EP4093535B1 - Method for producing a stable hydrocarbon-water dispersion for improving combustion processes, and a water-hydrocarbon dispersion that is easily separable into at least two phases as part of the clean-up process at accident locations - Google Patents

Description

The present invention relates to a process for producing a stable hydrocarbon-water dispersion using thermocavitation and supercavitation.

The present invention relates to a process for producing a water-hydrocarbon dispersion which can be easily separated into at least two phases and subsequent phase separation.

Description

It is known that adding water to the combustion process in heating oil and diesel fuel can lower the combustion temperature and result in more complete combustion. This means that fewer nitrogen oxides are produced and fewer soot particles are emitted. The same applies to oil burners. However, it is crucial that the diesel fuel or heating oil and water are used in as homogeneous a mixture as possible. The size of the water droplets in the dispersion is crucial for stability.

In the separation processes (cleaning processes), the proportion of water is significantly higher than in the stable hydrocarbon-water dispersion. This leads to the formation of an easily separable dispersion. This physical property is more promising for the natural ecosystem than the use of dispersants. Various devices for producing such oil-water emulsions are known from the literature. For example, the WO 2019/161852 A2 , EP674941B1 , DE 4137179 C2 or DE 4139782 A1 which describe devices for mixing oil and water to form an emulsion. WO 2019/161852 A2 discloses a process for producing a hydrocarbon-water fine dispersion with an emulsifier arranged between two pumps. EP 3 184 164 A1 discloses a device between two pumps which uses cavitation effects to generate bubbles in water.

The problem with the production and use of oil-water emulsions, especially diesel fuel-water emulsions, is their stability. One approach to stabilizing the emulsions is the use of emulsifiers, which heterogeneous phases (so-called emulsion). This is how the WO 01/55282 an emulsifier system for fuel-water emulsions, which comprises alkoxyals of polyisobutene. From the WO 2011/042432 The addition of alcohols, peroxides and surfactants as additives for the production of microemulsions in combustion engines is known.

However, the use of additives to stabilize oil-water emulsion often leads to a deterioration of the properties of the emulsion, in particular a deterioration of the combustion properties and an increase in combustion costs.

There is great interest in the industry in innovative solutions to develop a cost-effective process for producing a stable hydrocarbon-water dispersion.

The object of the present invention is to provide a stable hydrocarbon-water dispersion, in particular a stable fuel-water dispersion, without the use of additives such as emulsifiers.

This object is achieved by a method having the features of claim 1.

There are two different UADA versions: with and without an integrated premixer. The first version does not contain an integrated premixer for mixing the media. In the second version, the media are mixed directly in the premixer integrated in the pre-sound chamber of the UADA body.

The first embodiment is used in the present invention. For more information about the two modifications, see the patent RU2130503C1 , RU2462301C1 and the patent for the useful technical model RU134076U1 . The technical description of the UADA body and the acoustic panel are in Figures 6 and 7 shown.

In one embodiment of the plant based on the present process, at least one premixing unit for producing a coarse dispersion from the at least one medium 1 and medium 2 is arranged upstream of the at least one unit for producing a hydrocarbon-water dispersion.

The coarse disperser consists of at least two supply lines for two different media, each with a heat exchanger, an adjustment device for the media ratio and a premixer.

The coarse dispersant is the precursor to the fine dispersant or ultrafine dispersant.

• wobei die Anlage mindestens eine Einheit zur Herstellung einer Kohlenwasserstoff-Wasser-Dispersion im Fein-Dispergator aus mindestens Medium 1 als einem kohlenwasserstoffhaltigen Medium und Medium 2 als Wasser (VE-Wasser) und diese Einheit mindestens einen Vormischer (Grob-Dispergator), mindestens eine erste Pumpe, für eine Druckerhöhung im Zulauf der Kohlenwasserstoff-Wasser-Mischung in das Ultraschall-Akustik-Durchfluss-Aggregat (UADA als ein Teil des Fein-Dispergators); mindestens ein Ultraschall-Akustik-Durchfluss-Aggregat (UADA) zur Herstellung einer Kohlenwasserstoff-Wasser-Feindispersion mittels hydrodynamischer Kavitation und mindestens eine zweite Pumpe zur Erzeugung eines Unterdrucks hinter dem UADA,
• oder mindestens eine Einheit zur Herstellung einer instabilen Wasser-Kohlenwasserstoff-Trenndispersion aus mindestens Medium 1 als einem kohlenwasserstoffhaltigen Medium und Medium 2 als Wasser (VE-Wasser), wobei diese Einheit mindestens eine erste Pumpe, für eine Druckerhöhung im Zulauf Kohlenwasserstoff-Wasser-Mischung in das Ultraschall-Akustik-Durchfluss-Aggregat (UADA als ein Teil des Trenn-Dispergators); mindestens ein Ultraschall-Akustik-Durchfluss-Aggregat (UADA) zur Herstellung einer Kohlenwasserstoff-Wasser-Feindispersion mittels hydrodynamischer Kavitation, und mindestens eine zweite Pumpe zur Erzeugung eines Unterdrucks hinter dem UADA, umfasst.

