CAVITATION PROCESS FOR WATER-IN-FUEL EMULSIONS

Abstract

A cavitation process for preparing a water-in-oil emulsion including a) adding water to fuel in a range of 5% to 35% of the total volume; b) feeding both water and fuel into an enclosed space, where the mixture is accelerated through a pressure rise induced by a pumping system; c) forcing the mixture through an acceleration tunnel where it hits a first cavitation barrier with adjustable bolts; d) feeding the mixture through a first decompression chamber causing a pressure decrease and subsequent vaporization of the mixture to form a vaporized mixture, forming water droplets whose diameter ranges from 1 m to 3 m; e) feeding the vaporized mixture on the second cavitation barrier with adjustable bolts, to a second decompression and forming water droplets of diameter of 0.1 m or less.

Claims

1. A cavitation process for preparing a water-in-oil emulsion, comprising: a) adding water to fuel in a range of 5% to 35% of the total volume; b) feeding both water and fuel into an enclosed space, wherein the mixture is accelerated through a pressure rise induced by a pumping system; c) forcing the mixture through an acceleration tunnel wherein it hits a first cavitation barrier with adjustable bolts; d) feeding the mixture through a first decompression chamber causing a pressure decrease and subsequent vaporization of the mixture to form a vaporized mixture, forming water droplets whose diameter ranges from 1 m to 3 m; e) feeding the vaporized mixture on the second cavitation barrier with adjustable bolts, to a second decompression and adjusting the number and arrangement of adjustable bolts in order to control the formation of water droplets with a diameter between 0.1 m and 1 m.

2. A cavitation reactor for use in the process of claim 1, the reactor comprising a flanged prismatic body with a polygonal section with an acceleration tunnel comprising three distinct zones: a mixture entry; an acceleration tunnel, and a first and second decompression or expansion chamber wherein the second expansion chamber is also the mixture outlet.

3. The cavitation reactor according to claim 2, wherein the polygonal section of the reactor is triangular, quadrangular, hexagonal or octagonal.

4. The cavitation reactor according to claim 2, wherein the reactor is made of steel, tungsten or titanium.

5. The cavitation reactor according to claim 2, wherein the two cavitation barriers with adjustable bolts are placed in the acceleration tunnel in order to separate the two decompression chambers.

6. The cavitation reactor according to claim 2, wherein the adjustable bolts are adjustable from the reactor's outer part.

7. The cavitation reactor according to claim 6, said bolts comprising a fixing nut to fasten the plug to the reactor body, and a sealing nut to tighten the plug.

8. A Water-in-oil emulsion obtainable by the process of claim 1 wherein a water/fuel ratio is between 5% to 35% of the total volume, the water droplets have an uniform distribution of a diameter between 0.1 m to 1 m.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0035] FIG. 1shows the system working diagram, where (10) corresponds to a fuel tank, (11) a water tank, (12) an electric resistance, (13) a solenoid valve, (14) a level gauge transmitter, (15) (16) connections to production, (17) an inflow pressure transmitter, (18) an outflow pressure transmitter, (19) a fuel isolation valve, (20) a water isolation valve, (21) a fuel pump, (22) a water pump, (23) a fuel check valve, (24) a water check valve, (25) a fuel Coriolis flow meter, (26) a water ultrasonic flow meter, (27) a secondary passage valve, (28) a pressure gauge transmitter, (29) a reactor, (30) water-in-fuel emulsion outlet to the production, (31) the production, (32) a PLCPower Line Communication.

[0036] FIG. 2.1shows a side section of the reactor (29), where (1) corresponds to the reactor body, (33) the cavitation bolts, (2) the mixture inlet, (3) the acceleration tunnel, (4) (5) the expansion chambers, (6) the barriers with adjustable bolts, and (33) (7) the fixing flanges of the reactor (29).

[0037] FIG. 2.2shows a frontal section of the reactor (29) on one of the barriers (6) where are fixed the cavitation bolts (33), where (1) corresponds to the reactor body.

