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At SMM 2014 in Hamburg, GEA Westfalia Separator Group GmbH (GEA) presented the CatFineMaster, described by the company as "the first system capable of separating dangerous catalyst residues (cat fines) from the fuel more effectively than ever before – at the touch of a button".

Cat fines can significantly damage the engine and, under extreme circumstances, may also result in the total failure of the main engine.

GEA says its new CatFineMaster is able to perform the task of fuel processing "extremely efficiently and reliably".

Describing the product, GEA said: "The system consists of a separator as the core element and an innovative feed pump that can be regulated in the process. In order to achieve optimum separating behavior with the cat fines of varying sizes, the CatFineMaster enables two major processes parameters to be varied. The separating temperature can be altered: A hot separating method up to 110°C, that is presently unique on the market, lowers the viscosity of the fuel, enabling very small cat fines to be separated even more effectively. The second process variable is the flow rate which is regulated by means of a feed pump for optimum adjustment of the flow rate of the heavy oil to the respective process requirements. This provides an additional boost to efficiency and also results in energy savings. The CatFineMaster ensures an efficient reduction of cat fines, targeting a concentration of less than 5 ppm and separation of all particles larger than 3 µm.

"The CatFineMaster offers an extremely attractive ratio between the calculable additional costs of this system compared with the incalculable additional costs of repairing the main engines, possibly also temporary shutdowns, delays, downtimes, loss of charter contracts, etc. The CatFineMaster is the first system available on the market which ensures maximum reduction of cat fines and thus optimum fuel composition. The system is completed by the new GEA Westfalia Separator IO control system and optional measuring and analysis equipment," GEA said.

GEA Westfalia Separator unitrolplus

"GEA Westfalia Separator unitrolplus is an integrated fully automatic system that continuously monitors the water content and solid filling of the oil in a single stage. Depending on the water content of the oil, the separator adjusts automatically to function as a purifier or clarifier. The result: higher specific degree of separation with optimum separation efficiency. No regulating ring is needed for this automatic monitoring process – thanks to unitrolplus the user no longer has to make manual settings," GEA said.

Intelligent control

"Complex situations can be simplified by means of intelligent control technologies. IO is the new generation of control units that GEA Westfalia Separator Group used with the CatFineMaster.

"IO focuses on ease of operation: one touch is all that is required, to have the centrifuge automatically regulate the desired program. This innovative control system concentrates precisely on what the user requires for this specific task and results in enormous benefits for operations: Operating staff can easily master the use of the control system for the centrifuge; the familiarization time is relatively short, thus enhancing flexibility in operations. The processes have also become more reliable. IO enables the user to intuitively utilize the wide range of functionalities.

"In a future with unreliable bunker fuel quality the GEA Westfalia Separator CatFineMaster enables shipping companies and ship operators to protect their investments. The new system is therefore set to become a standard solution on board of ships against the background of stricter environmental conditions," GEA said.