The process according to the invention is carried out in a plant based on the present process for producing a stable hydrocarbon-water fine dispersion or a water-hydrocarbon separation dispersion (a water-hydrocarbon dispersion that can be easily separated into at least two phases, or an unstable separation dispersion),

• wherein the system comprises at least one unit for producing a hydrocarbon-water dispersion in the fine disperser from at least medium 1 as a hydrocarbon-containing medium and medium 2 as water (deionized water) and this unit comprises at least one premixer (coarse disperser), at least one first pump for increasing the pressure in the inlet of the hydrocarbon-water mixture into the ultrasonic acoustic flow unit (UADA as a part of the fine disperser); at least one ultrasonic acoustic flow unit (UADA) for producing a hydrocarbon-water fine dispersion by means of hydrodynamic cavitation and at least one second pump for generating a negative pressure behind the UADA,
• or at least one unit for producing an unstable water-hydrocarbon separation dispersion from at least medium 1 as a hydrocarbon-containing medium and medium 2 as water (deionized water), this unit comprising at least one first pump for increasing the pressure in the inlet of the hydrocarbon-water mixture into the ultrasonic acoustic flow unit (UADA as a part of the Separation-disperser); at least one ultrasonic acoustic flow unit (UADA) for producing a hydrocarbon-water fine dispersion by means of hydrodynamic cavitation, and at least one second pump for generating a negative pressure behind the UADA.

The plant based on the present method thus comprises, in the first aspect, a fine disperser consisting of a coarse disperser, a UADA module and a pump upstream of the UADA and a pump downstream of the UADA
and separation-disperser consisting of a UADA module and a pump upstream of the UADA and a pump downstream of the UADA.

• eine Einheit mindestens eine Heizvorrichtung für die Initiierung der Thermokavitation, mindestens eine erste Pumpe, für eine Druckerhöhung im Zulauf der Feindispersion in das Ultraschall-Akustik-Durchfluss-Aggregat (UADA als ein Teil des Ultrafein-Dispergators); mindestens ein Ultraschall-Akustik-Durchfluss-Aggregat (UADA) zur Herstellung einer Kohlenwasserstoff-Wasser-Ultrafeindispersion mittels hydrodynamischer Kavitation und mindestens eine zweite Pumpe zur Erzeugung eines Unterdrucks hinter dem Ultrafein-UADA
  oder
• eine Einheit mindestens einen Vormischer (Grob-Dispergator), mindestens eine Heizvorrichtung für die Initiierung der Thermokavitation, mindestens eine erste Pumpe, für eine Druckerhöhung im Zulauf der Feindispersion in das Ultraschall-Akustik-Durchfluss-Aggregat (UADA als ein Teil des Ultrafein-Dispergators); mindestens ein Ultraschall-Akustik-Durchfluss-Aggregat (UADA) zur Herstellung einer Kohlenwasserstoff-Wasser-Ultrafeindispersion mittels hydrodynamischer Kavitation und mindestens eine zweite Pumpe zur Erzeugung eines Unterdrucks hinter dem Ultrafein-UADA.

In one embodiment, a plant based on the present process for producing a stable hydrocarbon-water ultrafine dispersion comprises the ultrafine disperser downstream at least one unit for producing an ultrafine dispersion from at least medium 1 as a hydrocarbon-containing medium and medium 2 as water (deionized water) and

• a unit at least one heating device for initiating the thermocavitation, at least one first pump for increasing the pressure in the inlet of the fine dispersion into the ultrasonic acoustic flow unit (UADA as a part of the ultrafine disperser); at least one ultrasonic acoustic flow unit (UADA) for producing a hydrocarbon-water ultrafine dispersion by means of hydrodynamic cavitation and at least one second pump for generating a negative pressure behind the ultrafine UADA
  or
• a unit comprising at least one premixer (coarse disperser), at least one heating device for initiating thermocavitation, at least one first pump for increasing the pressure in the inlet of the fine dispersion into the ultrasonic acoustic flow unit (UADA as a part of the ultrafine disperser); at least one ultrasonic acoustic flow unit (UADA) for producing a hydrocarbon-water ultrafine dispersion by means of hydrodynamic cavitation and at least one second pump for generating a negative pressure behind the ultrafine UADA.

The plant based on the present method thus comprises, in a second aspect, a combination of an ultrafine disperser consisting of a heating device (heating cartridge with a screw-in heater) and UADA, the structure being as follows: heating device - first pump - first UADA - second pump.
or consisting of a premixer (coarse disperser), a heating device (heating cartridge with a screw-in heater) and UADA, the structure being as follows: coarse disperser-heating device- first pump- first UADA- second pump.

In one embodiment of the plant based on the present process, upstream of the at least one unit for producing a stable hydrocarbon-water ultrafine dispersion from at least medium 1 as a hydrocarbon-containing medium and medium 2 as water (deionized water) and
this unit comprises at least one premixer (coarse disperser), at least one first pump for increasing the pressure in the inlet of the hydrocarbon-water mixture into the ultrasonic acoustic flow unit (UADA as a part of the fine disperser); at least one ultrasonic acoustic flow unit (UADA) for producing a hydrocarbon-water fine dispersion by means of hydrodynamic cavitation, at least one heating device for initiating the thermocavitation, at least one second pump for increasing the pressure in the inlet of the fine dispersion into the ultrasonic acoustic flow unit (UADA as a part of the ultrafine disperser); at least one second ultrasonic acoustic flow unit (UADA) for producing a hydrocarbon-water ultrafine dispersion by means of hydrodynamic cavitation and at least one third pump for generating a negative pressure behind the ultrafine UADA.

