Patent Abstract:
A water-in-fuel emulsion system comprises a reactor device, a fuel intake connected to said reactor device, a water intake connected to said reactor device, a pump connected to said reactor device, and a circulating emulsion reprocessing inline loop connected to said pump and feeding a load as needed in real time, wherein said reactor device comprises a non-vibrating anvil shaped to create cavitation sufficient to emulsify water-in-fuel from said water intake and said fuel intake.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application, filed under 35 USC 111, is a continuation of International Application No. PCT/US2011/029306, filed Mar. 22, 2011, which is a continuation of U.S. application Ser. No. 12/761,685, filed on Apr. 16, 2010, which is a continuation-in-part of U.S. application Ser. No. 11/725,757, filed on Mar. 20, 2007, which is a non-provisional application of U.S. Provisional Application No. 60/786,881, filed on Mar. 30, 2006, the disclosures of which are incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention relates in general to emulsion. More particularly the invention relates to fuels and related compositions. Most particularly, the invention relates to methods, apparatus and systems for producing a fuel emulsion. 
         [0003]    Emulsion occurs when one liquid is suspended inside another liquid. Recent fuel developments have led to fuel emulsion, wherein water is suspended inside fuel. A number of water-in-fuel emulsions comprised essentially of a carbon based fuel, water, and various additives. These fuel emulsions may play a key role in finding a cost-effective way for internal combustion engines, boilers, furnaces and the like, to achieve greater efficiency and a reduction in emissions without producing significant modifications to the engines, fuel systems, or existing fuel delivery infrastructure. 
       SUMMARY OF THE INVENTION 
       [0004]    This invention relates to real time in-line a water-in-fuel emulsion system comprising a reactor device, a fuel intake connected to said reactor device, a water intake connected to said reactor device, a pump connected to said reactor device, and a circulating emulsion reprocessing inline loop connected to said pump and feeding a load as needed in real time, wherein said reactor device comprises a non-vibrating anvil shaped to create cavitation sufficient to emulsify water-in-fuel from said water intake and said fuel intake. 
         [0005]    Various advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a diagram of a fuel-water emulsion system. 
           [0007]      FIG. 2  is a diagram of a fuel-water emulsion system. 
           [0008]      FIG. 3  is a diagram of a fuel-water emulsion system. 
           [0009]      FIG. 4  is a cross-section of a reactor, showing an anvil encased spring. 
           [0010]      FIG. 5A  is a side view of a casing housing a self-contained fuel-water emulsion system. 
           [0011]      FIG. 5B  is a rear view of the system shown in  FIG. 5A , showing inlet and outlet ports for fuel, water and fuel-water emulsion. 
           [0012]      FIG. 5C  is a front view of the system in  FIGS. 5A and 5B , showing a pump drive. 
           [0013]      FIG. 6A  is a cross-section of an emulsion apparatus with inlet and outlet ports, an adjustable anvil, and a piezo electric drive. 
           [0014]      FIG. 6B  is a cross-section of the emulsion apparatus taken along lines B-B in  FIG. 6A . 
           [0015]      FIG. 7A  is cross-section of an injector installed in a cylinder head of an engine. 
           [0016]      FIG. 7B  is an enlarged view of Detail B shown in  FIG. 7A . 
           [0017]      FIG. 8  is a diagram of a fuel-water emulsion system, showing three-way valves and a flush system. 
           [0018]      FIG. 9  is a cross-section of a reactor, similar to that shown in  FIG. 4 , without an O-ring or spring. 
           [0019]      FIG. 10  is a diagram of a fuel-water emulsion system for small combustion devices. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0020]    Referring now to the drawings, there is illustrated in  FIG. 1  a block diagram of a system  100  for producing an intimate emulsion of water in oil at the point of combustion, wherein like numerals represent like parts throughout the several views. The system  100  may be in the form a real time in-line fuel-water emulsion system. Although the system may be in other forms, it may be in the form of a Hydrosonic system, wherein the flow of liquid creates cavitation and sound. The system  100  may be comprised of a fuel supply  110 , a water supply  120 , a fuel and water mixing junction  126 , a reactor or emulsion apparatus  150 , which may be near a point of combustion  190 . In addition, the system  100  may comprise an emulsified fuel circulating loop  170 , which may include a high pressure side  171 , a valve or solenoid valve (not shown), and a low pressure side  173 . 
