Abstract:
A fuel additive for hydrocarbon fuel that is fueled in fired burners and open flames for enhancing fuel storage, for enhancing fuel combustion by increasing fuel efficiency, and/or for reducing undesirable emissions, such as pollutants, includes an inorganic metal oxide, a metal carboxylate, an acid, and an organic dispersion fluid.

Description:
TECHNICAL FIELD OF THE INVENTION 
       [0001]    The present invention relates to the field of fuel additives, in particular, to an additive for hydrocarbon fuel fueled in fired burners and open flames to enhance storage, combustion by increasing fuel efficiency, and/or reduce undesirable emissions, such as pollutants. 
       BACKGROUND OF THE INVENTION 
       [0002]    Many hydrocarbon fuels have been used, each with their own advantages and drawbacks. Examples of such fuels include diesel, kerosene, coke, fuel oil, heavy distillates and bunker fuels. Chemical compounds have been used as combustion improvers to enhance combustion efficiency, of these types of fuels. Many of these additives contain metallic elements such as 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 fuels, toxicity, and expense as an additive. Interaction with sulfur and creation of sulfide precipitate may also occur, which is undesirable. 
         [0003]    In addition to the goal of improved combustion efficiency, smoke emissions reduction is also a concern, particularly for heavier fuels in direct fired applications. The industry has not made substantial progress on development of a fuel additive for reducing smoke and particulate emissions in these applications. 
         [0004]    A fuel additive that includes a combustion catalyst to reduce smoke and particulate emissions from open flame burners and other direct-fired applications would be advantageous. A fuel additive that increases efficiency and/or decreases pollutants for diesel and heavier fuels used in these applications would be particularly advantageous. It would also be advantageous to reduce smoke, particulate and nitrogen emissions from fuel applications. In addition to reduction of NOx, reduction or elimination of HCN emissions is highly desirable. 
         [0005]    An additive that does not result in the formation of precipitates and burns clean during the combustion process would be desirable. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention includes a fuel additive composition, an enhanced liquid hydrocarbon fuel, and a process of using the fuel additive in relation to liquid hydrocarbon fuel. 
         [0007]    The fuel additive of the invention includes an organic metal oxide, a metal carboxylate, an acid, and an organic dispersion fluid. 
         [0008]    The process of the invention consists of the steps of combining a fuel additive in an amount effective in the liquid hydrocarbon fuel to enhance fuel performance to the direct fired burner or open flame, and combusting said liquid hydrocarbon fuel with the fuel additive. The fuel additive includes an organic metal oxide; a metal carboxylate, an acid, and a organic dispersion fluid. 
         [0009]    The enhanced liquid hydrocarbon fuel of the invention includes a substancial amount of liquid hydrocarbon fuel suitable for combustion in a fired burner or open flame; and an amount of fuel additive operable to enhance combustion that includes an organic metal oxide, a metal carboxylate, an acid, and an organic dispersion fluid. 
     
