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Prepare for the Upcoming Change to the Permissible Sulphur Content of Marine Fuels

Posted by Hydraulic Filtration Team on 12 Jun 2019

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 ​The maritime industry is currently going through significant changes due to the introduction of tighter emission regulations. A stronger awareness in preserving the environment has pushed forward more stringent International Maritime Organization (IMO) legislation that imposes on ship owners and managers the use of new technologies that affect the day by day running of the vessel, starting with the choice of fuel, through changes in the engine operational parameters, and culminating in a severe reduction in allowable exhaust emissions.

The upcoming change to the permissible sulphur content of marine fuels burnt in the open ocean has brought the subject of compliance to the forefront. The most cost-effective way to meet the 0.5% sulphur limit is to blend the minimum amount of expensive, low sulphur fuel with the maximum amount of cheap, high sulphur fuel. Clearly, this leads to fuels that surf the compliance line very closely.

Of course, the issue of fuel compliance is not just restricted to sulphur. For instance, naval procurement often demands that distillate fuel supplies contain less than 0.1 % biodiesel [1, 2]. Recent technological advances mean that field spectrometers can measure sulphur and biodiesel concentrations within different fuels.

 

Prepare for the Upcoming Change to the Permissible Supphur Content of Marine Fuels - Parker KittiwakeDownload our white paper titled "The Science of Compliance" by Dr. David Atkinison to prepare for the upcoming change to the permissible sulphur content of marine fuels.

     

 

Unchartered operational territories

Combining these changes with the following factors  

  • A volatile fuel market.
  • High competition in cargo rates.
  • The pressure to reduce operating costs.
  • The introduction of new technological advancements.

have prompted the marine industry to abandon the ‘comfort zone’ that has been enjoyed for the last 20+ years. Today’s environment has a significant impact in the way two-stroke, slow speed, diesel engines are managed, introducing new challenges for different fuel types, different lubricants and ancillary equipment required to meet the new requirements.

 

Unintended consequences

Field experience has shown that all these factors can lead to:

  • Engine damage caused by poor fuel quality.
  • Lack of training/knowledge of the operators.
  • Incorrect lubrication choice.
  • Poor set up.

Solutions come in many shapes and sizes, from simple, two-minute handheld test kits to state-of-the-art online sensor technology. Through scientific testing, our lead-application engineers have demonstrated that a combination of these tools can deliver real savings by:

  • Preventing accelerated wear in liners, piston rings, and pistons.
  • Reducing lubricant costs by optimising feed rates.
  • Avoiding catastrophic engine damage.
  • Enabling proactive maintenance scheduling and eliminating costly, unexpected, downtime.
  Challenges facing the marine environment

Two-stroke, slow speed, diesel engines are used in the marine industry to power the largest commercial ships currently sailing on the seas. These internal combustion engines are used for their high thermal efficiency, exceptional reliability and ability to use a variety of fuel types including residual oils. These fuels are, broadly speaking, the very end product of the crude oil refining process and are commonly referred to in the marine industry as Heavy Fuel Oil (HFO) or Residual Fuel Oil (RFO). These fuels are regarded to be the most cost-effective available; for this reason, they’re the preferred choice to power main engines and generators in large, ocean-going, vessels. HFO comes in several grades; the best and most expensive grades have the lowest Sulphur content.

Choosing HFO, however, presents challenges in dealing with the varying sulphur contents in:

  • Available fuels.
  • High viscosity.
  • Significant water content.
  • The potential presence of abrasive aluminum silicate compounds.

These materials are carried over from catalytic cracking during the crude oil refining process and are referred to as catalytic fines or simply, ‘cat-fines’. The International Standards Organization has published a specification for marine HFO (ISO 8217:2010) which imposes upper limits on these, and other fuel parameters to provide consistency in the market. Nevertheless, bunkered HFO, even when conforming to these specifications, requires further onboard processing to reduce the water and solids contents to levels deemed acceptable for engine operation.

  Regulations present challenges to operators

In the marine industry, environmental regulation is on the increase and operators are facing new challenges that threaten their cash-tight budgets. But it is not just the added cost of more expensive alternative fuels or lubricants that can impact operators, critically, it is also the effect that these changes have on the operating conditions of the vessel, leading to unexpected damage and causing unplanned downtime.

With such stringent and widespread regulations, compliance with the rules becomes even more challenging. New operating methods and procedures for fuel changeover, oils, and equipment required for compliance can indeed lead to unintended consequences such as damage caused by out-of-specification fuel or incorrect/insufficient cylinder lubrication.

Amidst the omnipresent drive for safety and operational efficiency, effective condition monitoring tools and techniques have never been more valuable in helping operators manage, avoid or mitigate these costly issues.

