BRPI0610039A2 - hydrocarbon fuel additive consisting of inorganic, non-acidic boron compounds and related processes - Google Patents

Abstract

The present invention provides a fuel additive and a process for using and making the fuel additive. The fuel additive includes a salt containing non-acidic boron in a carrier fluid. The fuel additive enhances combustion by increasing fuel efficiency or decreasing pollutant production in a exhaust gas resulting from combustion of the fuel with the fuel additive.

Description

HYDROCARBON FUEL ADDITIVE CONSISTING INORGANIC, NON-ACIDIC BORO COMPOUNDS AND RELATED PROCESSES

Related Requests

This application is related and claims priority and benefit of Provisional Patent Application ÜS serial number 60 / 673,907, filed April 22, 2005, entitled "Additive For Hydrocarbon Fuel Consisting of Non-Acidic Inorganic Compounds of Boron and RelatedProcesses", which is incorporated here by reference in its entirety.

Technical Field of the Invention

The present invention relates to the field of fuel killers, and specifically to a boron-containing additive for hydrocarbon fuels used to improve efficiency and / or reduce pollution.

Background of the Invention

Many hydrocarbon fuels have been used, each with its own advantages and disadvantages. Examples of such fuels include gasoline, natural gas, diesel, kerosene, jet fuel, LPG, heavy distillates, GMP fuel, ethanol, coal, other similar solid hydrocarbon fuels. Chemical compounds have been used as fuel additives in the last century to improve various parameters, such as octane index, of various fuels. The use and subsequent prohibition of nagasolin lead has long been known. Tetraethyl lead had a positive effect on octane and a profoundly negative effect on the environment.

In addition to tetraethyl lead, several elements are known to have catalytic characteristics of combustion 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 specific applications. The disadvantages of certain iron compounds include limited gasoline solubility, toxicity and cost as an additive. Interaction with sulfur and sulfide precipitation may also occur, which is undesirable.

Another additive commonly used in gasoline is MTBE. Although this compound boosts octane levels significantly, it is considered to be the sejacarcinogenic compound. In addition, it mixes easily with water which is dangerous if there is a leak. Gasoline containing MTBE leaking from an underground tank at a gas station could potentially seep into the groundwater and contaminate the wells. As a result of the potential negative negative effect of MTBE on the environment, ethanol is also being evaluated as a degasoline additive to boost octane.

In addition to the industry's goal to increase combustion efficiency, reducing particulate matter and smoke emissions is also a concern, particularly for diesel fuel applications. The industry has not made substantial progress in the development of a fuel additive to reduce particulate matter and smoke emissions.

Finally, combustion parameters are adjusted to try to maximize the function to reduce CO and NO0X. Despite these and combinations of these attempts to minimize pollutants, fuel combustion continues to be the focus of interest to increase fuel efficiency and reduce pollutants. A fuel additive that includes a combustion catalyst to reduce particulate matter and smoke emissions from diesel engines. Buses, trucks and automobiles operating on gasoline fuels would be advantageous. It would also be advantageous for a fuel additive that would increase the efficiency and / or decrease pollutants for diesel fuel applications. It would be advantageous to reduce smoke, particulate matter and nitrogen emissions from fuel applications. An additive that does not result in deprecipated formation would also be advantageous. A hydrocarbon fuel additive that would reduce the level of NOx produced would also be advantageous. Finally, an additive that remained stable during the combustion process would be advantageous.

Summary of the Invention

Accordingly, the present invention provides a fuel additive comprising a mixture of at least one salt and a carrier fluid, the salt comprising [Y] aB bOc, wherein [Y] is a cation and the salt is non-acidic, the carrier fluid being operable. To keep salts within the carrier fluid in at least partially dispersed state, the fuel additive being operable to improve combustion when placed in contact with fuel in a combustion and burn zone, improved combustion being measurable by increased fuel efficiency or reduced pollutant production. exhaust gas resulting from the burning of the fuel and the fuel additive. A feature of the present invention is that [Y] is an ammonium compound. Alternatively, [Y] is an alkali metal.

The present invention also advantageously provides a process for improving the performance of a hydrocarbon fuel in a combustion system having a combustion zone comprising the steps of providing a combustible additive comprising a mixture of at least one sale of a carrier fluid, the salt comprising [Y] aBbOc, where [Y] is a cation and the salt is non-acidic, in an amount effective to improve combustion azone fuel performance and burn hydrocarbon fuel with the fuel additive. A feature of the present invention is that the fuel may be a solid or liquid hydrocarbon fuel.

