation of a three dimensional matrix of small hallow spheres each made of a layer of fuel around a volume of pressurized gas. In an alternate embodiment, external conditions such as inline pressure warps the spherical cells into a network of oblong shape cells where pressurized air is used as part of the combustion process. In yet another embodiment, additional gas such as air is added via a second inlet to increase the proportion of oxidant to carburant as part of the mixture.

Method of dynamic mixing of fluids

Abstract

Methods are provided for achieving dynamic mixing of two or more fluid streams using a mixing device. The methods include providing at least two integrated concentric contours that are configured to simultaneously direct fluid flow and transform the kinetic energy level of the first and second fluid streams, and directing fluid flow through the at least two integrated concentric contours such that, in two adjacent contours, the first and second fluid streams are input in opposite directions. As a result, the physical effects acting on each stream of each contour are combined, increasing the kinetic energy of the mix and transforming the mix from a first kinetic energy level to a second kinetic energy level, where the second kinetic energy level is greater than the first kinetic energy level.

Engine with integrated mixing technology

Abstract

The present disclosure generally relates to an engine with an integrated mixing of fluids device and associated technology for improvement of the efficiency of the engine, and more specifically to an engine equipped with a fuel mixing device for improvement of the overall properties by inline oxygenation of the liquid, a change in property of the liquid such as cooling form improved combustion, or the use of re-circulation of exhaust from the engine to further improve engine efficiency and reduce unwanted emissions.

Foaming of liquids

Abstract

Methods and systems for processing of liquids using compressed gases or compressed air are disclosed. In addition, methods and systems for mixing of liquids are disclosed.

Fluid mixer with internal vortex

Abstract

The present disclosure generally relates to a fluid mixer, a system for mixing fluids utilizing the fluid mixer, and a method of mixing fluids using the fluid mixer or the system for mixing fluids, and more specifically, to a compact static mixing device with no moving parts and capable of mixing any fluid, such as air, nitrogen gas, water, oil, polluted water, and the like. A first pressurized, incoming fluid is accelerated locally by a section reduction, is split into streams, and then is released into a second fluid found in a closed volume or an open volume after a period of stabilization. The directed and controlled first fluid slides along an insert up to directional and angled fins at a vortex creator where suction forces from a self-initiating vortex in an internal cavity draws in at least part of the first fluid to fuel the vortex. The compactness and simplicity of the fluid mixer with internal vortex can be used alone within a closed volume in a conduit, in a sprayer, or within a fixed geometry to direct the mixing vortex to specific dimensions. One or more fluid mixers can also be used in an open volume such as a reservoir, a tank, a pool, or any other fluid body to conduct mixing. The technology alone, as part of a multimixer system, or as a method of mixing using the fluid mixer with internal vortex is contemplated to be used in any field where mixing occurs.

Emulsion, apparatus, system and method for dynamic preparation

Abstract

The invention relates to a fluid composite, a device for producing the fluid composite, and a system for producing an aerated fluid composite therewith, and more specifically a fluid composite made of a fuel and its oxidant for burning as part of different systems such as fuel burners or combustion chambers and the like. The invention also relates to an emulsion, an apparatus for producing an emulsion, a system for producing an emulsion with the apparatus for producing the emulsion, a method for producing a dynamic preparation with the emulsion, and more specifically to a new type of a stable liquid/liquid emulsion in the field of colloidal chemistry, such as a water/fuel or fuel/fuel emulsion for all spheres of industry.

Foaming of liquids

Abstract

A foaming mechanism configured to receive a plurality of streams of gas and generate a foamed liquid, having an aerodynamic component and an aerodynamic housing disposed around at least a portion of the aerodynamic component. The aerodynamic housing includes a plurality of first channels and a plurality of second channels connected to the plurality of first channels at regular intervals on a distributed plane. The distributed plane is about perpendicular to the plurality of first channels, wherein the plurality of first channels and the plurality of second channels are configured to transform an axial stream of the gaseous working agent into a plurality of radial high-speed streams of the gaseous working agent by channeling the gaseous working agent through the plurality of first channels and into the plurality of second channels on the distributed plane. A hydrodynamic conical reflector and a hydrodynamic housing form a ring channel in an area between the hydrodynamic conical reflector and the hydrodynamic housing. An accumulation mechanism is configured to disperse the plurality of radial high-speed streams of the gaseous working agent into the ring channel and create turbulence to foam the liquid.

Fluid composite, device for producing thereof and system of use

Abstract

The current disclosure relates to a new fluid composite, a device for producing the fluid composite, and a method of production therewith, and more specifically a fluid composite made of a fuel and its oxidant for burning as part of different systems such as fuel burners, where the fluid composite after a stage of intense molecular between a controlled flow of a liquid such as fuel and a faster flow of compressed highly directional gas such as air results in the creation of a three dimensional matrix of small hallow spheres each made of a layer of fuel around a volume of pressurized gas. In an alternate embodiment, external conditions such as inline pressure warps the spherical cells into a network of oblong shape cells where pressurized air is used as part of the combustion process. In yet another embodiment, additional gas such as air is added via a second inlet to increase the proportion of oxidant to carburant as part of the mixture.