         [0021]    The system  100  may produce an emulsion  160  comprising oil  161  and water  163 . In particular, an emulsified fuel  160  may be formed from water droplets  163  in fuel oil  162 . The viscosity of the emulsified fuel  160  may be changed by introducing an atom, a molecule, or a particle at the center of the water droplets  163 , so as to form a three layer emulsified fuel, wherein the atom, molecule, or particle is surrounded by water  163 , which in turn is surrounded by fuel oil  162  to form a three layer emulsified fuel. For example, the introduction of a carbon atom may form a three layer hydrocarbon emulsified fuel. 
         [0022]    In  FIG. 2 , there is illustrated a schematic diagram of a system  200  comprising a fuel line  210  connected to a fuel supply, a fuel filter  212 , a fuel return  214 , a fuel metering valve  215 , a fuel diverter  216 , a fuel inlet valve  218 , a water line  220  connected to a water supply, a shut off valve  222 , a metering valve  225 . The fuel line  210  and the water line  220  may be connected to a mixing junction  226  (e.g., a Tee junction), which may be connected to a pump  230  and a reactor or emulsion apparatus  250 , which may be interfaced or connected with the fuel line  210 . Additionally, the system  200  may comprise an emulsion circulating loop  270  having a high pressure side  271 , a low pressure side  273 , one or more static mixers  272  (which may be optional), a pressure bypass valve  279  and an emulsion delivery to combustion valve  274 . The system  200  may further comprise an emulsion return line  275  connected to a load (e.g., an engine, a boiler, turbine, furnace or other device), a fuel return emulsion isolation valve  276 , an emulsion feed or combustion line  277  connected to the load, and an emulsion return valve  278  connected to the low pressure side  273  of the emulsion circulation loop  270 . 
         [0023]    When the fuel diverter  216  is closed and the valve  218  is opened, fuel flows through the metering device  215 , which may be controlled electronically or simply allowed to flow according to the demands of the load. Water may be introduced via the water line  220  through the shut off valve  222  to the metering device  225 . This may be done proportionately. Fuel and water, thus proportioned, may converge at the mixing junction  226  and may be delivered to the pump  230 . The pump  230  may pressurize and deliver the fuel and water mixture to the emulsion apparatus  250  where the fuel and water mixture may be constituted as an emulsion. From the emulsion apparatus  250 , the emulsion may enter the emulsion circulating loop  270  on the high-pressure side  271  of the emulsion circulating loop  270  and through the static mixer  272  and the pressure bypass valve  279 , which may maintain a desired delivery pressure through the emulsion to combustion line  277  via the fuel line  210 . 
         [0024]    The greater part of the emulsified fuel may be returned by the pressure bypass valve  279  to the low-pressure side  273  of the emulsion circulation loop  270  to the pump  230  to maintain stability of the emulsion in the emulsion circulation loop  270 , where the emulsion may be in a constant circulation at a rate that may be greater than the consumption rate of the load. The static mixers  272  may be desirable if the emulsion circulation loop  270  is sufficiently long. 
         [0025]    The emulsion that has been consumed may be constantly replenished by the proportioned mixture of fuel and water. The fuel return line  214  may be isolated from the main fuel supply by the fuel return emulsion isolation valve  276 , which when closed, may divert returned emulsion back to the low pressure side  273  of the emulsion circulation loop  270  to be maintained along with other unconsumed emulsion. 
