U.S. patent application number 11/408460 was filed with the patent office on 2006-10-26 for additive for hydrocarbon fuel consisting of non-acidic inorganic compounds of boron and related processes.
This patent application is currently assigned to EnviroFuels L.P.. Invention is credited to C. Edward JR. Baxter.
Application Number | 20060236596 11/408460 |
Document ID | / |
Family ID | 36809194 |
Filed Date | 2006-10-26 |
United States Patent
Application |
20060236596 |
Kind Code |
A1 |
Baxter; C. Edward JR. |
October 26, 2006 |
Additive for hydrocarbon fuel consisting of non-acidic inorganic
compounds of boron and related processes
Abstract
The present invention provides a fuel additive and a process for
using and making the fuel additive. The fuel additive includes a
non-acidic boron-containing salt in a carrier fluid. The fuel
additive enhances combustion by increasing fuel efficiency or
decreased pollutant output in an exhaust gas resulting from
combustion of the fuel with the fuel additive.
Inventors: |
Baxter; C. Edward JR.;
(League City, TX) |
Correspondence
Address: |
BRACEWELL & GIULIANI LLP
P.O. BOX 61389
HOUSTON
TX
77208-1389
US
|
Assignee: |
EnviroFuels L.P.
Houston
TX
|
Family ID: |
36809194 |
Appl. No.: |
11/408460 |
Filed: |
April 21, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60673907 |
Apr 22, 2005 |
|
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|
Current U.S.
Class: |
44/314 |
Current CPC
Class: |
C10L 1/1616 20130101;
C10L 1/1985 20130101; C10L 1/10 20130101; C10L 1/238 20130101; C10L
1/1266 20130101; C10L 1/1291 20130101; C10L 10/02 20130101 |
Class at
Publication: |
044/314 |
International
Class: |
C10L 1/30 20060101
C10L001/30 |
Claims
1. A fuel additive comprising a mixture of at least one salt and a
carrier fluid, the salt comprising [Y].sub.aB.sub.bO.sub.c, wherein
[Y] is a cation and the salt is non-acidic, the carrier fluid being
operable to maintain the salt within the carrier fluid in at least
a partially dispersed state, the fuel additive being operable to
enhance combustion when placed into contact with fuel in a
combustion zone and combusted, the enhanced combustion being
measurable by increased fuel efficiency or decreased pollutant
output in an exhaust gas resulting from the combustion of the fuel
and the fuel additive.
2. The fuel additive of claim 1 wherein the salt is selected from
the group consisting of metaborate, pentaborate, tetraborate and
orthoborate and combinations thereof.
3. The fuel additive of claim 1 further comprising
[NH.sub.4].sub.2B.sub.4O.sub.7.
4. The fuel additive of claim 1 further comprising an ammonium
compound.
5. The fuel additive of claim 1 wherein the pH of the solution is
between about 6.0 and 8.0.
6. The fuel additive of claim 1 wherein the salt is inorganic.
7. A process for enhancing fuel performance of a hydrocarbon fuel
in a combustion system having a combustion zone comprising the
steps of providing the fuel additive of claim 1 in an amount
effective to enhance fuel performance to the combustion zone and
combusting the hydrocarbon fuel with the fuel additive.
8. The process of enhancing fuel performance of claim 7 wherein the
hydrocarbon fuel is a liquid hydrocarbon fuel.
9. The process of enhancing fuel performance of claim 7 wherein the
hydrocarbon fuel is a solid hydrocarbon fuel.
10. The process of enhancing fuel performance of claim 7 wherein
the combustion zone is within an engine operating on gasoline
fuel.
11. The process of enhancing fuel performance of claim 7 wherein
the combustion zone is within an engine operating on diesel
fuel.
12. The process of enhancing fuel performance of claim 7, wherein
the fuel additive is operable to enhance combustion when placed
into contact with fuel in a direct fired burner or open flame in
the combustion zone and combusted, the enhanced combustion being
measurable by increased fuel efficiency or decreased pollutant
output in an exhaust gas resulting from the combustion of the fuel
and the fuel additive.
13. An enhanced fuel comprising a substantial amount of hydrocarbon
fuel suitable for combustion, and an amount of fuel additive of
claim 1 operable to enhance combustion.
14. The enhanced fuel of claim 13 wherein boron is present in the
hydrocarbon fuel in an amount of between about 5 and 10 ppm by
weight.