[0038] FIG. 2.3shows one of the cavitation bolts (33) of the reactor (29), where (8) corresponds to a sealing nut, and (9) a fixing nut.

DETAILED DESCRIPTION

[0039] The present cavitation process is meant to produce water-in-fuel emulsions, by using a hydrodynamic cavitation reactor (29), which has been specifically designed for the purpose. The reactor (29) is a key element of the proposed cavitation system.

[0040] The reactor (29) comprises a flanged prismatic body (1) with a polygonal section i.e. it can be triangular, quadrangular, hexagonal or octogonal in steel, tungsten or titanium. In the reactor an acceleration tunnel (3) has been constructed preferably drilled. The acceleration tunnel (3) comprises three distinct zones: the mixture entry (2); the acceleration tunnel (3), and the decompression or expansion chambers (4) (5). The second expansion chamber (5) is also the mixture outlet. Two cavitation barriers with adjustable bolts (33) are placed in the acceleration tunnel (3) in order to separate the two decompression chambers (4) (5). The quantity and size of the adjustable bolts (33) may be adapted, according to the fuel type to be emulsified with water, and the kind of metal the reactor (29) is made of. The adjustable bolts (33) are preferably built in the same metal as the reactor, e.g. steel, tungsten or titanium.

[0041] The bolts (33) are adjusted from the dispersive passive hydrodynamic cavitation reactor's (6) outer part. On the one hand, the fixing nut (9) enables to fasten the plug (6) to the reactor body (1), and, on the other hand, the sealing nut (8) is meant to tighten the plug (6), so that possible fuel leaks from the plug thread gauge can be prevented, taking into account that the pressure generated by the cavitation process is substantially high.

[0042] According to the fuel type to be emulsified with water, any adjustments on the bolts (33) can be made without interrupting the cavitation process.

[0043] Thus, on this water-in-fuel cavitation process, the mixture of fuel with water is accelerated by the pressure increase, caused by a pumping system (21) (22), which preferably operates on a range of 15 to 25 bar, and is forced to go through the acceleration tunnel (3) of the reactor (29), where it hits the first cavitation barrier with adjustable bolts (33). By expanding in the first decompression chamber (4), the mixture undergoes a pressure decrease and subsequent vaporization, releasing water droplets whose diameter ranges from 1 m to 3 m. Thereafter, the vaporized mixture hits the second cavitation barrier with adjustable bolts (33), where it undergoes a new decompression (5). The second vaporization of the mixture spawns a new micronization, since the acceleration tunnel (3) widens, causing a pressure decrease to 6 bar. This double vaporization process obtained from the architecture of the flow modelling system operated by a suitable combination of the number of adjustable bolts (33), the reactor (29), their size and distance range enable water droplet micronization, whereby the droplet diameter can range between 0.1 m and 1 m. This enables to emulsify fuel with water in such a way that the water percentage of the emulsion total volume can go even higher than 35%.

[0044] The results achieved by the present disclosure exceed by far those obtained through the existing processes available on the market. By producing a water-in-oil emulsion whose total volume contains around 35% of water, this process is capable of bringing about a reduction in fuel consumption 35%. Existing processes generate results that don't exceed 20% of fuel saving.

[0045] In terms of exhaust gas emissions, the emulsion is responsible for the following results:

a) NOX (nitrogen oxide)=65%
b) NO (nitrogen monoxide)=70%
c) CO2 (carbon dioxide)=75%
d) CO (carbon monoxide)=100%
e) SO2 (sulphur dioxide)=100%
f) O2 (oxygen)=+30%

g) XAIR=+350%

[0046] The current process enables the creation of water nanoparticles homogeneously dispersed, encapsulated inside a drop of fuel. When the fuel nano-emulsion is sprayed into a superheated engine combustion chamber, the water part of the water-in-oil emulsion expands, and a micro-explosion takes place due to a sudden temperature rise. This reaction creates the fuel separation around the water that falls in the form of minuscule particles. These minuscule water particles will then expand and explode. As a result, the combustible air-fuel surface increases significantly which leads to a more efficient fuel combustion.