    
     DETAILED DESCRIPTION 
       [0010]    The present invention is directed to fuel additive compositions and processes for improving combustion in fired burners and open flames, and substantially reducing potentially hazardous exhaust emissions. This invention is particularly adapted for reducing the percentages of hydrocarbons, carbon monoxide and molecular oxygen in fired burners and open flames exhaust emissions. 
         [0011]    The term “hydrocarbon fuel” is employed herein to describe fuels in which carbon is the principal constituent and is intended to cover both powdered fuels such as coal and petroleum fuels oils which are primarily hydrocarbons. 
         [0012]    The term “liquid hydrocarbon fuel” is intended to include combustible pills which are liquid or are capable of being liquefied when preheated. Thus, many of the residual oils are semi-solid in nature and are heated to temperatures of around 82.22° C. (180° F.) in order to increase their fluidity before they are used as burning fuels in fired burners and open flames. It will be understood that the term “liquid hydrocarbon fuel” includes these semi-solid types of residual oils as well as the liquid types of fuel oils. 
         [0013]    While the invention is not limited to any theory, it is believed that the combined action of the active ingredients of the fuel additive composition in some way interferes with or alters the formation of sulfates of a type which would ordinarily produce adherent slag deposits. That the result is due to a combined or synergistic effect of the active components is indicated by the fact that neither metal oxide alone nor organic dispersion fluid alone nor acid alone nor metal soap alone will produce the desired result. 
         [0014]    The invention is especially advantage in improving the storage and transportation of the liquid hydrocarbon fuel by avoiding the slag deposits (improve the pre-flame condition of the liquid hydrocarbon fuel), also improves the combustion of liquid hydrocarbon fuel in fired burners and open flames by reducing the drop size during the spray of the liquid hydrocarbon fuel (improve the flame condition of the liquid hydrocarbon fuel), and substantially reducing potentially hazardous exhaust emissions (improve the post-flame condition of the liquid hydrocarbon fuel). 
         [0015]    The practice of the invention also reduces adherent acidic deposits, and provides a neutralizing action in the devices of the fired burners and open flames, therefore the corrosion is reduced. The compositions employed in the practice of the invention are readily prepared in a form in which they can be fed to the combustion chamber or the fuel while maintaining freedom from feeding difficulties in chemical vats, pumps, distribution lines and in fired burners and open flames. 
         [0016]    The fuel additive composition of the present invention is formulated by combining a variety of inorganic metal oxides and organic components. With respect to the inorganic metal oxides, the composition contains at least one metal oxide selected from the group consisting of magnesium oxide, iron oxide, copper oxide, cobalt oxide, ruthenium oxide, osmium oxide and palladium oxide, and combinations of the same, in a preferred embodiment, the metal oxide is magnesium oxide. For preferred compositions, the total amount of inorganic metal oxides utilized generally ranges from about 30% to about 40% by weight, and more preferably from about 33% to about 38% by weight. 
         [0017]    In an embodiment of the present invention, the inorganic metal oxide is added or mixed with an organic dispersion fluid. The organic dispersion fluid is a fluid that is operable to maintain the metal oxides 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. The organic dispersion fluid may be selected from the group of hydrocarbons, gasoline, polygas, kerosene, diesel, mineral oil, benzene, toluene, xylene, aromatic oils, polybutenes, polyglycols, heavier oils, naphtha, naphthalene, and combinations thereof. In a preferred embodiment, the organic dispersion fluid is naphtha. For preferred compositions, the total amount of organic dispersion fluid utilized generally ranges from about 10% to about 20% by weight, and more preferably from about 13% to about 17% by weight. 
         [0018]    The fuel additive composition of the present invention is neutralized by the addition of an acid that will substantially produce no water as a by-product. Typical acids include ammonium chloride, which is preferred, as well as ammonium salts of other common inorganic acids such as phosphoric, sulfuric and the like as well as organic acids such as acetic, citric and the like. For preferred compositions, the total amount of acid utilized generally ranges from about 1% to about 10 by weight, and more preferably from about 3% to about 7% by weight. 
         [0019]    The fuel additive composition of the present invention includes a suitable stabilizer such as metal carboxylates. Particularly suitable metal carboxylates include, but are not limited to manganese octoate, cobalt octoate, zirconium octoate, calcium octoate and mixtures thereof. For preferred compositions, the total amount of metal carboxylate utilized generally ranges from about 10% to about 20% by weight, and more preferably from about 13% to about 17% by weight. 
       EXAMPLES 
       [0020]    A fuel additive composition is prepared by combining 35% by weight of magnesium oxide, 15% by weight of calcium octoate, 5% by weight of ammonium chloride, and 15% by weight of naphtha. 
       Control Example 
       [0021]    A sample of coke without fuel additive was calcined in a muffle furnace to a temperature of 900° C. (1,652° F.). Table 1 shows the content percent of the ash and the ash composition. 
         [0000]    
       
         
               
               
               
               
             
               
               
               
               
             
               
             
               
               
               
               
             
           
               
                   
                 TABLE 1 
               
               
                   
                   
               
               
                   