15. The enhanced fuel of claim 13 wherein the amount of fuel
additive is the amount operable to reduce emissions upon combustion
of the enhanced fuel as compared to the combustion of the
hydrocarbon fuel without the fuel additive.
16. The enhanced fuel of claim 13 wherein boron is present in the
hydrocarbon fuel in an amount less than about 25 ppm by weight.
17. A process for creating an enhanced hydrocarbon fuel for use in
a combustion system comprising the step of: adding an amount
effective to enhance fuel performance to the hydrocarbon fuel of a
chemical addition composition, the chemical addition composition
comprising the product from the dispersion of a non-acidic borate
salt in water.
18. The process of claim 17, wherein the salt is inorganic.
19. A process for creating a fuel additive for enhancing combustion
of a hydrocarbon fuel, the process comprising the steps of: adding
the salt [Y].sub.aB.sub.bO.sub.c, wherein [Y] is a cation and the
salt is non-acidic, to a fluid to at least partially disperse the
salt in the fluid to create a boron-containing parent dispersion;
mixing the boron-containing parent dispersion with carrier fluid
such that the boron-containing parent dispersion is generally
dispersed in the carrier fluid; and removing a substantial portion
of the fluid from the mixture of the boron-containing parent
dispersion with the carrier fluid to create a fuel additive that is
operable to enhance combustion when added to a combustion zone in
the presence of a hydrocarbon fuel and combusted.
20. The process of claim 19, wherein the salt is inorganic.
Description
RELATED APPLICATIONS
[0001] This application is related to and claims priority and
benefit of U.S. Provisional Patent Application Ser. No. 60/673,907,
filed Apr. 22, 2005, titled "Additive For Hydrocarbon Fuel
Consisting of Non-Acidic Inorganic Compounds of Boron and Related
Processes," which is incorporated herein by reference in its
entirety.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to the field of fuel
additives, and in particular, to a boron-containing additive for
hydrocarbon fuels used to enhance efficiency and/or reduce
pollution.
BACKGROUND OF THE INVENTION
[0003] Many hydrocarbon fuels have been used, each with its own
advantages and drawbacks. Examples of such fuels include gasoline,
natural gas, diesel, kerosene, jet fuel, LPG, heavy distillates,
bunker fuel, ethanol, coal, other solid hydrocarbon fuels and the
like. Chemical compounds have been used as fuel additives over the
past century to improve various parameters, such as octane number,
of various fuels. The use, and subsequent banning, of lead in
gasoline has been known for a long time. Tetraethyl lead showed a
positive effect on octane and a profoundly negative effect on the
environment.
[0004] In addition to tetraethyl lead, several elements are known
to have combustion catalyst characteristics in gasoline or other
hydrocarbon fuels. Examples, in addition to lead, are manganese,
iron, copper, cerium, calcium and barium. Each of these elements
has advantages and disadvantages in particular applications.
Drawbacks of certain iron compounds include limited solubility in
gasoline, toxicity, and expense as an additive. Interaction with
sulfur and creation of sulfide precipitate may also occur, which is
undesirable.
[0005] Another commonly-used additive in gasoline is MTBE. While
this compound boosts octane levels significantly, the compound is
thought to be carcinogenic. Also, it mixes easily with water which
is hazardous should there be a leak. Gasoline containing MTBE
leaking from an underground tank at a gas station could potentially
leach into groundwater and contaminate wells. As a result of the
believed negative potential effect of MTBE on the environment,
ethanol is also being evaluated as a gasoline additive to boost
octane.
[0006] In addition to the industry goal of improved combustion
efficiency, reduction of smoke and particulate emissions is also a
concern, particularly for diesel fuel applications. The industry
has not made substantial progress on development of a fuel additive
for reducing smoke and particulate emissions.
[0007] Finally, adjustment of combustion parameters is made to
attempt to maximize function to reduce CO and NOx. In spite of
these and combinations of these attempts to minimize pollutants,
fuel combustion continues to be a focus of interest to improve fuel
efficiency and reduce pollutants.
[0008] A fuel additive that includes a combustion catalyst to
reduce smoke and particulate emissions from bus, truck and
automobile engines operating on gasoline fuels would be
advantageous. Also advantageous would be a fuel additive that
increases efficiency and/or decreases pollutants for diesel fuel
applications. It would be advantageous to reduce smoke, particulate
and nitrogen emissions from fuel applications. An additive that
does not result in the formation of precipitates would be also
advantageous. An additive for hydrocarbon fuel that reduces level
of NOx produced would also be advantageous. Finally, an additive
that remains stable during the combustion process would be
advantageous.