The plant based on the present process thus comprises, in a third aspect, a combination of a coarse disperser, a fine disperser and a downstream ultrafine disperser.

The basis of the process is the principle of cavitation. Cavitation is the formation and implosive dissolution of vapor bubbles in liquids. The UADA is used to produce a hydrocarbon-water dispersion using cavitation.

The principle of dispersion generation using the above-mentioned system is based on the fact that a mixture of at least two different media is pressed through special nozzles in a UADA.

The at least two different media are premixed with each other. The further steps of producing a hydrocarbon-water dispersion using cavitation take place in at least one or two UADA modules. In a first UADA module, supercavitation takes place, as an individual case of hydrodynamic cavitation, while in the other, second UADA module, thermal and supercavitation take place. The two UADA modules are connected one after the other.

The type and intensity of the cavitation varies the size of the water droplets in the dispersion. Stronger cavitations result in a smaller diameter of the enclosed droplet. The present process enables the production of a hydrocarbon-water dispersion with a droplet size in the range of 10 to 100 µm. The stability of the dispersion increases as the droplet diameter decreases.

For the quality of the hydrocarbon-water dispersion produced with the above-mentioned system, it is important to set the optimal intensity of cavitation. The droplet size in the dispersion is regulated by varying degrees of cavitation. The droplet size, phase distribution and morphology in turn influence the stability of the dispersion. The cavitation is set, varied and controlled by varying the pressure behind the UADA.

The droplet size, phase division and morphology have an influence on the stability (quality) of the dispersion. The cavitation is set, varied and controlled by varying the pressure behind the UADA. The droplet size in the dispersion is regulated by varying degrees of cavitation. For the quality of the hydrocarbon-water dispersion produced with the above-mentioned system, it is important to set the optimal intensity of the cavitation.

• Tröpfchendurchmesser in der Grobdispergierung größer als 1 mm
• Tröpfchendurchmesser in der Feindispergierung kleiner als 1 mm und größer als 100 µm
• Tröpfchendurchmesser in der Ultrafeindispergierung kleiner als100 µm

Three different levels of droplet fineness are achieved with the described system:

• Droplet diameter in coarse dispersion greater than 1 mm
• Droplet diameter in fine dispersion smaller than 1 mm and larger than 100 µm
• Droplet diameter in ultrafine dispersion smaller than 100 µm

The system described makes it possible to keep the water content and the process parameters pressure, temperature and throughput constant in order to ensure a consistent quality of the water-oil dispersion produced.

The developed process can be structured in two or three process engineering stages. The first involves a technological implementation of coarse and fine dispersion. The other technological solution for deeper dispersion consists of coarse, fine and ultra-dispersion.

According to the present method, before producing the fine dispersion, a coarse dispersion can be provided from the pre-tempered medium 1 as a hydrocarbon-containing medium and the pre-tempered medium 2 as water by mixing medium 1 and medium 2 in at least one premixing unit (coarse disperser).

• Herstellen einer Kohlenwasserstoff-Wasser-Feindispersion, oder einer Wasser-Kohlenwasserstoff-Trenndispersion in einem Ultraschall-Akustik-Durchflussaggregat (UADA), indem die Kavitation nicht aktiv eingebracht wird, sondern entsteht aufgrund der Strömungen im UADA .

According to claims 1 and 2, the invention therefore provides a process for producing a hydrocarbon-water dispersion (fine dispersion) or a water-hydrocarbon dispersion (separation dispersion) that can be easily separated into at least two phases, the process being carried out in particular in a plant as described above and comprising the following steps:

• Production of a hydrocarbon-water fine dispersion, or a water-hydrocarbon separation dispersion in an ultrasonic acoustic flow unit (UADA), whereby the cavitation is not actively introduced, but occurs due to the flows in the UADA.

For the adjustment, variation and control of the cavitation or cavitation regime, a pressure is set in front of the UADA module (pre-pressure) and a pressure behind the UADA.

In the UADA module, three flow velocity ranges are constructed one after the other: pre-sonic, sonic and ultrasonic velocities.

The presonic velocity is a transverse deformation of flows through the formation of vortex ring flows.

In the range of the speed of sound, the resulting flow becomes so large that cavitation occurs. Furthermore, long-chain hydrocarbons are torn apart thermomechanically. The inflow is accelerated tangentially in the radial direction, in which the chamber flows are sheared against each other and the relative speed is doubled. The high speed creates the vapor bubbles and the displaced vortex flows balance each other out. This creates constant, stable vortices that are separated according to hydrodynamic properties.

This leads to the acoustic initiation of the product, the so-called ultrasonic cavitation, which further leads to a change in the state of aggregation and the activation of chemical compounds.

The ultrasonic velocity occurs after the flows meet and the energy of the flows is concentrated in the limited volume. The concentrated energy promotes the energy-mass exchange and accelerates the physico-chemical transformation. The dispersion formed is discharged from the module through the drain.

Downstream, after the first UADA module, negative pressure is generated.