                 Element 
                 Result (% P) 
                 Test method 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Ash 
                 0.79 
                 ASTM D-482 
               
             
          
           
               
                 Ash composition 
               
             
          
           
               
                   
                 Aluminium oxide 
                 &lt;0.45 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Calcium oxide 
                 9.10 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Iron oxide 
                 2.60 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Magnesoum oxide 
                 30.40 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Potassium oxide 
                 0.44 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Sodium oxide 
                 2.70 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Silicon dioxide 
                 11.25 
                 Gavimetric analysis 
               
               
                   
                 Vanadium pentoxide 
                 41.70 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Phosphates 
                 &lt;0.05 
                 Spectrophotometry 
               
               
                   
                 Sulfates 
                 1.60 
                 Gavimetric analysis 
               
               
                   
                   
               
             
          
         
       
     
       Example 2  
       [0022]    Use of 0.1% by weigth of the fuel additive composition described above in combination with coke. This combination of coke and fuel additive was calcined in a muffle furnace to a temperature of 900° C. (1,652° F.). Table 2 shows the content percent of the ash and the ash composition. 
         [0000]    
       
         
               
               
               
               
             
               
               
               
               
             
               
             
               
               
               
               
             
           
               
                   
                 TABLE 2 
               
               
                   
                   
               
               
                   
                 Element 
                 Result (% P) 
                 Test method 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Ash 
                 5.83 
                 ASTM D-482 
               
             
          
           
               
                 Ash composition 
               
             
          
           
               
                   
                 Aluminium oxide 
                 &lt;0.4 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Calcium oxide 
                 3.6 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Iron oxide 
                 0.6 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Magnesoum oxide 
                 74.7 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Potassium oxide 
                 0.12 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Sodium oxide 
                 0.27 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Silicon dioxide 
                 &lt;2.0 
                 Gavimetric analysis 
               
               
                   
                 Vanadium pentoxide 
                 5.16 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Phosphates 
                 &lt;0.05 
                 Spectrophotometry 
               
               
                   
                 Sulfates 
                 15.0 
                 Gavimetric analysis 
               
               
                   
                   
               
             
          
         
       
     
       Example 3  
       [0023]    Use of 0.15% by weigth of the fuel additive composition described above in combination with coke. This combination of coke and fuel additive was calcined in a muffle furnace to a temperature of 900° C. (1,652° F.). Table 3 shows the content percent of the ash and the ash composition. 
         [0000]    
       
         
               
               
               
               
             
               
               
               
               
             
               
             
               
               
               
               
             
           
               
                   
                 TABLE 3 
               
               
                   
                   
               
               
                   
                 Element 
                 Result (% P) 
                 Test method 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Ash 
                 3.98 
                 ASTM D-482 
               
             
          
           
               
                 Ash composition 
               
             
          
           
               
                   
                 Aluminium oxide 
                 &lt;0.4 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Calcium oxide 
                 4.38 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Iron oxide 
                 0.98 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Magnesoum oxide 
                 78.9 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Potassium oxide 
                 0.06 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Sodium oxide 
                 0.37 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Silicon dioxide 
                 &lt;2.0 
                 Gavimetric analysis 
               
               
                   
                 Vanadium pentoxide 
                 7.70 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Phosphates 
                 &lt;0.05 
                 Spectrophotometry 
               
               
                   
                 Sulfates 
                 7.70 
                 Gavimetric analysis 
               
               
                   
                   
               
             
          
         
       
     
       Example 4  
       [0024]    Use of 0.20% by weigth of the fuel additive composition described above in combination with coke. This combination of coke and fuel additive was calcined in a muffle furnace to a temperature of 900° C. (1,652° F.). Table 4 shows the content percent of the ash and the ash composition. 
         [0000]    
       
         
               
               
               
               
             
               
               
               
               
             
               
             
               
               
               
               
             
           
               
                   
                 TABLE 4 
               
               
                   
                   
               
               
                   
                 Element 
                 Result (% P) 
                 Test method 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Ash 
                 7.19 
                 ASTM D-482 
               