SUMMARY OF THE INVENTION
[0009] Accordingly, the present invention provides a fuel additive
comprising a mixture of at least one salt and a carrier fluid, the
salt comprising [Y].sub.aB.sub.bO.sub.c, wherein [Y] is a cation
and the salt is non-acidic, the carrier fluid being operable to
maintain the salts within the carrier fluid in at least a partially
dispersed state, the fuel additive being operable to enhance
combustion when placed into contact with fuel in a combustion zone
and combusted, the enhanced combustion being measurable by
increased fuel efficiency or decreased pollutant output in an
exhaust gas resulting from the combustion of the fuel and the fuel
additive. A feature of the present invention is that [Y] is an
ammonium compound. Alternately, [Y] is an alkali metal.
[0010] The present invention also advantageously provides a process
for enhancing fuel performance of a hydrocarbon fuel in a
combustion system having a combustion zone comprising the steps of
providing a fuel additive comprising a mixture of at least one salt
and a carrier fluid, the salt comprising [Y].sub.aB.sub.bO.sub.c,
wherein [Y] is a cation and the salt is non-acidic, in an amount
effective to enhance fuel performance to the combustion zone and
combusting the hydrocarbon fuel with the fuel additive. A feature
of the present invention is that the fuel can be a solid or liquid
hydrocarbon fuel.
DETAILED DESCRIPTION
[0011] The present invention includes a fuel additive and a method
of using the additive in relation to hydrocarbon fuel. The fuel
additive of the invention includes a boron-containing salt which
preferably includes [Y].sub.2B.sub.40.sub.7, wherein Y is a cation.
Ammonium is a preferred inorganic cation. Alkali metals are another
preferred inorganic cation, more preferably those alkali metals
with atomic weights under 50.0.
[0012] In one embodiment, the boron salts are at least partially
dispersed in water or another aqueous fluid to create a
boron-containing parent dispersion. The boron salts are dispersed
in the water or aqueous fluid, and no dissociation or dissolving of
the salts occurs. The stable dispersion of boron salts at a
preferred particle size of 5 microns or less, more preferably from
2-5 microns, provides a heterogeneous combustion catalyst in
hydrocarbon fuel that provides emissions reductions and fuel
economy improvements.
[0013] In an embodiment of the present invention, the
boron-containing parent dispersion is added or mixed with a
dispersion fluid. The dispersion fluid is a fluid that is operable
to maintain the salts within the dispersion fluid in at least a
partially dispersed state and that is miscible, or capable of being
maintained in solution, in the hydrocarbon fuel. In a preferred
embodiment, the water, for example, is largely removed from the
boron-containing parent dispersion in the dispersion fluid through
thermal means to create the fuel additive. The dispersion fluid is
preferably a Group II base oil. Other preferred dispersion fluids
include light hydrocarbons, gasoline, polygas, kerosene, diesel,
naphtha light oils, Group I, III, IV, V or VI base oils as defined
by API, aromatic oils, polybutenes, polyglycols, heavier oils or
combinations of the same.
[0014] The fuel additive is operable to enhance combustion when
placed into contact with fuel, regadless of the fuel's sulfur
content. Enhanced combustion means that fuel efficiency is
increased when compared to fuel without the fuel additive, or that
pollutant output in an exhaust gas from the combustion is
decreased, or a combination of these effects. Typical pollutants
can include NOx, particulate matter, carbon monoxide and other
recognized pollutants resulting from the combustion of hydrocarbon
fuel. It is noted that different geographical regions focus on
minimizing a particular pollutant depending on air characteristics.
Reduction of a target pollutant or a combination of pollutants,
such as NOx and CO, is highly advantageous. Alternately, increased
fuel efficiency results in a total lower volume of pollutants, as
well as economic advantage.
[0015] When the fuel additive is prepared using ammonium compounds,
ammonium compounds are defined as those compounds containing
NR.sub.x groups, where R can be for example, hydrogen. NH.sub.4 is
particularly preferred. Ammonium compounds have been found to have
particularly strong catalytic combustion properties, for example,
in terms of NOx reduction, when used in boron-containing salts in
accordance with the present invention.