The vapor pressure of water must be reduced to below the operating pressure by means of hydrostatic pressure and temperature adjustment (vapor pressure curve) by increasing the speed (energy conversion/kinetic pressure component). This results from the vapor pressure curve for water as in Figure 1 shown.

• wobei das Verhältnis des Vordruckes vor dem UADA des Fein-Dispergators und des Unterdruckes nach dem UADA des Fein-Dispergators bei mindestens 10 liegt.

The pressure ratio between the pre-pressure and the negative pressure in the fine disperser or in the separating disperser influences the type, strength and form of cavitation in the UADA. The stronger the cavitation, the smaller the diameter of the droplets in the dispersion,

• whereby the ratio of the pre-pressure before the UADA of the fine disperser and the negative pressure after the UADA of the fine disperser is at least 10.

• wobei diese Einheit zur Verstärkung der Effektivität und Stabilität die hydrodynamische Kavitation mit der Thermokavitation kombiniert.

In one embodiment of the present method, the hydrocarbon-water fine dispersion is introduced into at least one further unit for producing an ultrafine dispersion (ultrafine disperser) after leaving the fine disperser, this unit comprising at least one further ultrasonic acoustic flow unit (UADA) for producing a hydrocarbon-water ultrafine dispersion by means of a combination of thermo- and hydrodynamic cavitation,

• This unit combines hydrodynamic cavitation with thermocavitation to increase effectiveness and stability.

The conditions for initiating thermal cavitation are created in a heating device with low pressure and elevated temperature. The local heating in the heating device creates small vapor bubbles on the surface, which are dislodged by the flow and collapse again in the liquid due to a reduction in temperature. This thermal cavitation catalyzes the hydrodynamic cavitation in the subsequent UADA and thus increases the mixing of the dispersion.

The process technology is designed in such a way that there is a negative pressure in the heating device. To initiate ultrasonic cavitation in the subsequent UADA, the pressure is built up again and the pressure is reduced behind the UADA.

• wobei das Verhältnis des Druckes vor dem UADA des Ultrafein-Dispergators (Vordruck) und des Druckes nach dem UADA des Ultrafein-Dispergators (Unterdruck) bei mindestens 12 liegt.

The combination of thermo- and hydrodynamic or super-cavitation creates better conditions for producing ultra-stable and ultra-fine dispersion. The pressure ratio between the pre-pressure and the negative pressure in the ultra-fine disperser influences the type, strength and form of cavitation in the UADA. The stronger the cavitation, the smaller the diameter of the droplets in the dispersion.

• whereby the ratio of the pressure before the UADA of the ultrafine disperser (pre-pressure) and the pressure after the UADA of the ultrafine disperser (negative pressure) is at least 12.

Ultrafine dispersion can be technologically realized either after coarse dispersion or after fine dispersion.

The cavitation process used in the described system in an ultrasonic acoustic flow unit (UADA) is known from the patents RU2130503C1 , RU2462301C1 and the patent for the useful technical model RU134076U1 known and enables the production of a stable dispersion of fuel and water. In the system described, this UADA is expanded in combination with heat exchangers and pressure boosters, so that the stability of the hydrocarbon-water dispersion formed is significantly increased. The heat exchangers installed in the system described allow a separately tempered hydrocarbon and water supply. A moisture sensor can also be installed in the feed line of the mixing device (UADA) in order to continuously check and control the water content. In addition, control or metering valves are installed in the hydrocarbon and water addition, which allow the mixing ratio to be changed.

The developed technology produces a long-term stable dispersion of water and hydrocarbons. The long-term stability is significantly influenced by the droplet size. A droplet size of less than 100 µm can achieve a stability of at least 1 year up to 7 years. This increases the stability of bunker oils, for example, which means that the use of additives is no longer necessary. There are fewer or no unwanted reactions in the storage or transport fuel tank and the flocculation of paraffins can be reduced or even suppressed.

The fine droplets in the dispersion allow the fuel to be burned more optimally, as they evaporate suddenly in the combustion chamber and the combustion of the fuel is more homogeneous due to the increase in surface area to volume. Fewer soot particles are produced during combustion. The efficiency of the combustion, in relation to the primary energy introduced, is increased, with the fuel being converted almost completely into energy.

In addition, the pollutants are reduced when the dispersion is burned compared to the pure fuel. For example, when the water content is more than 10%, the combustion temperature is reduced, which in turn can minimize the emission of pollutants such as NO _x .

The development of this additive-free process for the cost-effective removal of oil disasters by producing the separation dispersion makes an enormous contribution to nature and species protection. Oil pollution of the environment, especially the seas, through Crude oil or petroleum products from damaged oil tankers or platforms can be cleaned using this technology and the associated plant and the separated hydrocarbons can be recycled.

media

The present method allows the mixing of at least two different media. In the system described, liquid media with a viscosity of 1 mm ² /s to 1,000 mm ² /s, preferably from 100 mm ² /s to 800 mm ² /s, in particular from 300 mm ² /s to 500 mm ² /s can be processed.

The media used are summarized in Table 1. Table 1: Media for the preparation of the hydrocarbon-water dispersion Media1 Media2 • Heavy oil • Drinking water • Diesel fuel • VE water • Heating oil • Sludge: Products from oil separators, waste oil, bilge water from ships

Medium 1 (as main medium) refers to the hydrocarbon-containing, oil-containing component, which corresponds to more than 60 wt% of the dispersion in combustion processes.