         [0026]    The system  200  may be installed in parallel with an existing conventional fuel (e.g., a non-emulsified fuel) delivery system in order to facilitate rapid changeover between the emulsion and the existing conventional fuel supply. The reasons for the dual parallel system are to flush the injector pump, the fuel delivery pump, and the fuel line to avoid contamination by water when the emulsion separates during extended shut down, and to avoid interruption of service during maintenance by incorporating certain redundancy. Since the existing conventional fuel delivery system is still intact and the fuel-water emulsion system is in parallel and simply interrupts the existing conventional fuel supply and the return lines, the change over between the fuel-water emulsion and the existing conventional fuel supply may be accomplished easily as follows. During the emulsion mode of operation, the fuel inlet valve  218 , the metering valve  222 , and the emulsion return valve  278  are open. The fuel diverter valve  216  and the fuel return emulsion isolation valve  276  are closed. During conventional fuel mode, the fuel inlet valve  218 , the metering valve  222 , and the emulsion return valve  278  are closed and the fuel diverter valve  216  and the fuel return emulsion isolation valve  276  are open. The changeover from conventional fuel to emulsion fuel may be automated by using solenoids or other equivalent automation for controlling the valves  216 ,  218 ,  222 ,  276  and  278 , instead of using the manual valves. 
         [0027]    The operation of the system  200  is described as follows. As the diverter valve  216  is closed and the fuel inlet valve  218  is opened, fuel flows through metering fuel device  215 , which may be controlled electronically or simply allowed to flow according to the demands of the load. Water (e.g., tap water) is introduced through the water line  220  through the shut off valve  222  to the metering valve  225  proportionately. The fuel and water, thus proportioned, converge at fuel and water mixing junction  226  and are delivered to the pump  230  to be pressurized and delivered to the reactor or emulsion apparatus  250 , where they are comprise an emulsion. From the emulsion apparatus  250 , the emulsion may enter the emulsion circulating loop  270  on high-pressure side  271  and through an optional static mixer  272  and pressure bypass valve  279 , which maintains the desired delivery pressure through emulsion to the combustion line  277  via the fuel line  210 . The greater part of the emulsified fuel is returned by the pressure bypass valve  279  to the low-pressure side  273  of the emulsion circulating loop  270  to the pump  230  to maintain stability of the emulsion in the emulsion circulating loop  270 , where it is in constant circulation at a rate greater than the consumption rate of the load. The static mixers  272  may be desirable if the emulsion circulating loop  270  is sufficiently long. 
         [0028]    The emulsion that has been consumed is constantly replenished by the proportional fuel and water supply. The fuel return line  214  is isolated from the fuel supply by the isolation valve  276 , which when closed, diverts returned emulsion back to the low pressure side  272  of the emulsion circulating loop  270  to be maintained along with the rest of the unconsumed emulsion. 
         [0029]    In  FIG. 3  there is illustrated a schematic diagram of a system  300  of this invention comprising a fuel line  310 , a fuel filter  312 , a fuel return  314 , a fuel metering valve  315 , a fuel diverter  316 , a fuel inlet valve  318 , a having a water line  320  having a shut off valve  322  and a metering valve  325 , a fuel water mixing junction  326 , a pump  330 , a reactor, such as the Hydrosonic emulsion apparatus  350 , an existing fuel supply  360 , an emulsion circulating loop  370 , having a high pressure side  371 , a low pressure side  373 , one or more static mixers  372 , an emulsion delivery to combustion valve  374 , an emulsion return line  375  connected to a load, a fuel return emulsion isolation valve  376 , an emulsion combustion line  377  connected to the load, and an emulsion return valve  378  connect to the low pressure side  373  of the emulsion circulation loop  370 .  FIG. 3  also illustrates an open loop  370 , which may incorporate a float switch  368  in a production tank  369 . The float switch  368  may activate the fuel inlet valve  318  and the shut off valve  322  simultaneously (e.g., by solenoid or other suitable device) in order to replenish the emulsion production tank  369  and emulsion circulating loop  370  at a substantially constant and proportional rate of flow. 
         [0030]    In  FIG. 4 , there is illustrated a cross-section of an exemplary reactor or emulsion apparatus  400  suitable for use in the systems  200 ,  300  described above. The emulsion apparatus  400  may include a housing or casing  450 , an inlet  460 , an orifice  462 , an inlet end-cap  463 A, an outlet end-cap  463 B, an anvil  464 , a threaded or partially threaded shaft  465 , a spring  466  encased within the anvil  464 , an external adjustment  467 , an  0 -ring seal  468 , and an outlet  469 . Fuel and water entering the inlet  460  may pass through the orifice  462  and impinge on the anvil  464  to create a substantially constant cavitation along the trailing surface of the anvil  464  sufficient to emulsify the water in the fuel. The emulsion may exit through the outlet  469  directly to the load via the emulsion loop. 