The proper combination of condition monitoring techniques provides a wealth of information, allowing ship operators to take immediate corrective actions to mitigate any damage, to allow continued, efficient operation and prevention of the high costs associated with undetected liner wear events. The savings associated with these early warnings far outweigh the cost of the condition monitoring tools used to detect them.

Prepare for the Upcoming Change to the Permissible Sulpher Content of Marine Fuels - Download White Paper - Parker KittiwakeDownload the white paper and learn how the combination of offline and online condition monitoring techniques can be successfully used to prevent engine damage and avoid unplanned maintenance costs due to downtime.

 

Are you attending the CIMAC 2019 Congress?

 

Prepare for the Upcoming Change to the Permissible Sulphur Content of Marine Fuels - Booth 316 Parker Hannifin - KittiwakeVisit Parker at Stand #316 to learn more about our energy efficient, high-performance solutions for combustion engine applications. The CIMAC international congress and exhibition, held every three years, is a unique opportunity to stay current with technology for the internal combustion engine industry and meet with specialists in the field. Our engineers are ready for your questions.
 

 

 

 

 

 

Prepare for the Upcoming Change to the Permissible Sulphur Content of Marine Fuels -  Dr. David Atkinson - Parker KittiwakeArticle contributed by Dr. David Atkinson, principal chemist, Parker Kittiwake, part of Parker's Hydraulic and Industrial Process Filtration Division. 



 

 

 

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  •  Efficient operation of baghouses is an expected and necessary element of foundry productivity. These manufacturing facilities and systems assure clean and safe work environments, allowing people and equipment to operate without interruption. When the media, often filter bags, employed in the baghouses plugs with collected solid matter, immediate maintenance is an absolute priority. The proper function of baghouse filtration is integral to efficient foundry operations.

    This was the case at a large foundry located in the United States where restricted air flow to mold cooling and sand handling equipment had reached a critical point.

     

     For more information on this application and to learn how BHA® PulsePleat® filters can help you reduce costs and improve baghouse performance, download the full case study.

     

     

     

    The problem

    The foundry employed a 450-bag Carborundum pulse-jet baghouse. The system had been designed with an air-to-cloth ratio of 9.3:1, aggressive by any standards. The processing at the foundry exposed the filter media to very fine particulate. Specifically, the particulate came from the sand handling system. This particulate, along with high moisture and hydrocarbon carryover from the mold cooling line, formed a substantial and difficult dustcake on the filter media in the baghouse. After only six months of service, blinded filter bags caused differential pressure to exceed 8” w.c., greatly reducing airflow venting of the applications. As a result, time-consuming and costly filter bag and cage change outs were required.


    The solution

    The foundry determined that they needed the help of experts in the area of filtration, specifically with baghouse efficiency and performance. They turned to Parker Hannifin, a leader in the design and manufacture of filtration systems.  Parker recommended replacing filter bags and cages with BHA® PulsePleat® Filter Elements — a versatile and cost-effective solution. They designed the system in order to increase the total filtration area of the dust collector by over 220%. This was done with no physical modification of the dust collector.

     Benefits of BHA® PulsePleat® filters elements
    • Spunbound polyester media provides superior filtration efficiency.
    • Promote better airflow for increased throughput.
    • Pleated design increases filtration surface area up to 4X.
    • Molded bottom helps resist abrasive wear.
    • Reduce air-to-cloth ratios.
    • Reduce operating differential pressure.
    • Reduce compressed air consumption.
    • Eliminate the need for cages.
    • Easy installation and removal.
    • Installation typically requires no modification to existing equipment.
     
    Results

     

    Performance

    The new system, featuring an increased filter surface area of the pleated elements, helped lower average differential pressure to 3.5” w.c. — a greater than 40% reduction from the peak of 8” w.c.  

    Fan amps went up by 157%, increasing air volume through the dust collection system and providing the ventilation needed by the process applications for optimum performance.  

    Installation and maintenance

    The one-piece bottom-load design of BHA® PulsePleat® filters elements reduced filter installation time by 70%.
    The increased filter surface area contributed to a dramatic reduction of unplanned maintenance time and expense.


    Conclusion

    By installing BHA PulsePleat filter elements, the foundry returned to efficient production and avoided the high costs of unplanned maintenance and baghouse redesign or replacement.

    To learn more about BHA PulsePleat filter elements, watch this video:


     For more information on this application and to learn how BHA® PulsePleat® filters can help you reduce costs and improve baghouse performance, download the full case study.
     

    Article contributed by the Industrial Air Filtration Team.
     