When the process is used as a separation process, the proportion of medium 1 is less than 40 wt%.

Medium 2 (as the second medium) corresponds to the water-containing component, which in combustion processes represents less than 40 wt% of the dispersion. The effective proportion of medium 2 in separation processes is over 60 wt%.

In one embodiment, demineralized (deionized) water is used to produce the hydrocarbon-water dispersion. In another embodiment, normal tap water or so-called brackish water can also be used.

Premixing / coarse dispersion

As mentioned above, a premixing unit can be installed upstream of the fine disperser.

In one embodiment of the described system, the at least one premixing unit comprises at least one heat exchanger for medium 1, at least one heat exchanger for medium 2 and at least one mixing apparatus for premixing medium 1 and medium 2. The heat exchanger for adjusting the temperature and indirectly the viscosity of the hydrocarbon as medium 1 can be designed as a heat exchanger with a bypass.

Medium 1 and medium 2 are, as defined in claim 3, heated to temperatures between 30 and 90 °C, preferably between 40 and 80 °C, and introduced into the premixer. At least two different pre-heated media are thus mixed together in the coarse dispersion. The prerequisite for the optimal production of the coarse dispersion is identical absolute feed pressures of the media.

In the supply line for the hydrocarbon-containing component, in particular for the fuel, devices (e.g. sensors) for measuring the temperature and volume flow of the fuel in the fuel supply line can also be provided.

In a further embodiment of the system based on the method, at least one filter for removing dirt particles from the medium 1 is provided on or in the supply line of medium 1 as a hydrocarbon-containing medium. A pressure sensor is arranged upstream of the filter and a pressure sensor is arranged downstream of the filter to monitor the filter occupancy level.

As mentioned above, at least one heat exchanger for adjusting the water temperature to the temperature of the oil-containing component is provided in or on the supply line for medium 2 as water, in particular demineralized and deionized water. Devices (e.g. sensors) for measuring the volume flow and the temperature of the water are preferably provided in front of and behind the heat exchanger in the water line.

The premixing device mentioned above is used to premix the components described above. This mixing device is designed for media of different viscosities. The water is mixed into the oil flow in laminar This coarse mixing optimizes the actual mixing process and protects the pump from the UADA, as a sudden change of hydrocarbon and water is prevented.

In a further embodiment, devices (e.g. sensors) for measuring the temperature and pressure of the hydrocarbon-water coarse dispersion are provided downstream of the premixer.

The tempered mixture with the preset volume or percentage proportion then goes to the next stage for fine dispersion after coarse dispersion.

Fine dispersion

After the coarse dispersion has been prepared, the stable hydrocarbon-water dispersion is prepared in the next step.

As stated above, the at least one fine disperser comprises at least one first pump for a first pressure increase in the inlet of the coarse hydrocarbon-water dispersion; the at least one first ultrasonic acoustic flow unit (UADA) and at least one second pump.

The hydrocarbon-water coarse dispersion is, as covered in claim 5, brought to pressures of up to 2.5 MPa, preferably to pressures between 0.5 MPa and 2 MPa, particularly preferably between 1 MPa and 1.5 MPa, using a first pump before entering at least one first ultrasonic acoustic flow unit (UADA). The pre-pressure built up before the first UADA can be, for example, between 0.6 and 2.5 MPa.

The pump used for this purpose can be designed for high-volume-flow refueling processes or for continuous low-volume-flow production processes, e.g. for volume flows between 5 m ³ /h and 100 m ³ /h, preferably between 10 m ³ /h and 80 m ³ /h, particularly preferably between 20 m ³ /h and 60 m ³ /h. Typical volume flows can be e.g. 6 m ³ /h; 20 m ³ /h and 100 m ³ /h.

In a further preferred embodiment, the plant based on the method has a device for measuring the water content in the hydrocarbon-water coarse dispersion arranged downstream of this first pump. This device for measuring the moisture can be designed in the form of a bypass and enables If there are deviations from the desired water proportion, the water proportion can be readjusted, e.g. via a control valve in the water pipe.

The setting of the water content is preferably automated, which enables inline and more precise water dosing as well as control of the volume flow and temperature. These are prerequisites for a consistent quality of the dispersion to be produced. Furthermore, the amount of water in the fuel can be easily varied. The amount of water, the throughput of hydrocarbons, the temperature and the pressure in the cavitation area are important for consistent quality.

In addition, the water content in the dispersion can be variably adjusted and measured. The water content is important for the later use and combustion properties and is in a range of 1 wt% to 40 wt%, preferably 5 to 30 wt%, particularly preferably 10-15 wt% (based on the total volume of the dispersion to be produced).

The device for measuring and adjusting the water content in the hydrocarbon-water coarse dispersion is followed downstream by further measuring devices (e.g. sensors) for temperature and pressure before entering the first ultrasonic acoustic flow unit (UADA).

According to the invention, the fine dispersion is produced in an ultrasonic acoustic flow unit (UADA) in which the cavitation is not actively introduced but is generated due to the flows in the UADA.

To adjust the cavitation regime, a pre-pressure between 0.6 and 2.5 MPa is set upstream of the UADA module (as described above) and approximately 0.06 MPa downstream of the UADA module.