             
          
           
               
                 Ash composition 
               
             
          
           
               
                   
                 Aluminium oxide 
                 &lt;0.4 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Calcium oxide 
                 3.67 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Iron oxide 
                 0.57 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Magnesoum oxide 
                 91.90 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Potassium oxide 
                 0.05 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Sodium oxide 
                 0.19 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Silicon dioxide 
                 &lt;2.0 
                 Gavimetric analysis 
               
               
                   
                 Vanadium pentoxide 
                 3.50 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Phosphates 
                 &lt;0.05 
                 Spectrophotometry 
               
               
                   
                 Sulfates 
                 &lt;0.50 
                 Gavimetric analysis 
               
               
                   
                   
               
             
          
         
       
     
       Example 5  
       [0025]    Use of 0.05% by weigth of the fuel additive composition described above in combination with coke. This combination of coke and fuel additive was calcined in a muffle furnace to a temperature of 900° C. (1,652° F.). Table 5 shows the content percent of the ash and the ash composition. 
         [0000]    
       
         
               
               
               
               
             
               
               
               
               
             
               
             
               
               
               
               
             
           
               
                   
                 TABLE 5 
               
               
                   
                   
               
               
                   
                 Element 
                 Result (% P) 
                 Test method 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Ash 
                 2.74 
                 ASTM D-482 
               
             
          
           
               
                 Ash composition 
               
             
          
           
               
                   
                 Aluminium oxide 
                 &lt;0.4 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Calcium oxide 
                 3.1 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Iron oxide 
                 0.4 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Magnesoum oxide 
                 71.1 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Potassium oxide 
                 0.14 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Sodium oxide 
                 0.21 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Silicon dioxide 
                 &lt;2.0 
                 Gavimetric analysis 
               
               
                   
                 Vanadium pentoxide 
                 4.8 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Phosphates 
                 &lt;0.05 
                 Spectrophotometry 
               
               
                   
                 Sulfates 
                 19.1 
                 Gavimetric analysis 
               
               
                   
                   
               
             
          
         
       
     
       Example 6 
       [0026]    Use of 0.25% by weigth of the fuel additive composition described above in combination with coke. This combination of coke and fuel additive was calcined in a muffle furnace to a temperature of 900° C. (1,652° F.). Table 6 shows the content percent of the ash and the ash composition. 
         [0000]    
       
         
               
               
               
               
             
               
               
               
               
             
               
             
               
               
               
               
             
           
               
                   
                 TABLE 5 
               
               
                   
                   
               
               
                   
                 Element 
                 Result (% P) 
                 Test method 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Ash 
                 8.15 
                 ASTM D-482 
               
             
          
           
               
                 Ash composition 
               
             
          
           
               
                   
                 Aluminium oxide 
                 &lt;0.4 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Calcium oxide 
                 3.7 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Iron oxide 
                 0.61 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Magnesoum oxide 
                 93.9 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Potassium oxide 
                 0.06 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Sodium oxide 
                 0.21 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Silicon dioxide 
                 &lt;2.0 
                 Gavimetric analysis 
               
               
                   
                 Vanadium pentoxide 
                 4.0 
                 Atomic absorption 
               
               
                   
                   
                   
                 spectroscopy 
               
               
                   
                 Phosphates 
                 &lt;0.05 
                 Spectrophotometry 
               
               
                   
                 Sulfates 
                 &lt;0.5 
                 Gavimetric analysis 
               
               
                   
                   
               
             
          
         
       
     
         [0027]    In this manner, a reduction of vanadium peroxide (V 2 O 5 ) occurs and at the same time, the catalytic conversion of SO 2  to SO 3  is also expected to inhibit the formation of the highest oxidation level of vanadium; vanadium pentoxide. This reduction of vanadium pentoxide further reduces associated ash problems. 
         [0028]    Although the present invention has been described by way of particular embodiments and examples thereof, it should be noted that it will be apparent to persons skilled in the art that modifications may be applied to the present particular embodiment without departing from the scope of the present invention.