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    Choosing the Best Dust Collector for Air Quality Control in Manufacturing

     

    Filtration Team
    Filtration Team
    • 5 Dec 2019
    How to Solve Baghouse Airflow Restriction in Foundry Applications
    Efficient operation of baghouses is an expected and necessary element of foundry productivity. These manufacturing facilities...
  • Listening, Learning and Applying Knowledge in Product Development_Filter and Dispense System Scanner_Parker Bioscience FiltrationAlthough bulk filtration of a product prior to shipping was one of the first bioprocessing steps to benefit from single-use technology, it has been one of the last to benefit from single-use automation.

    Indeed, for many biopharmaceutical manufacturers, the process has changed very little from the days before single-use technology was adopted: the main differences have been the replacement of the stainless steel tank with a bag and the steam cross with aseptic connectors. 

    Parker Bioscience Filtration was approached by a customer to develop a solution that would address concerns around the bulk filtration unit operation. 

     

    Listening, Learning and Applying Knowledge in Product Development_Implementation of Single-Use in Drug Substance Filling Before Transportation White Paper_Parker Bioscience Filtration

     

     

     

    To learn more, download the full white paper: Implementation of Single-Use in Drug Substance Filling Before Transportation

     

     
            What were the customer's concerns?
    • Protection - As the customer was filling high potency active pharmaceutical ingredients (HPAPIs), it needed to eliminate open processing to protect the operator and the product. 

    • Standardization and simplification - The customer needed to standardize the filling platform in order to create a standard operating procedure (SOP); this would simplify training and eliminate process variation.

    • Hygiene -The customer wanted to reduce the number of people involved directly in the filling. 

     

    How Parker helped

    Working closely with the customer, Parker Bioscience Filtration developed the Generation One SciLog® Filter and Dispense System. This enabled fully enclosed automated bulk filling of the HPAPI into bottles in preparation for transportation to a filling site. 

    Parker was able to identify several benefits of automated closed filling:

    • No more false positives - The elimination of false positives meant that the customer would not be exposed to the costs (and lost time) of the quarantine and investigation process related to a false positive. Nor would it be exposed to the risk of a batch being rejected. 

    • Saving time - Comparing manual filling and automated filling, data was generated on time savings based on two filling volumes and a set batch size. If these time savings were applied to a facility producing 35 batches per year, the cost reductions generation could run into €100,000s.

    • Reduction in clean room personnel required - As the process is fully enclosed and automated, the need for QC sampling and QA oversight was reduced - this meant fewer staff were required in the clean room. 

    • Standardization driving simplification - Training and SOP became simpler as a result of standardization. The risk of deviation and human error was also reduced, and the supply chain and handling process was simplified. 

     

    The development of the generation two system

    Although we had developed a solution for a fully enclosed and automated filling process, collaboration with the customer did not stop there. The safe arrival of the bottles at a filling site was the customer's priority - and taking into account their feedback, we developed the generation two SciLog® Filter and Dispense System.

     

    How did Parker do it? Increasing the filling accuracy

    The filling accuracy of the generation one system was +/- 10 percent - initially deemed acceptable.

    However, the filling accuracy was increased to a much higher level of +/- 100 mg following feedback from the customer's QA team and our knowledge of how many bottles they needed to fill, as well as product and consumable reconciliation. 

    With the generation one system, based on a 20 L and a 500 ml fill, anywhere between 36 and 44 bottles were required. With the generation two system, the maximum number of bottles required is 40 and the minimum is 39. 

    Improving the filling process

    As the generation two system allows a rapid fill to 90 percent of target volume, the process can be run at a slower rate to ensure accuracy. This balances the requirement for product quality and process efficiency.

    Parker also introduced a J-tube system which diverts the flow of liquid to the side of the bottle. This was developed to prevent the foaming that would occur if liquid was dropped into a bottle vertically. 

    Component selection driven by process facility knowledge

    It is essential to choose materials that can support the process - and this can only be done if the full extent of the storage conditions is known. A solution may be filled following cold storage at 4°C, for instance, but may then be stored in dry ice at -78.5°C. This will have a critical impact on the choice of materials. In addition, not all products will be compatible with all of the materials used in a single-use assembly. Again, knowledge is key.

    Validating the system

    While the system was validated to perform the fully automated and contained filtration and dispense of bulk APIs, this was not the end of the validation process. 

    Shipping of the product to the final destination was also part of the solution Parker needed to provide for the customer and, therefore, this also needed to be validated. To do this, Parker subjected the bottles to further testing to demonstrate their post-shipping integrity — a crucial final step in validating the entire process.

     

    Conclusion

    Our work in developing the generation two SciLog® Filter and Dispense System underlined the importance of truly understanding what matters to a customer — and in this case, that went beyond the system's functionality.