         [0031]    The anvil  464  may be attached on the threaded shaft  465 , which may or may not carry the  0 -ring  468 . The threaded shaft  465  may allow for adjustment in the compression of the spring  466  by means of a stop-nut  474  threadably engageable with a threaded shaft  480  in an end cap of the casing  450 . The shaft  480  is provided with a seal  479 . Pressure, amplitude and frequency may be adjusted externally by the external adjustment  467  in order to obtain optimum cavitation. 
         [0032]    The anvil  464  does not vibrate on the spring  466  but rather the velocity of the liquid and pressure drop across the face combined with the shape of the anvil  464  creates a substantially constant cavitation, which may roll down the trailing surface of the anvil  464 . The spring  466  may maintain a constant pressure between the anvil  464  and inlet orifice  462  and act as a pressure relief in case blockage occurs. 
         [0033]    An exemplary process for assembling the reactor or emulsion apparatus  400  may comprise one or more steps selected from the group comprised of providing or machining a substantially cylindrical anvil having an opening near a working surface, adding an O-ring seal inside the opening in the anvil near the working surface, providing or machining a shaft that is at least partially threaded, installing a spring stop or adjustable nut on the threaded shaft, sliding a spring onto the threaded shaft, sliding the anvil over the threaded shaft and the spring, encasing the spring with the anvil, sealing the anvil and shaft with the O-ring, encasing the anvil in a chamber, providing an emulsion outlet port from the chamber, installing a threaded end of the threaded shaft in an outlet side of the chamber, providing or machining a low pressure side outlet end cap with a threaded hole, installing the end cap on the shaft at a low pressure side of the chamber, providing or machining a high pressure side inlet end cap with an inlet orifice machined to match the working surface of the anvil, installing the high pressure side inlet end cap onto the other end or a high pressure side of the chamber, connecting the inlet orifice to a pump discharge, and connecting the outlet port to an emulsion circulating loop. 
         [0034]    In  FIGS. 5A-5C , there is illustrated a compact self-contained emulsion system  500 , which may be particularly suitable for smaller emulsion applications. The system  500  may be comprised to a fuel inlet  510 , a fuel return  514 , a water inlet  520 , a housing or casing  550 , an emulsion outlet  571 , an emulsion return  572 , and a pump pulley or other suitable pump drive  590 , which may be connected to the load. The pump may be electrical, hydraulic or magnetic. Besides being compact and self-contained, the emulsion system  500  may be powered by the load on which it is installed. The system  500  may combine the pump  230 ,  330  and the reactor or emulsion apparatus  250 ,  350  in the housing  550 . The emulsion outlet  571  and the emulsion return  572  may respectively form the high pressure side and the low pressure side of an emulsion circulating loop. 
         [0035]    In  FIGS. 6A-6B , there are illustrated cross-sections of a reactor or emulsion apparatus  600  suitable for use in the systems  200 ,  300  described above. The apparatus  600  may be in the form of a piezoelectric ally driven unit comprising an emulsifying chamber with an adjustable anvil or working surface  664 . The apparatus  600  may be comprised of a fuel inlet  610 , an adjustable fuel control valve  615 , a water inlet  620 , an adjustable water control valve  625 , a body or casing  650 , an emulsion outlet  661 , an adjustable anvil or working surface  664 , an external anvil adjustment  667 , an adjustment lock and seal  668  (e.g., a locking and sealing nut), an emulsion return  675 , a mixing or emulsifying chamber  680 , an O-ring seal  682 , and an ultrasonic piezoelectric probe  685  (e.g., acoustic type probe). This configuration may not require its own pressure pump, as it may be driven by the existing conventional fuel delivery system pump. 
         [0036]    In  FIG. 6A , there is illustrated a side cross-section of the emulsion apparatus  600  taken along the line A-A in  FIG. 6B , showing the fuel return  675 , the emulsion outlet  661 , and adjustable anvil or working surface  664 , the anvil adjustment  667  and adjustment lock and seal  668 , which together enable adjustment of the emulsifying chamber  680 . The piezoelectric ally driven probe  685  may work against the adjustable anvil  664 , creating cavitation within the fuel and water sufficient to form a homogenous emulsion. The probe  685  may be sealed within the casing  650  by the  0 -ring seal  682  at its nodal point. 