[0016] The borate salts are essentially neutral but more
particularly are not highly acidic. In a preferred embodiment, the
boron-containing parent dispersion has a pH between about 6.0 and
8.0. Boric acid is typically not present at this relatively neutral
pH range. Pentaborates and tetraborates are disclosed herein, for
example. The borate salts can be in any form including metaborate,
orthoborate or any form of borate that is not acidic, or
combinations thereof. The salts can be either anhydrous or in
various levels of hydration. The preferred boron salts according to
the present invention are inorganic, nonacidic, insoluble and
dispersible.
[0017] The boron-containing parent dispersion of one embodiment of
the invention can be used in any type of environment, for example,
either hydrophilic or hydrophobic environments. In the case of a
hydrophobic environment, it may be necessary that a carrier fluid
or fluids be selected to allow for proper dispersion. In a
preferred embodiment, the carrier fluid can be polyoxpropylene
monols, diols and polyols, polyoxybutylene monols, diols and
polyols, particularly Bayer Actaclear ND17. A dispersant used in
conjunction with the carrier fluids to create the fuel additive is
also encompassed in a preferred embodiment. Preferred dispersants
include polyalkenyl succinimides such as Texaco TFA 4690C, Oronite
ODA 78012 and Ethyl Hitec 646. For liquid hydrocarbon fuel
applications, at least one carrier fluid can preferably be a fluid
with at least some hydrophilic character that is miscible with the
fuel to act as compatibilizing agent in conjunction with
dispersant.
[0018] The fuel additive of the invention is useful to enhance
combustion such that more complete combustion is achieved with
increased combustion to CO.sub.2 and H.sub.2O as compared to the
combustion of the fuel without the fuel additive. The outcome is
the reduction of products of partial combustion as well as
NO.sub.x, thereby increasing fuel efficiency.
[0019] The fuel additive is used by adding the additive to the fuel
in an amount sufficient to increase fuel efficiency and/or to
reduce pollutants. The terms enhanced and enhanced combustion refer
to either of these effects. An example of reduced pollutants is a
reduction of NOx and CO in an exhaust gas produced from an internal
combustion engine or direct fired open flame burner.
Advantageously, both of these effects are observed though the
addition of the fuel additive of the current invention. A preferred
embodiment includes the addition of between about 5 and 10 ppm
boron by weight into the fuel though the addition of the fuel
additive. Increased amounts of boron up to 25 ppm boron by weight
are effective as well. It is notable that a very cost-effective
solution can be prepared with low weight percent of boron, i.e.,
less than 20 ppm. Another preferred target is less than 15 ppm
boron. Relatively low concentrations of boron advantageously
provide economic benefits, may be more environmentally acceptable
and may provide cleaner operations in the engine with reduced
deposits and residues.
[0020] Included in the invention is a process for enhancing fuel
performance of a hydrocarbon fuel in a combustion system including
the steps of providing the fuel additive described above in an
amount effective to enhance fuel performance to the hydrocarbon
fuel and combusting the hydrocarbon fuel with the fuel additive.
The combustion system can be any means known to those with ordinary
skill in the art for combusting hydrocarbon. The combustion system
can include any of various internal combustion engines. In a
preferred embodiment, this process is used with a liquid or
liquefied hydrocarbon fuel. Alternatively, the process may also be
utilized with solid hydrocarbon fuel. The result of adding the
additive to the hydrocarbon fuel is an enhanced fuel that has a
substantial amount of hydrocarbon fuel suitable for combustion, and
an amount of the fuel additive operable to enhance combustion.
Preferably, the enhanced fuel contains boron in an amount operable
to reduce emissions and improve efficiency upon combustion of the
enhanced fuel as compared to the combustion of the hydrocarbon fuel
without the fuel additive. More preferably, the enhanced fuel
contains boron of between about 5 and 10 ppm by weight. Increased
amounts of boron up to 25 ppm boron by weight are effective as
well. It is notable that a very cost-effective solution can be
prepared with low weight percent of boron, i.e., less than 20 ppm.
Another preferred target is less than 15 ppm boron.
[0021] An alternate embodiment of the invention includes a process
for enhancing fuel performance of a hydrocarbon fuel in a
combustion system including the steps of adding a chemical addition
composition to the hydrocarbon fuel in an amount effective to
enhance fuel performance.
[0022] The chemical addition composition, also called the
dispersion fluid, can be created by creating an intermediate
aqueous parent dispersion by dispersing the borate salt in water.