Detailed Description

The present invention includes a fuel additive and a method of using the hydrocarbon fuel additive. The fuel additive of the invention includes a boron-containing salt which preferably includes [Y] 2B407, wherein Y is a cation. Ammonium is a preferred organic cation. Alkali metals are another preferred inorganic cation, more preferably those alkali metals with atomic weights below 50.0.

In one embodiment, the boron salts are at least partially dispersed in water or other aqueous fluid to create an original boron-containing dispersion. Borosal salts are dispersed in water or aqueous fluid, and no dissociation or dissolution of salts occurs. The stable dispersion of boron salts at a preferred particle size of 5 microns or less, more preferably 2-5 microns, provides a heterogeneous hydrocarbon fuel combustion catalyst that provides emission reductions and improvements in fuel economy.

In one embodiment of the present invention, the original boron-containing dispersion is added or mixed with a dispersing fluid. Dispersing fluid is a fluid that is operable to maintain salts within the dispersing fluid in an at least partially dispersible state and which is miscible, or capable of being maintained in solution, of hydrocarbon fuel. In a preferred embodiment, water, for example, is largely removed from the original boron-containing dispersion in the dispersion fluid by thermal means to create the fuel additive. The dispersing fluid is preferably a group II base oil. Other preferred dispersing fluids include light hydrocarbons, gasoline, polygas, kerosene, diesel, light naphtha oils, Group I, III, IV, V or VI base oils as defined by API , aromatic oils, polybutenes, polyglycols, heavier oils or combinations thereof.

The fuel additive is operable to improve combustion when in contact with the fuel, regardless of the sulfur content of the fuel. Improved combustion means that fuel efficiency is increased compared to fuel without the fuel additive, or that the production of pollutant in a discharge gas from combustion is reduced, or a combination of these effects. Typical pollutants may include NOx, particulate matter, carbon monoxide and other known pollutants resulting from the combustion of hydrocarbon fuel. It is observed that different geographic regions focus on minimizing a specific pollutant depending on air characteristics. Reduction of a target pollutant or a combination of pollutants, such as NOx and CO, is highly advantageous. Alternatively, increased fuel efficiency results in lower total pollutant volume as well as economic advantage.

When the fuel additive is prepared using ammonium compounds, the ammonium compounds are defined as those compounds containing NRX groups, where R may be, for example, hydrogen. NH4 is especially preferred. Ammonium compounds have been found to have particularly enhanced catalytic combustion properties, for example in terms of NOx reduction, when used in boron-containing salts according to the present invention.

Borate salts are essentially neutral, but more particularly not highly acidic. In a preferred embodiment, the original boron-containing dispersion has a pH between about 6.0 and 8.0. Acidoboric acid is typically not present in this relatively neutral pH range. For example, pentaborates and tetraborates are disclosed herein. The borate salts may be in any form including metaborate, orthoborate or any form of non-acidic borate, or combinations thereof. The salts may be anhydrous or various levels of hydration. Preferred boron salts according to the present invention are inorganic, non-acidic, insoluble and dispersible.

The original boron-containing dispersion of one embodiment of the invention may be used in any environment, for example in hydrophilic or hydrophobic environments. In the case of a hydrophobic environment, it may be necessary for a carrier fluid or fluids to be selected to allow adequate dispersion. In a preferred embodiment, the carrier fluid may be polyoxypropylene monols, diols and polyols; polyoxybutylene monols, diols and polyols, particularly Bayer ActaclearND17. A dispersant used in conjunction with 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 may preferably be a fluid of at least some hydrophilic nature that is susceptible to the fuel to act as a decompatibility agent together. with the dispersant.

The fuel additive of the invention is useful for improving combustion such that more complete combustion is achieved with increased combustion to CO2 and H2O compared to combustion of fuel without fuel additive. The result is a reduction in partial combustion products as well as NOx, thereby increasing fuel efficiency.

The fuel additive is used by adding the fuel additive in an amount sufficient to increase fuel efficiency and / or reduce pollutants. The terms improved and improved combustion refer to any of these effects. An example of reduced pollutants is a reduction of NOx and CO in a exhaust gas produced from an internal combustion engine or direct injection exposed flame burner. Advantageously, both effects are observed through the addition of the fuel additive of the present invention. A preferred embodiment includes the addition of between about 5 and 10 ppm boron by weight in the fuel by addition of the fuel additive. Increased amounts of boron up to 25 ppm boron by weight are also effective. It is noted that a very cost effective solution can be prepared with low percentage by weight of boron, i.e. less than 20 ppm. Another preferred target is less than 15 ppm boron. Relatively low boron concentrations advantageously provide economic advantages, may be more environmentally acceptable and may provide cleaner engine operations with reduced deposits and debris.