         [0037]    In  FIG. 6B , there is illustrated a top cross-section taken along the line B-B in  FIG. 6A , showing the fuel inlet  610  controlled by the adjustable fuel control valve  615  and the water inlet  620  controlled by the adjustable water control valve  625 , the emulsion outlet  661  connected to the load, the emulsion return port  675 , and the anvil working surface  664 . 
         [0038]    A process for emulsifying fuel-water in accordance with any one of the system above may comprise one or more steps selected from the group comprised of diverting and metering and controlling a fuel line into an inlet, delivering metering and controlling water into the inlet resulting in proportioned mixture of fuel and water, pumping the proportioned mixture into an emulsion apparatus via a pump, impinging the mixture across an anvil causing cavitation which in turn results in emulsification of water-in-fuel. The method may further comprise the steps of circulating the water-in-fuel emulsion into an emulsion circulating loop in series with the pump and the emulsion apparatus, delivering the water-in-fuel emulsion to a load (e.g., an engine, a boiler, a turbine, furnace, or other device), isolating a fuel supply return from the emulsion circulating loop, re-circulating and reprocessing any unused emulsion through the pump into the emulsion circulating loop in series with the emulsion apparatus. 
         [0039]    In  FIGS. 7A-7B , there is illustrated a compact self contained piezoelectric ally driven fuel-water emulsion injector system  700 , which may atomize and deliver emulsified fuel directly to a load, such as an engine combustion chamber  790 . The system  700  may be comprised of a fuel inlet  710 , a water inlet  720 , a piezoelectric metering valve  715 , a check valve  716 , a piezoelectric ally driven ultrasonic injector tip  728 , a cup  730  formed, machined or otherwise integrated into a casing, housing or body  750 , an  0 -ring seal  782 , and an ultrasonic or piezo-electric crystal stack probe  785 . The combustion chamber  790  may be comprised of a cylinder head  792 , a cylinder wall  794 , a piston  796 , and a connecting rod  798 . The system  700  may include a configuration for the injection and atomization of fuel at low pressure and varying viscosities and volumes, via the piezo-electrically driven ultrasonic injector tip  728 , directly to the combustion chamber  790 . 
         [0040]    In  FIG. 7A , there is illustrated a side view of the injector system  700  installed in relation to the combustion chamber. The piezo electric probe  785  of the injector system  700  vibrates the tip  728 . A vibration of approximately  20 , 000  cycles per second may emulsify the fuel-water mixture delivered through the fuel inlet  710  and the water inlet  720  through the check valve  716  to the cup  730  where the fuel and the water are simultaneously emulsified and atomized directly into the combustion chamber. The cup  730  may be formed in the body  750  and the probe  785  may be sealed within the body  750  by the O-ring  782  at the nodal point of the probe  785 . The cup  730  may be formed so as to protrude directly into combustion chamber  790  and the cylinder head  792  in the place of a conventional injector. Due to more complete combustion, less carbon is built up and less wear and tear is experienced by the piston  796  and the cylinder wall  794 . The connecting rod  798  is illustrated in the interest of clarity. 
         [0041]    In  FIG. 7B  there is illustrated an enlarged view of Detail B shown in  FIG. 7A , showing the cup  730  formed into the injector body  750 , although it may be otherwise formed in the injector or the atomizing tip  728 . 
         [0042]    In diesel engine practice, the high injection pressures may necessitate very precise pumps and in order to atomize the fuel at a very high pressure. The injector system  700  may use low injection pressures and a method of atomization that would allow a wide range of fuel to be used. For instance, distillates, residuals, emulsions and slurries could all be used with equal facility. 