     

    Listening, Learning and Applying Knowledge in Product Development_Implementation of Single-Use in Drug Substance Filling Before Transportation White Paper_Parker Bioscience FiltrationTo learn more download the full white paper: Implementation of Single-Use in Drug Substance Filling Before Transportation

     

     

    Listening, Learning and Apply Knowledge in Product Development_Guy Matthews_Parker Bioscience Filtration

    This post was contributed by Guy Matthews, division marketing manager, Parker Bioscience Filtration, United Kingdom

    Parker Bioscience Filtration specializes in automating and controlling single-use bioprocesses. By integrating sensory and automation technology into a process, a manufacturer can control the fluid more effectively, ensuring the quality of the final product. Visit www.parker.com/bioscience to find out more.

     

     

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    Four Sources of Process Variation in Biopharmaceutical Manufacturing

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    Bioprocess Pharmaceutical Filtration Team
    Bioprocess Pharmaceutical Filtration Team
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    Although bulk filtration of a product prior to shipping was one of the first bioprocessing steps to benefit from single...
  • Early Adoption Single-Use Technology Can Ensure Successful Process Scale-Up_Filter Trials with SciLog FilterTec System_Parker Bioscience FiltrationWhether you are running a process in a 30,000 L bioreactor in fed-batch mode, a 200 L continuous process, or have scaled-out (rather than up), you will start at small scale and look to increase the volume - scale-up - to some degree.

    However, we are recognizing that some biotech companies aren't adopting single-use automated technology until the process reaches pilot scale. This can reduce the likelihood of a successful outcome or the speed of the development process, as process rework may need to be managed further along the manufacturing development process. In some cases, changes to inefficient processes may be more difficult to implement, especially if they have already been approved.

    The adage "start with the end in mind" has never been more relevant. For scale-up to be successful, we recommend using the same automated single-use equipment, strategies and materials from the R&D stage through to manufacturing scale. That way, speed to market can be optimized through simplified technology transfer of optimal process. You will also avoid unexpected rework that may come about due to material compatibility or availability issues.

    Start as you mean to go on

    Speed to market is of critical importance, both from a return on investment point of view, but also with the benefits to patients in mind.

    Having single-use automated technology in place at the R&D stage can make the move into the manufacturing stage more efficient.

    The benefits include:

    • Materials are pre-qualified at the R&D stage and approved for use in the application.
    • Vendors are pre-qualified, audited and already in the supply chain.
    • Operator training time is reduced.
    • User confidence with the technology is increased.
    • Using scalable automation solution and single-use components increases the likelihood that control parameters developed on a smaller scale system are available on a larger system.

    And, if you use single-use technology during R&D you can also benefit from:

    • Decreased turnaround times - as components don't require cleaning or regeneration.
    • More consistent results - from using pre-made disposable manifolds, rather than building a flow path for each different processing run.

    However, there are a few common pitfalls to avoid, which include making incorrect assumptions regarding how processes will behave at larger scale.

    Ensuring successful scale-up in single-use bioprocessing webinar

    Parker Bioscience Filtration is delivering a webinar on November 12th, 2019 which will help biopharmaceutical manufacturers build a strategy for effective scale-up of filtration and single-use processes that will facilitate technology transfer, in order to avoid delays in commercialization caused by inconsistent scale-up of a single-use process between R&D and manufacturing.

    It will explain how to conduct a small-scale filtration trial using an automated single-use system at laboratory scale and examine the advantages this provides.

    The webinar will also further explore the benefits of single-use technology in both R&D and manufacturing, and consider how to ensure successful implementation of single-use automation from laboratory scale through to large-scale production.

     

    Register now for our webinar: Ensuring Successful Scale-Up in BioprocessingEarly Adoption Single-Use Technology to Ensure Successful Scale-Up_Webinar sign up now icon_Parker Bioscience Filtration

     

     

     

     

    Early Adoption Single-Use Technology to Ensure Successful Scale-Up_David Heaney_Parker Bioscience FiltrationThis post was contributed by David Heaney, market development manager (life sciences), Parker Bioscience Filtration, United Kingdom.

    Parker Bioscience Filtration specializes in automating and controlling single-use bioprocesses. By integrating sensory and automation technology into a process, a manufacturer can control the fluid more effectively, ensuring the quality of the final product. Visit www.parker.com/bioscience to find out more.

     

     

     

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    Protecting Your Bioprocess From the Risk of Human Error

    How to Successfully Scale-Up Automated Single-Use Bioprocesses

    Automating and Enclosing Bulk Fill Operations - the Way Forward?

     

    Bioprocess Pharmaceutical Filtration Team
    Bioprocess Pharmaceutical Filtration Team
    • 30 Oct 2019
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    Whether you are running a process in a 30,000 L bioreactor in fed-batch mode, a 200 L continuous process, or have scaled...
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