[0047] In fact, the oxidized particles are much smaller, and as the vapor superheats them, the reaction occurs instantly and smoothly.

[0048] Consequently, the fuel combustion is more effective when comparing the present disclosure with the processes whereby the water particles are released in their conventional size.

[0049] The described phenomenon, as previously mentioned, enables to achieve a much higher fuel saving, as well as a significant reduction of harmful exhaust gases emitted into the atmosphere, caused by fuel combustion, without compromising the engine performance, whether it is a combustion engine, a generator, a boiler, a burning furnace, or any other equipment that can use a water-in-oil emulsion. Moreover, the water-in-oil emulsions obtained through the current process are unquestionably more stable, because the water droplets have a uniform diameter distribution (diameter=0.1 m to 1 m), which enables the emulsion to be stored and remain stable and unchanged for a period of time longer than two years.

[0050] To sum up, this process and the resulting emulsion has the following advantages: [0051] 1. Reduction of polluting gas emissions; [0052] 2. Decrease of the fuel consumption; [0053] 3. More efficient and reliable combustion engine cleaning, as the produced water-in-oil emulsion has less particles; [0054] 4. Greater quality and more effective fuel combustion; [0055] 5. Applicability to two-cycle low speed engines, and four-cycle medium and high speed engines; [0056] 6. Applicability to existing and future designed ships engines, and fossil fuel burning power plants; [0057] 7. Capability of processing water-in-oil emulsions with heavy fuel oils and light fuel oils; and [0058] 8. Greater stability of the produced water-in-oil emulsions wherein the water part doesn't separate from the fuel over a long period of time (more than two years).

[0059] As it is detailed below, the proposed process and reactor (29) can be used in different ways. One of them is to apply the process to the emulsion production of several batches of fuel to be stored in a storage tank, and then transferred to the feeding tank.

[0060] As the engine starts, it is connected to the fuel feeding tank (10), and the connection to the emulsion tank (31) is performed. The isolation valves are opened (19) (20). It is noted that there is no fuel spill into the water tank (11), because the valve (16) prevents such a spill. The command is entered in the PLC (Power Line Communication) (32) for the boot sequence to begin. The fuel pump (21) starts, and after a few seconds, the water pump (22) starts as well. The starting routine checks the regular engine performance and initiates the by-pass valve (27) closing. The PLC (32) regulates the fuel pump (21) to the desired flow of the reactor (29), forcing the desired water percentage to be added to the water-in-oil emulsion to the water pump (22). Any variation of the suction pressure is offset by the increase or decrease of the rotation in both pumps (21) (22).

[0061] Through the PLC (32) dashboard the following parameters can be permanently (locally or remotely) monitored:

1. Instant fuel flow;
2. Fuel capacity totalizer (in liter);
3. Instant water flow;
4. Water capacity totalizer (in liter);
5. Fuel/water percentage;
6. Inner tank temperature setting;
7. Water temperature;
8. Water tank minimum level warning;
9. Water tank below minimum level warning.

[0062] By monitoring one or more of these parameters, the operator can readily and effectively manage the production of the desired batches of water-in-oil emulsions as well as the available storage tanks.

[0063] Another possible use of the proposed process is the in-line operation upstream and downstream of the preparation water-in-oil emulsion facility whose tanks are connected to the combustion engine feeding tank.

[0064] In this embodiment, the equipment is connected to the fuel line in (15) and (30), and the by-pass valve (27) is open. The fuel valves (19) and the water valves (20) are also open. The equipment is on stand-by mode, and the engine feeding fuel is passing directly through the valve (27). When the start command is entered in the PLC (32), the boot sequence initiates, as it is described on the previous operation mode.