         [0043]    In  FIG. 8 , there is illustrated an emulsion fuel system  800 , similar to system  200 , utilizing three-way valves and a secondary bypass  803  in order to avoid any unburned emulsion retutning to fuel supply  802 . The three-way valves replace the two-way valves  270 ,  278  in the system  200 . The operation of the system  800  may be similar to the system  200 , except upon shutdown. When shutdown, the valves  817 ,  879  are returned to the fuel position. A diverter valve  804  diverts returning emulsion in the fuel to a return line  814 , and back to the combustion device  803  via line  805 , which may be connected to the fuel inlet line  810  for a time sufficient for all emulsion to be consumed by the combustion device  803 , at which time the diverter valve  804  returns to the fuel position. This system may be controlled automatically by a simple electronic circuit with the following logic. The load (e.g., the combustion device  803 ) starts. The emulsion unit  801  starts. The three-way valves  817 ,  879 ,  804  are in the fuel position. Load running reactor pressure is achieved. The valves  817 ,  879 ,  804  switch to emulsion position, diverting fuel in line  810  through the emulsion unit  801  and isolating the fuel supply  802  from return line  814 . At this stage, the load  803  is running on emulsion. To shut down, the emulsion unit  801  shuts down. The three-way valves  817 ,  879  return to the fuel position. The diverter valve  804  continues to divert the return line  814  back to load via the bypass  805  until all emulsion has been consumed and replaced by pure fuel entering the fuel inlet line  810  directly from fuel supply  802 . When all emulsion has been consumed, the diverter valve  804  returns to the fuel position and combustion device  803  shuts down 
         [0044]    In  FIG. 9 , there is illustrated a cross-section of a reactor or emulsion apparatus  900  similar to the reactor  400 , without a spring and including a closed anvil  964 , eliminating the need for an O-ring seal, which may be used in the systems  200 ,  300 ,  800 , as well as other processing applications. The reactor  900  may include a tubular housing or casing  950 , an inlet  960 , an orifice  962 , an inlet end cap  963 A, an outlet end cap  963 B, a stationary anvil  964  with a cone-shaped end creating orifice  962 , and a lip  967 . The anvil  964  may be supported by a threaded rod  965 . The orifice  962  may be adjusted by means of external adjustment  967 . The seal  978  may prevent leakage between threaded rod  965  and end cap  963 B. One or more miscible or immiscible liquids or solids may pass through the orifice  962 . The orifice  962  may cone-shaped with an angle corresponding to the angle of a cone-shaped anvil  964 . The liquids or solids accelerate along the anvil  964  and around the lip  967 . This may create a pressure drop, which may create cavitation along trailing surface of the anvil  964  sufficient to create an emulsion or breakdown of solids within the liquid. The area of the space between the anvil  964  and the casing  950  may be at least as great as the area of the diameter of outlet  979 . Once processed, material may exit the reactor through the outlet  979 . 
         [0045]      FIG. 10  illustrates an emulsion fuel conversion  1000  that may be used on smaller combustion devices. A standard fuel, such as heating fuel or biodiesel, may flow through an existing fuel inlet line  1002 , which is fitted with check valve  1004 . The fuel may be mixed with water at mixing tee  1006 . The water may be introduced by means of line  1008  controlled by a solenoid valve  1010 , which may be normally closed, and check valve or back flow preventer  1014 . The water flow may be controlled by a fixed orifice or Dole type flow control valve  1016 . The size of the control valve  1016  may be determined by the capacity of the combustion device. For example, if an oil burner has a one gallon per hour nozzle and 15% emulsion is required, the control valve  1016  may be sized at 0.15 gallons per hour. The water thus metered may be introduced to the fuel stream at the mixing tee  1006 . The proportioned fuel-water mixture may flow into an existing pressure pump  1018 . If the flow rate of the pressure pump  1018  is greater than the burn rate of the combustion device, the mixture may be re-circulated many times. A shearing effect emulsifies the mixture. Emulsified and pressurized, the emulsion fuel flows to the burner nozzle or injector  1020 . The shearing effect and pressure drop across the nozzle  1020  may serve to further reduce particle size and evenly distribute the water particles throughout the emulsion, whereupon it may be immediately combusted. The system  1000  may utilize a control  1012 , which may be connected to existing combustion device on/off controls. This may automatically open the solenoid valve  1010  after the combustion device starts and close solenoid valve  1010  a short time before combustion device stops. 