Included in the invention is a process for improving the 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 improve the fuel performance of the hydrocarbon fuel and burning hydrocarbon fuel with the fuel. fuel additive. The combustion system may be any known to those of ordinary skill in the art for hydrocarbon burning. The combustion system may include any of several internal combustion engines. In a preferred embodiment, this process is used as a liquid or liquefied hydrocarbon fuel. Alternatively, the process may also be used as solid hydrocarbon fuel. The result of adding the hydrocarbon fuel additive is an improved fuel having a substantial amount of hydrocarbon fuel suitable for combustion, and an amount of operable fuel additive to improve combustion. Preferably, the improved fuel contains boron in an amount operable to reduce emissions and improve combustion efficiency of the improved fuel compared to hydrocarbon fuel combustion without the fuel additive. More preferably, the improved fuel contains boron between about 5 and 10 ppm by weight. . Increased amounts of boron up to 25 ppm boron by weight are also effective. It is noted that a very cost effective solution can be prepared with low percentage by weight of boron, i.e. less than 20 ppm. Another preferred target is less than 15 ppm boron. An alternative embodiment of the invention includes a process for improving the 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 improve the efficiency of the fuel. fuel performance.

The chemical addition composition, also called dispersion fluid, can be created by creating an intermediate original aqueous dispersion by dispersing the borate salt in water. The next step includes combining the original aqueous boron-containing dispersion with a fluid carrier in the presence of various dispersants, surfactants and the like and then removing water to create the boron-containing dispersion fluid.

The original solution, or the boron-containing dispersing fluid of the invention, may be added to or include a combustion fuel. Again, it may be advantageous to include dispersants to promote dispersion in hydrocarbon fuels. Example fuels are kerosene, diesel fuel and residual fuels.

An improved fuel is created when a substantial amount of a suitable fuel for combustion is combined with an amount of the original boron-containing dispersion or chemical addition composition sufficient to reduce emissions or to increase the combustion efficiency of the improved fuel. Egasoline diesel are two examples of suitable combustion fuels. Other hydrocarbon fuels useful for combustion in a combustion engine are also covered. In certain circumstances, the dispersing fluid is an amount of a target fluid, that is, a fluid that contains the desired fuel. Example 1: Preparation of the aqueous solution containing boron

To 83.5 grams loaded ammonium pentaborate hydrochloride (NH4B508-8H20; mol by weight (544.3 grams / mol)) was added 417.7 grams of deionized water. The mixture was heated, with stirring, to 80 ° C until all osal dispersed. The solution remained clear at 80 ° C and contained 1.8 wt% boron.

Example 2: Preparation of Boron Containing Dispersing Fluid

At 1,200 grams of a base oil stock in a 4 liter Erlenmeyer flask, 90 grams of Lubrizol 400A, a patented dead pack containing a dispersant mix, and 180 grams of kerosene were added. The mixture was stirred at

room temperature until a clear solution was obtained. To the oil solution was added 166.0 grams of the original aqueous boron-containing 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 a Dean-Starke stirrer and condenser siphon. The mixture was heated with stirring to a maximum temperature of 150 ° C for a period of approximately 1 hour to remove water. The result was a dispersion of the borate salt in the oil matrix. Final water content was 6,480 ppm with a final borothoric content of 1,827 ppm.

Example 3: Preparation of Boron-containing two-stroke engine fuel treatment

A lubricating oil suitable for dilution with gasoline and use as a two-stroke motor fuel was prepared by mixing the boron-containing dispersion fluid of Example 2 with Tufflo 6036, a patented dead pack containing various dispersing detergents to a final boron content of approximately 300 ppm. The fuel was then added to the mixture in a 50: 1 ratio to provide a final boron content of approximately 6 ppm.