The pressure setting of the fine dispersion on the ultrasonic acoustic flow unit in the fine disperser should therefore have the following pressure ratio: $$DruckverH\mathrm{ä}{\mathit{ltnis}}_{\mathit{Fine}-\mathit{Dispersing}}=\frac{{\mathit{form}}_{\mathit{before}\mathit{UADA}}}{{\mathit{negative\; pressure}}_{\mathit{after}\mathit{UADA}}}\ge 10$$

This influences the type, strength and shape of the cavitation in the UADA. The stronger the cavitation, the smaller the diameter of the droplets in the dispersion.

After fine dispersion, further monitoring and possible readjustment of the water content can be carried out, inline or in the form of a bypass (analogous to that described above).

The fine dispersion can be discharged from the system. In this case, it is a two-stage process for producing the stable hydrocarbon-water dispersion by coarse dispersion (premixing to produce the mixture) and fine dispersion, whereby the recording of the process-technical regime of the ultrasonic acoustic flow units makes a significant contribution.

Alternatively, the fine dispersion can also be subsequently converted into ultrafine dispersion.

Ultrafine dispersion

As already described above, at least one unit for producing a stable hydrocarbon-water dispersion in the ultrafine disperser can be arranged downstream of the at least one unit for producing a stable hydrocarbon-water dispersion in the fine disperser, this unit comprising at least one second ultrasonic acoustic flow unit (UADA) for producing a stable hydrocarbon-water ultrafine dispersion by means of a combination of thermal and hydrodynamic cavitation.

In one embodiment, the ultrafine disperser comprises at least one heating device for heating the fine dispersion flowing under negative pressure, (downstream) at least one pump for generating the negative pressure in the heating device and for increasing the pressure in the inlet of the heated hydrocarbon-water fine dispersion; (downstream) at least one second ultrasonic acoustic flow unit (UADA) and (downstream) at least one pump for adjusting the negative pressure, which leads to the adjustment, variation and control of the cavitation regime.

• das Verhältnis des Vordruckes vor dem UADA und des Untedruckes nach dem UADA im Fein-Dispergator liegt bei mindestens 10, gemäß $$Druckverh\mathrm{ä}{\mathit{ltnis}}_{\mathit{Fein}-\mathit{Dispergator}}=\frac{{\mathit{Vordruck}}_{\mathit{vor}\mathit{UADA}}}{{\mathit{Unterdruck}}_{\mathit{nach}\mathit{UADA}}}\ge 10$$
  
• das Verhältnis des Vordruckes vor dem UADA und des Druckes nach dem UADA des Unterdruckes im Ultrafein-Dispergators liegt bei mindestens 12, gemäß $$Druckverh\mathrm{ä}{\mathit{ltnis}}_{\mathit{Ultrafein}-\mathit{Dispergator}}=\frac{{\mathit{Vordruck}}_{\mathit{vor}\mathit{UADA}}}{{\mathit{Unterdruck}}_{\mathit{nach}\mathit{UADA}}}\ge 12$$
  

Accordingly, a three-stage process for producing the ultrastable hydrocarbon-water dispersion by coarse dispersion, fine dispersion and ultrafine dispersion can be provided, whereby a recording of the process engineering regimes of the ultrasonic acoustic flow units makes a significant contribution, whereby the following applies:

• the ratio of the pre-pressure before the UADA and the negative pressure after the UADA in the fine disperser is at least 10, according to $$DruckverH\mathrm{ä}{\mathit{ltnis}}_{\mathit{Fine}-\mathit{Dispersant}}=\frac{{\mathit{form}}_{\mathit{before}\mathit{UADA}}}{{\mathit{negative\; pressure}}_{\mathit{after}\mathit{UADA}}}\ge 10$$
  
• the ratio of the pre-pressure before the UADA and the pressure after the UADA of the negative pressure in the ultrafine disperser is at least 12, according to $$DruckverH\mathrm{ä}{\mathit{ltnis}}_{\mathit{Ultrafine}-\mathit{Dispersant}}=\frac{{\mathit{form}}_{\mathit{before}\mathit{UADA}}}{{\mathit{negative\; pressure}}_{\mathit{after}\mathit{UADA}}}\ge 12$$
  

The at least one heating device preferably consists of at least one heating cartridge. It is also possible to use several heating cartridges that can be switched on in parallel. The at least one heating cartridge consists of a heating jacket and a screw-in heating element.

The hydrocarbon-water fine dispersion is heated in the at least one heating device, in particular a heating cartridge, to up to 80 °C before entering the at least second ultrasonic acoustic flow unit (UADA).

To produce the ultrafine dispersion, thermal cavitation is combined with hydrodynamic cavitation to increase effectiveness and stability. The conditions for initiating thermal cavitation are created in a low-pressure heating device. The local heating in the heating device creates small vapor bubbles on the surface, which are released by the flow and collapse again in the liquid due to a drop in temperature. This thermal cavitation increases the hydrodynamic cavitation in the subsequent UADA and thus supports the mixing of the dispersion.

The process application is designed in such a way that negative pressure prevails in the heating device. To initiate ultrasonic cavitation in the subsequent UADA, the pressure is built up again in front of the UADA and the negative pressure is set behind the UADA.

