COMBUSTION ENHANCER FOR SOLID AND LIQUID HYDROCARBON AND ORGANIC FUELS

Abstract

A combustion enhancer designed for solid and liquid hydrocarbon and organic fuels increases solid and liquid hydrocarbon and organic fuels' thermal efficiency and promotes more favorable environmental outcomes. The fuel additive consists of a composition containing natural minerals that can be added to solid and liquid hydrocarbon and organic fuels before their entry into a combustion chamber. This additive interacts with the fuel during combustion in various settings, including direct-fired burners, furnaces, or open flames.

Claims

1. A fuel combustion enhancer designed for improving the thermal and environmental efficiency of solid and liquid hydrocarbon and organic fuels the fuel combustion enhancer comprising insoluble natural minerals, the insoluble natural minerals comprising a finely ground powder with a particle size of no greater than 50 microns, wherein the fuel combustion enhancer is composed of insoluble natural minerals no less than 90% by weight.

2. The fuel combustion enhancer of claim 1, comprising no more than one percent water by weight.

3. The fuel combustion enhancer of claim 1, wherein the insoluble natural minerals consists of the group comprising one or more of SiO2, MgO, Fe2O3, and Fe3O4, which collectively make up at least 70% by weight.

4. The fuel combustion enhancer of claim 1, further comprising one or more additive selected from the group comprising Al2O3, CaO, TiO2, and SO3; wherein each of the one or more additives does not individually exceed 5% of the total weight of the fuel combustion enhancer.

5. The fuel combustion enhancer of claim 4, wherein each of the one or more additives are characterized by a particle size no greater than 40 microns.

6. The fuel combustion enhancer of claim 5, wherein the content of additional impurities remains within 10% of the total weight of the additive.

7. A method for enhancing the thermal and environmental efficiency of solid and liquid hydrocarbon and organic fuels irrespective of the fuel type or equipment employed, the method comprising providing the fuel combustion enhancer of claim 1; wherein the fuel combustion enhancer comprises SiO2, MgO, Fe2O3, and Fe3O4, which collectively make up at least seventy percent by weight.

8. The method of claim 7, wherein the fuel combustion enhancer further comprises Al2O3, CaO, TiO2, and SO3, each of which does not exceed five percent by weight individually.

9. The method of claim 8, wherein each of the SiO2, MgO, Fe2O3, Fe3O4, Al2O3, CaO, TiO2, and SO3 possesses a density not exceeding 5.3 g/cm3 and an ultimate tensile strength of no more than 30 N/mm2.

10. A method for enhancing the thermal and environmental efficiency of solid and liquid hydrocarbon and organic fuels irrespective of the fuel type or equipment employed, the method comprising providing the fuel combustion enhancer of claim 1; blending the fuel combustion enhancer with a fuel; and combusting the fuel.

11. A fuel combustion enhancer designed for improving the thermal and environmental efficiency of solid and liquid hydrocarbon and organic fuels, the fuel combustion enhancer comprising between twenty-five and thirty-five percent SiO2 by weight; between fifteen and twenty-five percent MgO by weight; between ten and twenty percent Fe2O3 by weight; and between one and ten percent Fe3O4 by weight.

12. The fuel combustion enhancer of claim 11, further comprising between one and ten percent Al2O3 by weight; between one and ten percent CaO by weight; between one and ten percent TiO2 by weight; and between one and ten percent SO3 by weight.

13. The fuel combustion enhancer of claim 11, wherein components in addition to those listed here do not comprise more than ten percent of the fuel combustion enhancer by weight.

14. The fuel combustion enhancer of claim 11, wherein the fuel combustion enhancer contains no particles greater in size than 50 microns.

Description

DETAILED DESCRIPTION

[0028] As discussed above, embodiments of the present disclosure relate to a catalyst or additive, and more particularly to a combustion enhancer for solid and liquid hydrocarbon and organic fuels as used to improve the efficiency and cleanliness of a combustion system.

[0029] Generally, the combustion enhancer for solid and liquid hydrocarbon and organic fuels offers advantage in enhancing the combustion processes of solid and liquid hydrocarbon and organic fuels and reducing pollution. More particularly, the present disclosure describes a fuel additive for combustion with the fuel in a direct-fired burner, furnace, or open flame.