         [0046]    The ultrasonic probe  785 , in which a booster and a velocity transformer are engineered to withstand the compression pressure of a diesel engine, will atomize the fuel ultrasonically as it passes its tip, since the pressures of the fuel and the pressures in the combustion chamber are at or near equilibrium at the top of the stroke. The fine atomization and precise control afforded by this device should improve efficiency and reduce emissions. 
         [0047]    A process for emulsifying water-in-fuel may comprise one or more steps selected from the group comprised of assembling an emulsion chamber with plurality of inlet and outlet ports, diverting fuel from an existing fuel supply line to the inlet port of the emulsion chamber, introducing water from 5% to 30% volume with respect the fuel volume to the inlet port, cavitating the mixture in the emulsion chamber resulting in emulsification, circulating the emulsion in an emulsion circulating loop around the emulsion chamber, delivering a smaller part of the emulsion to a load on demand, re-circulating excess emulsion in the emulsion circulating loop at a rate greater than maximum demands of the load, replenishing the emulsion in the emulsion circulating loop from the emulsion chamber, and replenishing fuel and water supply at the inlet ports. 
         [0048]    The process for producing a fuel may comprise the step of delivering water and oil (e.g., hydrocarbon fuels, biofuels, or other fuels) to an apparatus in the form of a reactor or emulsion apparatus, which may create sufficient substantially constant cavitation to create an emulsion without the use of chemical surfactants or emulsifiers. The emulsified fuel may be delivered directly to the burner or an injector pump, which may draw on demand, with excess emulsified fuel re-circulating back through the apparatus in a constant circulating loop at a greater rate than the maximum requirements of the load or application. The apparatus for creating cavitation may be comprised of a reactor or emulsion apparatus in which fuel and water enter an orifice and impinge on a specially shaped, spring loaded anvil, which encloses the spring so as not to interrupt the flow of cavitation bubbles. 
         [0049]    The emulsified fuel may be sent to a storage tank, which may feed the load (e.g., an engine, a boiler, a turbine, furnace, or other device). If supply exceeds demand, the emulsified fuel may be re-circulated through the apparatus at reduced pressure and flow. Due to the thixotropic nature of the emulsion and the cavitation effect of the apparatus, this process may also be used to reduce the viscosity of fuels in order to make the fuels more mobile. 
         [0050]    The apparatus may include a structure to agitate the fuel-water to create cavitation, which may include a chamber comprising two adjustable angled flat blades, which converge to form a flat aperture. Pressurized fuel-water may cavitate along these blades due to the shape of the blades, the flow of the fuel-water through a flat aperture, and the impingement of the fuel-water on to a third adjustable flat blade, causing all three blades to vibrate, causing cavitation within the mixture to form a finely dispersed stable emulsion with reduced viscosity. 
         [0051]    The systems, apparatus and methods described above may produce an ultra fine droplet size that has a less dramatic an effect on the secondary atomization or micro explosions that may occur when the water turns to super heated steam in the combustion chamber. Water droplets of ten plus microns inside a film of oil or other fuel are more effective in causing micro explosions or scattering and re-atomizing the fuel. This presents more fuel surface area for a more complete combustion, resulting in less unburned fuel which translates to reduced emissions and fuel consumption. 
         [0052]    These simple onboard or onsite apparatus may assure a constant supply of substantially uniform emulsion at the desired water and fuel ratio, water dispersion, or droplet size to the load (e.g., an engine, a boiler, a turbine, furnace, or other device), which may otherwise be unstable but for the emulsion maintained in the circulating loop. 
         [0053]    It should be appreciated that the shape and size of the apparatus or system may be modified, as may the shape and size of the various components, including the anvil. Additionally, the pressure across the anvil may be varied. Further, the apparatus may be in the form of a Hydrosonic or ultrasonic device, a colloid mill, a cavitating valve, a liquid whistle, or other suitable device that may produce cavitation or otherwise suitably change in character in a fuel-water mixture. 