The synergism of the effects of thermo- and hydrodynamic cavitation creates ideal conditions for the production of stable and ultra-fine hydrocarbon-water dispersion.

As already mentioned above, at least one additional pump is provided downstream of the second UADA to control the cavitation regime. At the same time, this additional pump serves to convey the hydrocarbon-water dispersion formed to the discharge line and further to the measuring section and to the storage tanks. This pump is also equipped with pump protection, which consists of a negative pressure sensor in front of the pump and an overpressure sensor behind it.

Furthermore, at least one filter is provided downstream of the at least one additional pump for conveying the hydrocarbon-water dispersion formed. The filter is arranged in particular in front of the measuring section in order to filter out coarse particles and thus protect sensitive sensors in the measuring section. Pressure sensors are installed in front of and behind the filter, which allow the differential pressure to be measured in order to detect any blockage of the filter at an early stage.

The measuring section mentioned serves to record the temperature, pressure and volume flow of the hydrocarbon-water dispersion formed.

A branch is provided behind the measuring section, which allows the dispersion to be guided in an inner circuit via the UADA modules during the start-up and shut-down process of the system. A built-in control technology enables a smooth switchover from the inner recirculation to production. The recirculation line is also equipped with a check valve, a pressure sensor and a volume flow monitor.

With the present process, a stable hydrocarbon-water dispersion with a water droplet size of less than 10 µm can be produced with a water content of 1 to 50 wt%, preferably 5 to 30 wt%, particularly preferably 10 to 15 wt% (based on the total mass of the dispersion to be produced).

Ultrafine dispersion can be technologically realized either after coarse dispersion or after fine dispersion.

Separation process

In a further aspect of the present invention, which is covered in claim 2, the separation disperser (unit constructed identically to the fine disperser, but either without or with a premixer - coarse disperser integrated in the UADA body) is followed by at least one separation tank for separating the water-hydrocarbon dispersion (separation dispersion), which can be easily separated into at least two phases, into hydrocarbon and water.

• mindestens eine Einheit zur Herstellung einer Wasser-Kohlenwasserstoff-Trenndispersion, wobei diese Einheit mindestens ein erstes Ultraschall-Akustik-Durchfluss-Aggregat zur Herstellung einer Wasser-Kohlenwasserstoff-Trenndispersion mittels hydrodynamischer Kavitation umfasst und
• mindestens einen Separationstank zum Auftrennen der Wasser-Kohlenwasserstoff-Trenndispersion in Kohlenwasserstoff und Wasser.

In this case, a plant for separating a water-hydrocarbon dispersion is provided, the plant comprising the following elements:

• at least one unit for producing a water-hydrocarbon separation dispersion, said unit comprising at least one first ultrasonic acoustic flow unit for producing a water-hydrocarbon separation dispersion by means of hydrodynamic cavitation and
• at least one separation tank for separating the water-hydrocarbon separation dispersion into hydrocarbon and water.

• Bereitstellen von mindestens einer in mindestens zwei Phasen trennbaren Wasser-Kohlenwasserstoff-Mischung (Verschmutzung aus Havarieorten) und
• Herstellen einer leicht in mindestens zwei Phasen trennbaren Wasser-Kohlenwasserstoff-Dispersion in mindestens einer Einheit zur Herstellung einer Wasser-Kohlenwasserstoff-Trenndispersion, wobei diese Einheit mindestens ein erstes Ultraschall-Akustik-Durchfluss-Aggregat (UADA) zur Herstellung einer Wasser-Kohlenwasserstoff-Trenndispersion mittels hydrodynamischer Kavitation umfasst und
• Einleiten der gebildeten und leicht in mindestens zwei Phasen trennbaren Wasser-Kohlenwasserstoff-Dispersion in mindestens einen Separationstank zum Auftrennen der Wasser-Kohlenwasserstoff-Trenndispersion in Kohlenwasserstoff und Wasser.

The process for separating a water-hydrocarbon dispersion that can be carried out in such a plant comprises the following steps:

• Provision of at least one water-hydrocarbon mixture separable into at least two phases (pollution from accident sites) and
• Producing a water-hydrocarbon dispersion which can be easily separated into at least two phases in at least one unit for producing a water-hydrocarbon separation dispersion, said unit comprising at least one first ultrasonic acoustic flow unit (UADA) for producing a water-hydrocarbon separation dispersion by means of hydrodynamic cavitation and
• Introducing the water-hydrocarbon dispersion formed and easily separable into at least two phases into at least one separation tank for separating the water-hydrocarbon separation dispersion into hydrocarbon and water.

When applying the technology as a separation process, the proportion of medium 1 as a hydrocarbon-containing medium of the water-hydrocarbon separation dispersion is below 50 wt%. The effective proportion of medium 2 as water in separation processes is over 50 wt%.

To initiate phase separation, a separation dispersion with a desired water content of over 60 wt% is prepared.