[0030] The present fuel additive is a carefully processed, dry, odorless substance that has been ground into a fine powder with a particle size of fewer than 50 microns. More particularly, the present fuel additive comprises insoluble natural minerals, primarily consisting of SiO2, MgO, Fe2O3, and Fe3O4, which collectively make up at least 70% by weight. Alongside these core components, the additive's composition includes additional substances such as Al2O3, CaO, TiO2, and SO3, each of which does not exceed 5% individually or 20% collectively. The content of other impurities remains within 10% of the total weight of the additive. The enhancer possesses a density not exceeding 5.3 g/cm3 and an ultimate tensile strength, determined by standard methods, of no more than 30 N/mm.sup.2 with the particle size of the additive ranging by 40 microns.

[0031] Experimentally, it has been found that the combination of SiO2, MgO, Fe2O3, and Fe3O4 together create an advantageous chemical situation leading to more efficient combustion processes. It is believe that this is, at least in part, due to the free valence of these compounds. The present combustion enhancer composition contains natural minerals with a specific volumetric atomization energy value that cannot fall below empirically determined levels. The energy released from these minerals is constrained by an upper limit equal to the specific energy of adhesion of atomic cores and bonding electrons-Wi [5-6].

[0032] When the combustion enhancer is applied, its natural minerals (i.e., SiO2, MgO, Fe2O3, and Fe3O4) act as additional active centers, enhancing mass exchange processes and stimulating the combustion process of the primary fuel, which significantly increases combustion efficiency. For the purpose of this specification, an active center is defined as a compound or a location upon a compound where a substrate binds to the compound in order for catalysis to take place.

[0033] The process of initiating energy release from the mineral components, and catalysis, in the combustion enhancer requires a certain amount of energy to be obtained from the combustion of the primary fuel, equal to their volumetric specific atomization energy. As a result, the first application of the combustion enhancer may require some time for the combustion enhancer to become fully activated. The activation period can vary depending on the specific conditions under which the enhancer is employed.

[0034] Each dose of the combustion enhancer into a combustion process has a long-lasting effect that results from a cyclic process of internal energy release and the absorption of energy of photons by the mineral atoms in the enhancer. This prolonged action of each dose of the combustion enhancer leads to a cumulative effect, intensifying the combustion process even further.

[0035] For best performance, the combustion enhancer should be distributed relatively evenly throughout the fuel volume supplied to the combustion chamber. The optimal dosage of the combustion enhancer per ton of fuel should be individually calculated for each fuel type, while considering the specific technical parameters of the combustion equipment used. Examples of these doses are provided in this disclosure.

[0036] In various embodiments, the combustion enhancer may be applied to the fuel in different ways. For a liquid fuel, simple mixing of the combustion enhancer in the fuel at the combustion chamber may be expedient. Alternatively, the enhancer can be integrated with secondary air injected into oil and gas boilers. However, in the case of solid fuels, other solutions may be desirable in order to achieve near-homogenous mixing of the combustion enhancer with the fuel. For example, in the case of wood pellets, the combustion enhancer may be incorporated in the composition of the wood pellet itself during manufacture of the pellet.

[0037] When the present additive is introduced to the fuel, it modifies the combustion parameters based on the principles of branched chain reactions theory. This theory considers combustion as a self-accelerating process that initiates with the formation of single active centers, represented by molecules of substances with free valences. The external manifestation of this reaction becomes observable only when a sufficient concentration of these centers is reached.

[0038] When the present additive is applied, its components act as additional active centers, enhancing mass exchange processes and stimulating the combustion process of the primary fuel, which results in a significant increase in combustion efficiency.

[0039] The present enhancer's composition contains natural minerals with a specific volumetric atomization energy value that cannot fall below empirically determined levels. The energy released from these minerals is constrained by an upper limit equal to the specific energy of adhesion of atomic cores and bonding electrons-Wi [5-6].