Example 4: Testing with foliage harvesterHelelite Yard Broom II

The Homelite YardBroom II foliage gatherer is a handheld machine that uses a 30cc two-stroke agasoline engine. The leaf collector is used to analyze improvements in engine efficiency, especially increased fuel economy. To establish a baseline, standard Homelite two-stroke oil was mixed 50: 1 with 87 octane ordinary unleaded gasoline. Exactly 250 milliliters of the fuel mixture was added to the leaflet's fuel tank. The engine was then started at full RPM until the fuel was completely consumed and the engine died. Operating time, RPM and discharge temperature were measured and recorded. The test was repeated using Example 3 boron-containing oil at a dilution of 50: 1 and approximately 6 ppm boron. The result was a 2.3% RPM increase, a 6.5% decrease in exhaust air temperature and a 11.8% increase in operating time. These values demonstrate a significant improvement in engine operating efficiency with the inventive boron-containing oil. Example 5: Combustion of diesel fuel in an exposed flame

An exposed diesel fuel burned burner was used to measure CO emissions. A baseline was established by burning untreated diesel fuel in specific and controlled fuel and air mixtures. For this test the fuel / air mixture was not varied. The deboro dispersion fluid of Example 2 was diluted to 20 ppm B with No. 2 diesel of high sulfur content. This mixture was then used to feed the burner and during 14 measurements a 11.5% CO reduction was evaluated.

Claims (20)

1. A fuel additive comprising a mixture of at least one salt and a carrier fluid, the salt comprising [Y] aBbOc, where [Y] is a cation and the salt is non-acidic, the carrier fluid being operable to keep salt within the Carrier fluid in a at least partially dispersed state, the fuel additive being operable to improve combustion when placed in contact with the fuel in a burned-off combustion zone, improved combustion being measurable by increased fuel efficiency or decreased pollutant output in a resulting exhaust gas. fuel combustion and fuel additive. The fuel additive of claim 1, wherein the salt is selected from the group consisting of metaborate, pentaborate, tetraborate and orthoborate and combinations thereof. The fuel additive of claim 1, further comprising [NH 4 E 2 O]. The fuel additive of claim 1, further comprising an ammonium compound. The fuel additive of claim 1, wherein the pH of the solution is between approximately 6.0 and 8.0. The fuel additive of claim 1, wherein the salt is inorganic. A process for improving the 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 improve the fuel performance of the combustion zone and burning the fuel. of hydrocarbon with the fuel additive. The process of improving the fuel performance of claim 7, wherein the hydrocarbon fuel is a liquid hydrocarbon fuel. The process of improving the fuel performance of claim 7, wherein the hydrocarbon fuel is a solid hydrocarbon fuel. The process of improving the fuel performance of claim 7, wherein the combustion zone is within a gasoline engine running engine. The process of improving the fuel performance of claim 7, wherein the combustion zone is within an engine running on diesel fuel. The process of improving the fuel performance of claim 7, wherein the fuel additive is operable to improve combustion when placed in contact with fuel in an exposed or direct flame burner in the burned zone, enhanced combustion being measurable by efficiency. increased fuel production or decreased pollutant in a discharge gas resulting from the combustion of the fuel and the fuel additive. An improved fuel comprising a substantial amount of hydrocarbon fuel suitable for combustion, and an amount of combustible additive of claim 1 operable to improve combustion. The improved fuel of claim-13, wherein boron is present in the hydrocarbon fuel in an amount between about 5 and -10 ppm by weight. The improved fuel of claim 13, wherein the amount of fuel additive is the amount operable to reduce improved fuel combustion emissions compared to combustion of hydrocarbon fuel without the fuel additive. The improved fuel of claim 13, wherein boron is present in the hydrocarbon fuel in an amount of less than approximately 25 ppm by weight. 17. A process for creating an improved hydrocarbon fuel for use in a combustion system comprising the steps of: adding an effective amount to improve the fuel performance of the hydrocarbon fuel of a chemical addition composition, the chemical addition composition comprising the product from the dispersing a boratonon acidic salt in water. The process of claim 17, wherein the salt is inorganic. 19. The process for creating a fuel additive to improve combustion of a hydrocarbon fuel, the process comprising the steps of: adding the salt [Y] aBbOc, where [Y] is a cation and the non-acidic salt to a fluid. to at least partially disperse the salt in the fluid to create an original boron-containing dispersion, mix the original boron-containing dispersion with fluid carrier such that the original boron-containing dispersion is generally dispersed in the carrier fluid; removing a substantial portion of the fluid from the mixture of the original boron-containing dispersion with the carrier fluid to create a fuel additive that is operable for improved combustion when added to a combustion zone in the presence of a hydrocarbon fuel and burnt. The process of claim 19, wherein the salt is inorganic.