[0065] The fuel pump (21) starts, adjusting its operation in accordance with the line pressure input by the pressure transmitter (17). Thereby, the cavitation is initiated. Downstream, the pressure transmitter (18) checks the load loss imposed by the cavitation reactor (29), and increases the fuel pump (21) rotations, based upon the required pressure on the outlet (18). During this period, the water pump (22) starts, and injects gradually the required water percentage until it reaches the programmed value to produce the water-in-oil emulsion.

[0066] Regardless of the operation mode applied to the engine, the pressure balance and the water/fuel mix are held simultaneously.

[0067] In case the engine stops, the cavitation system stops as well. The by-pass valve (27) opens, being the equipment in stand-by mode for a new boot sequence.

[0068] As a last note, the reactor (29) can be used to process dry fuel, i.e. without adding water to it. In such operation mode, the achieved result consists in an improved fuel combustion thanks to the cracking effect caused by the reactor (29), as it is capable of breaking hydrocarbon long molecules into less complex ones, which boosts the improvement of hydrocarbon burning and reduces the hydrocarbon combustion residues.

[0069] Embodiment 1 A cavitation process for preparing a water-in-oil emulsion, characterized by the steps of: [0070] a) adding water to fuel in a range of 5% to 35% of the total volume; [0071] b) feeding both water and fuel into an enclosed space, wherein the mixture is accelerated through a pressure rise induced by a pumping system (21) (22); [0072] c) forcing the mixture through an acceleration tunnel (3) wherein it hits a first cavitation barrier with adjustable bolts (33); [0073] d) feeding the mixture through a first decompression chamber (4) causing a pressure decrease and subsequent vaporization of the mixture to form a vaporized mixture, forming water droplets whose diameter ranges from 1 m to 3 m; [0074] e) feeding the vaporized mixture on the second cavitation barrier with adjustable bolts (33), to a second decompression and adjusting the number and arrangement of adjustable bolts in order to control the formation of water droplets of diameter of 0.1 m or less.

[0075] Embodiment 2Cavitation reactor (29) for use in the process of Embodiment 1, the reactor (29) comprising a flanged prismatic body (1) with a polygonal section with an acceleration tunnel (3), comprising three distinct zones: a mixture entry (2); an acceleration tunnel (3), and a first and second decompression or expansion chamber (4) (5) wherein the second expansion chamber (5) is also the mixture outlet.

[0076] Embodiment 3The cavitation reactor according to Embodiment 2, wherein the polygonal section of the reactor is triangular, quadrangular, hexagonal or octagonal.

[0077] Embodiment 4The cavitation reactor according to any of the embodiments 2 or 3, wherein the reactor is made of steel, tungsten or titanium.

[0078] Embodiment 5The cavitation reactor according to any of the Embodiments 2 to 4, wherein the two cavitation barriers with adjustable bolts (33) are placed in the acceleration tunnel (3) in order to separate the two decompression chambers (4) (5).

[0079] Embodiment 6The cavitation reactor according to any of the Embodiments 2 to 4, wherein the adjustable bolts (33) are adjustable from the reactor's (6) outer part.

[0080] Embodiment 7The cavitation reactor according to Embodiment 6, said bolts (33) comprising a fixing nut (9) to fasten the plug to the reactor body (1), and a sealing nut (8) to tighten the plug (6).

[0081] Embodiment 8A Water-in-oil emulsion obtainable by the process of Embodiment 1, wherein the water/fuel ratio between 5% to 35% of the total volume, the water droplets have a uniform distribution of a diameter between 0.1 m to 1 m.

[0082] All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. Combinations is inclusive of blends, mixtures, alloys, reaction products, and the like. The terms first, second, and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms a and an and the do not denote a limitation of quantity, and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Or means and/or unless clearly stated otherwise. Reference throughout the specification to some embodiments, an embodiment, and so forth, means that a particular element described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described elements can be combined in any suitable manner in the various embodiments.

[0083] Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this application belongs.