[0040] The process of initiating energy release from the mineral components in the present additive requires a certain amount of energy to be obtained from the combustion of the primary fuel, equal to their volumetric specific atomization energy. As a result, the first application of the present additive may require some time for the additive to become fully activated. The activation period can vary depending on the specific conditions under which the additive is employed.

[0041] Each dose of the present additive has a long-lasting effect that results from a cyclic process of internal energy release and the absorption of energy of photons by the mineral atoms in the additive. This prolonged action of each dose of the present additive leads to a cumulative effect, intensifying the combustion process even further.

[0042] For best performance, the present enhancer should be distributed relatively evenly throughout the fuel volume supplied to the combustion chamber. The optimal dosage of the present enhancer per ton of fuel should be individually calculated for each fuel type while considering the specific technical parameters of the combustion equipment used.

[0043] Depending on the type of fuel, the recommended proportion of the present additive per ton of fuel ranges from 0.03% to 0.1%, equivalent to 300 (0.3 kg) to 1000 grams (1 kg) per ton of fuel.

[0044] The process of adding the present enhancer to the fuel is straightforward and does not require any complex procedures. It can be added directly to the fuel before it enters the combustion chamber irrespective of the fuel type or equipment employed.

[0045] More particularly, the process of applying the present additive to the fuel before it reaches the combustion or heating chamber can be accomplished through a variety of methods that share a high degree of similarity. These methods, while distinct in their specific details, maintain a common essence, making the additive introduction process universally applicable regardless of the type of fuel or equipment utilized.

[0046] Such methods include:

[0047] 1. Blending the additive with the fuel during the fuel feeding process into the fuel hopper.

[0048] 2. Introducing the additive into the conveyor belt, moving grates, or fuel augers.

[0049] 3. Incorporating the additive as a component during pre-processing of coal for use in Pulverized Coal (PC) Boilers, Pressurized Circulating Fluidized Bed (PCFB) Boilers, and Circulating Fluidized Bed (CFB) Boilers.

[0050] 4. Incorporating the additive as a component during the production of fuel through pelletizing, briquetting, or pressing.

[0051] 5. Adding the additive to municipal solid waste during the mixing stage of Municipal Solid Waste (MSW).

[0052] 6. Mixing the additive with heavy fuel oil before the fuel feeding process into the heating chamber.

[0053] 7. Integrating the enhancer with secondary air injected into oil and gas boilers.

[0054] The introduction of the additive using any of the methods does not necessitate modifications to the boiler or combustion zone. Furthermore, these methods do not involve any intricate procedures and may require only a modest capital investment, if at all.

DESCRIPTION OF THE EMBODIMENTS

[0055] A preferred embodiment of the combustion enhancer may be formed of the following components, with percentages measured by approximate weight: thirty percent SiO2; twenty percent MgO; fifteen percent Fe2O3; five percent Fe3O4; five percent Al2O3; five percent CaO; five percent TiO2; and five percent SO3. This composition leaves five percent room for error, either of increased proportions of the given ingredients, or of impurities. In any case, impurities (compounds in addition to those listed) should not exceed ten percent for desirable effectiveness. It may be envisioned that in some embodiments, fillers could be added for particular needs. However, it is desired for most applications that the combustion enhancer be as pure as possible, containing only the components listed here, so that it may be added to fuels of various types at controllable proportions.

[0056] In a broader range of embodiments, the combustion enhancer may include the following components, with percentages measured by approximate weight: 25 to 35 percent SiO2; 15 to 25 percent MgO; 10 to 20 percent Fe2O3; 1 to 10 percent Fe3O4; 1 to 10 percent Al2O3; 1 to 10 percent CaO; 1 to 10 percent TiO2; and 1 to 10 percent SO3.

[0057] In the following section, combustion enhancer will be described in more detail, with reference to specific examples. It should be noted, however, that these examples are meant solely for the purpose of illustrating the invention and should not be construed as limiting the scope of protection for the present invention.

[0058] A series of tests were conducted on different combustion systems, utilizing various hydrocarbon organic fuels, to evaluate the effects of the present invention on thermal efficiency and environmental outcomes. Each test was conducted with and without the present fuel enhancer on two identical units of equipment under the same operating conditions.