         [0054]    The apparatus, system and process may be safe, secure, simple, elegant, sleek and aesthetically pleasing. They may be easy to manufacture, install, use or operate, and service or maintain. They may be efficient, affordable and cost effective. They may be long lasting and durable, and provide rugged reliability. They may have a low high mean time between failures. They may be easy to store and ship for portable applications. They may provide an alternative to costly exhaust side emissions management 
         [0055]    The apparatus, system and process may be universal in application for providing energy for all types of loads and incorporated into all types of loads, including engines, boilers, turbine, furnaces, and other devices. They may be easily scaled up or down in size. The emulsion may be operate or delivered to multiple loads. 
         [0056]    The apparatus, system and process may be user friendly so as to be suitable for a novice as well as sophisticated expert user. They may be intuitive and user transparent, such that it requires no additional training. 
         [0057]    The apparatus, system and process may mainly standard off the shelf modular parts and other components. They may be integrated in-line as an OEM apparatus, system or process, or as an aftermarket or retrofit apparatus, system or process into the load environment. They may utilize existing parts, controls, modules and operating procedures, obviating any further training of the operators. They may be packaged as an integrated unobtrusive compact modular apparatus, system and method. They may be made of modular components. They may be manufactured and maintained with ease. They may be user friendly and use mainly standard off the shelf modular parts and other components. 
         [0058]    The apparatus, system and process may readily facilitate switching back and forth between a conventional fuel delivery system and an emulsified fuel system automatically so as to be operator transparent. Additionally, they may facilitate an automatic switch in the case of a system failure. They may provide easy interruption free installation without substantially modifying the existing load with little down time and even zero down time in the case of redundant conventional fuel delivery systems. 
         [0059]    Start-up, shutdown and emulsion flush cycles may be automated and also controlled by management system or computer of the load, or by simple timers, or by other suitable devices. Water and fuel ratios may be controlled by the management system or computer of the load (e.g., an engine, boiler, turbine, furnace and other device), or by real time emissions monitoring devices. 
         [0060]    The emulsion system pump may replace the existing or conventional fuel delivery system pump, which may function as redundant or back up pump. Alternatively, pressure to create cavitation may be achieved by existing the fuel delivery system pump or the injector pump. In certain applications, the fuel and water may be emulsified by the fuel delivery system pump, or by an atomization device, once delivered by the emulsion circulating loop. 
         [0061]    The apparatus, system and process may provide uniform emulsification. They may provide emulsified fuel in real time on demand. They may circulate emulsified fuel in a loop at a rate greater or far greater (e.g., an order of magnitude) than the demands of the load. 
         [0062]    All types of fuels, including hydrocarbon fuels (e.g., fossil fuels), biofuels, and other fuels, any be emulsified by the apparatus, systems and processes. The apparatus, system and process may have the ability to adjust water ratio for special applications as balance between economy and environment. The fuel type or viscosity may be changed by introducing an atom, molecule or other equivalent particle at the center of the water droplet. Other materials, such as powdered limestone, may be added to an aqueous phase to serve as a vehicle for sulfur, which may then be captured on the exhaust side. They may reduce fuel viscosity, for example, in the case of hydrocarbons, Bitumen. 
         [0063]    The apparatus, system and process may use little additional energy when compared to the potential savings. They may reduce emissions, reduce fuel consumption of the load, and otherwise be environmentally friendly. They may reduce maintenance and hence reduce life cycle cost of the load. 
         [0064]    The apparatus, system and process may meet all federal, state, local and other private standards guidelines, regulations, and recommendations with respect to safety, environment, and energy consumption. They may be reliable, such that risk of failure is minimized, require little or no maintenance, and have a low mean time between failures. They may be long lasting made from durable material. They may be physically safe in a normal environment as well as in accidental situations. 
         [0065]    Features and functions of the electronics and controls associated with the apparatus, systems or processes may also be modified. The apparatus, system and process may have multiple uses in a wide range of situations and circumstances. They may easily adaptable for other uses. For example, they may be adapted for use in applications, such as emulsifying food, paint, cosmetics, and the like. 
         [0066]    Other changes, such as aesthetics and substitution of newer materials, as they become available, which substantially perform the same function in substantially the same manner with substantially the same result without deviating from the spirit of the invention may be made. 
         [0067]    In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.

Technology Classification (CPC): 8