The next step includes combining the aqueous boron-containing
parent dispersion with a carrier fluid in the presence of various
dispersants, surfactants and the like and then removing the water
to create the boron-containing dispersion fluid.
[0023] The parent solution, or the boron-containing dispersion
fluid of the invention, can be added into or include a combustion
fuel. Again, it can be advantageous to include dispersants to
promote dispersion in fuels that are hydrocarbon based. Exemplary
fuels are kerosene, diesel fuel and residual fuels.
[0024] An enhanced fuel is created when a substantial amount of a
fuel suitable for combustion is combined with an amount of the
boron-containing parent dispersion or the chemical addition
composition sufficient to reduce emissions or to increase
efficiency upon combustion of the enhanced fuel. Diesel and
gasoline are two examples of fuels suitable for combustion. Other
hydrocarbon fuels useful for combustion in a combustion engine are
also encompassed. In certain circumstances, the dispersion fluid is
a quantity of a target fluid, that is, a fluid that contains the
desired fuel.
EXAMPLE 1
Preparation of Boron-Containing Aqueous Parent Solution
[0025] Charged 83.5 grams of ammonium pentaborate octahydrate
(NH.sub.4B.sub.5O.sub.8-8H.sub.20; mol wt 544.3 grams/mole)) was
added to 417.7 grams of deionized water. The mixture was heated
with stirring to 80.degree. C. until all of the salt had dispersed.
The solution remained clear at 80.degree. C. and contained 1.8%
weight boron.
EXAMPLE 2
Preparation of the Boron-Containing Dispersion Fluid
[0026] To 1200 grams of a mineral oil basestock, in a 4-liter
Erlenmeyer flask, was added 90 grams of Lubrizol 400A, a
proprietary additive package containing a mixture of dispersants,
and 180 grams of kerosene. The mixture was stirred at ambient
temperature until clear solution was obtained. To the oil solution
was added 166.0 grams of the boron-containing aqueous parent
dispersion prepared in Example 1. The two solutions were mixed
together using a high speed hand mixture to form a water-in-oil
emulsion. The emulsion was transferred to a 3-liter round bottom
flask equipped with agitator and Dean-Starke trap with condenser.
The mixture was heated with agitation to a maximum temperature of
150.degree. C. over a period of about one hour to remove the water.
The result was a dispersion of the borate salt in the oil matrix.
The final water content was 6,480 ppm with a final theoretical
boron content of 1,827 ppm.
EXAMPLE 3
Preparation of Boron-Containing Two Cycle Engine Fuel Treatment
[0027] A lubricating oil suitable for dilution with gasoline and
use as two cycle engine fuel was prepared by mixing the boron
containing dispersion fluid of Example 2 with Tufflo 6036, a
proprietary additive package containing various detergents and
dispersants to a final boron content of about 300 ppm. Fuel was
then added to the mixture at a 50:1 ratio to provide a final boron
content of about 6 ppm.
EXAMPLE 4
Homelite Yard Broom II Leaf Blower Test
[0028] The Homelite Yard Broom II Leaf Blower is a hand held blower
that uses a 30 cc two cycle gasoline engine. The leaf blower is
used to screen for engine efficiency improvements, especially
increased fuel economy. To establish a baseline, the standard
Homelite two cycle oil was mixed 50:1 with regular unleaded
gasoline of 87 octane. Exactly 250 milliliters of the fuel mixture
was added to the leaf blower fuel tank. The engine was then run at
full RPM until the fuel was totally consumed and the engine died.
The run time, RPM and exhaust temperature were measured and
recorded. The test was repeated using the boron-containing oil from
Example 3 at 50:1 dilution and about 6 ppm boron. The result was an
increase in RPM of 2.3%, a decrease in exhaust air temperature of
6.5% and an increase in run time of 11.8%. These values demonstrate
a significant improvement in engine operation efficiency with the
boron-containing oil of the invention.
EXAMPLE 5
Diesel Fuel Combustion in an Open Flame
[0029] A diesel fuel fired open flame burner was used to measure CO
emissions. A baseline was established by burning untreated diesel
at specific and controlled fuel and air mixtures. For this test the
fuel:air mixture was not varied. The boron dispersion fluid of
Example 2 was diluted to 20 ppm B with high sulfur No. 2 diesel.
This mixture was then used to fuel the burner and over 14
measurements a reduction in CO of 11.5% was measured.
* * * * *