[0059] The tests have been conducted in compliance with the following international standards: ISO 1928:2016, ISO 4264, UNI EN 14774-3:2009, UNI EN 14775:2010, UNI EN 14918:2010, UNI EN 15103:2010, UNI EN 14789:2005, EPA 3A: 2006, EN 14792:2005, EN 13284-1:2001, UNI 10169:2001, EN 14790:2005.

[0060] The following are a few examples of such tests:

Example #1

[0061] Combustion equipment: Coal boiler [0062] Primary fuel: Lignite A [0063] Present invention mass ratio: 0.05% per ton of primary fuel

[0064] Comparing the thermal efficiency and environmental outcomes of burning modified fuel to burning unmodified fuel, the following improvements were observed: [0065] a) Increase in thermal efficiency: 31% [0066] b) Decrease in CO emissions: 73% [0067] c) Decrease in NOx emissions: 42% [0068] d) Decrease in SO2 emissions: 6% [0069] e) Decrease in ash and slag residues: 47%

Example #2

[0070] Combustion equipment: Biomass boiler [0071] Primary fuel: Coniferous wood chips [0072] Present invention mass ratio: 0.05% per ton of primary fuel

[0073] Comparing the thermal efficiency and environmental outcomes of burning modified fuel to burning unmodified fuel, the following improvements were observed: [0074] a) Increase in thermal efficiency: 28% [0075] b) Decrease in CO emissions: 68% [0076] c) Decrease in NOx emissions: 33% [0077] d) Decrease in SO2 emissions: 5% [0078] e) Decrease in ash and slag residues: 45%

Example #3

[0079] Combustion equipment: Biomass boiler [0080] Primary fuel: Hardwood pellets [0081] Present invention mass ratio: 0.05% per ton of primary fuel

[0082] Comparing the thermal efficiency and environmental outcomes of burning modified fuel to burning unmodified fuel, the following improvements were observed: [0083] a) Increase in thermal efficiency: 35% [0084] b) Decrease in CO emissions: 71% [0085] c) Decrease in NOx emissions: 34% [0086] d) Decrease in SO2 emissions: 7% [0087] e) Decrease in ash and slag residues: 54%

Example #4

[0088] Combustion equipment: Heavy fuel oil boiler [0089] Primary fuel: HFO #6 [0090] Present invention mass ratio: 0.1% per ton of primary fuel

[0091] Comparing the thermal efficiency and environmental outcomes of burning modified fuel to burning unmodified fuel, the following improvements were observed: [0092] a) Increase in thermal efficiency: 38% [0093] b) Decrease in CO emissions: 79% [0094] c) Decrease in NOx emissions: 45% [0095] d) Decrease in SO2 emissions: 5%

[0096] Furthermore, the utilization of the present invention showcased supplementary environmental advantages, including: [0097] 1. Eliminating burning odors to the extent of none or close to none [0098] 2. Cleaning of previously built-up soot, tar, and other deposits from the chimneys/filter equipment to the extent of none or close to none [0099] 3. Cleaning of previously built-up soot, tar, and other deposits from the inner surfaces of equipment such as combustion chamber and flues.

[0100] The utilization of the present invention has further revealed that during prolonged and uninterrupted fuel combustion, it is feasible to decrease the quantity of the additive introduced into the combustion process without compromising thermal efficiency. For instance, in experimental coal combustion, during the initial 20 hours of boiler operation, the additive was added at a rate of 0.05%, equivalent to 500 grams per metric ton of fuel in the furnace. Subsequently, from the 21st hour, the subsequent 20-hour combustion cycle was carried out with a reduced additive input rate of 0.03%, equivalent to 300 grams per metric ton of fuel, while maintaining the same thermal efficiency levels in the coal boiler. Depending on the variations in thermal efficiency, it is possible to sustain the reduced additive rate or return to the original rate of 0.05% per metric ton of fuel. This approach significantly reduces the amount of the additive required for long or continuous combustion cycles, resulting in substantial cost savings in operational expenses.

[0101] The embodiments of the invention described herein are exemplary and numerous modifications, variations and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention. Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientist, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application.