1. a) Festlegung der einstufigen Herstellung mit Druckeinstellung der Dispergierung am Ultraschall-Akustik-Durchfluss-Aggregat des Druck-Verhältnisses: $$Druckverh\mathrm{ä}{\mathit{ltnis}}_{\mathit{Dispergierung}}=\frac{{\mathit{Vordruck}}_{\mathit{vor}\mathit{UADA}}}{{\mathit{Unterdruck}}_{\mathit{nach}\mathit{UADA}}}\ge 12$$
   

The one-step cleaning process therefore comprises the production of the water-hydrocarbon separation dispersion by dispersion in the separation-disperser, on the ultrasonic acoustic flow unit, whereby the following applies:

1. a) Determination of the single-stage production with pressure adjustment of the dispersion on the ultrasonic-acoustic flow unit of the pressure ratio: $$DruckverH\mathrm{ä}{\mathit{ltnis}}_{\mathit{Dispersing}}=\frac{{\mathit{form}}_{\mathit{before}\mathit{UADA}}}{{\mathit{negative\; pressure}}_{\mathit{after}\mathit{UADA}}}\ge 12$$
   

The separation dispersion is stored for subsequent separation until at least two phases of the original media separate. The phase formation occurs by coalescence of the hydrocarbon droplets. This creates aggregates of the hydrocarbon droplets. According to Stokes' equation, gravity forces the hydrocarbon aggregates to form a hydrocarbon phase. After separation, the separated media are recycled.

When using the technology as a separation process, especially separation dispersion, the optimal water content is above 60 wt%. The resulting water-hydrocarbon dispersion is unstable.

The mobility of the separation system enables the accident medium, contaminated water, to be fed directly into the separation disperser to produce the water-hydrocarbon separation dispersion and then to phase separation. This allows the technology to be used as a separation process at the accident site.

An essential aspect of the plant based on the process is its modular design, which allows several combinations regarding plant and process implementation.

• Grob-Dispergator,
• Fein-Dispergator, bestehend aus einem Grob-Dispergator (Vormischer), einem UADA-Modul und jeweils vor- und nachgeschalteter Pumpe,
• Ultrafein-Dispergator, bestehend aus Heizvorrichtung, erster Pumpe, UADA-Modul, zweiter Pumpe.

Individual modules:

• Coarse dispersant,
• Fine disperser, consisting of a coarse disperser (premixer), a UADA module and upstream and downstream pumps,
• Ultrafine disperser, consisting of heater, first pump, UADA module, second pump.

In particular, the fine disperser can be used individually.

• Fein-Dispergator;
• Fein-Dispergator mit vorgeschaltetem Grob-Dispergator;
• Fein-Dispergator mit nachgeschaltetem Ultrafein-Dispergator,
  wobei der Aufbau wie folgt ist: erste Pumpe- erstes UADA - Heizvorrichtung- zweite Pumpezweites UADA - dritte Pumpe; d.h. es kann bei einer Kombination von Fein-Dispergator und Ultrafein-Dispergator auf eine Pumpe nach dem ersten UADA verzichtet werden;
• Fein-Dispergator - Separationstank.

Combination of individual modules:

• Fine dispersant;
• Fine disperser with upstream coarse disperser;
• Fine disperser with downstream ultrafine disperser,
  the structure is as follows: first pump - first UADA - heating device - second pump - second UADA - third pump; ie in a combination of fine disperser and ultrafine disperser, a pump after the first UADA can be dispensed with;
• Fine disperser - separation tank.

• einstufiges Verfahren bei singulärer Verwendung von Fein-Dispergator;
• einstufiges Verfahren aus Feindispergierung mit vorgeschalteter Grobdispergierung;
• zweistufiges-Verfahren aus Feindispergierung und anschließender Feindispergierung;
• einstufiges Trennverfahren mittels Trenndispergierung und anschließender Phasentrennung.

This results in the following possible procedural variants:

• one-step process with singular use of fine dispersant;
• single-stage process of fine dispersion with preceding coarse dispersion;
• two-stage process of fine dispersion and subsequent fine dispersion;
• One-stage separation process using separation dispersion and subsequent phase separation.

Figur 1

Dampfdruckkurve von Wasser

Figur 2

eine schematische Darstellung einer ersten Ausführungsform der erfindungsgemäßen Dispersions-Anlage;

Figur 3

eine schematische Darstellung einer Ausführungsform eines Grob-Dispergators;

Figur 4

eine schematische Darstellung einer Ausführungsform eines Fein-Dispergators;

Figur 5

eine schematische Darstellung einer Ausführungsform eines Ultrafein-Dispergators;

Figur 6

eine schematische Darstellung einer Ausführungsform des erfindungsgemäßen Trenn- Dispergators;

Figur 7

eine detaillierte Darstellung eines erfindungsgemäß verwendeten Ultraschall-Akustik-Durchfluss-Aggregates; und

Figur 8

eine detaillierte Ansicht einer in dem Aggregat der Figur 7 verwendeten akustischen Platte.

The present invention is explained in detail below using an embodiment with reference to the figures. They show:

Figure 1

Vapor pressure curve of water

Figure 2

a schematic representation of a first embodiment of the dispersion plant according to the invention;

Figure 3

a schematic representation of an embodiment of a coarse disperser;

Figure 4

a schematic representation of an embodiment of a fine disperser;

Figure 5

a schematic representation of an embodiment of an ultrafine disperser;

Figure 6

a schematic representation of an embodiment of the separation dispersant according to the invention;

Figure 7

a detailed representation of an ultrasonic acoustic flow unit used according to the invention; and

Figure 8

a detailed view of a unit in the Figure 7 used acoustic panel.

Plant for producing a stable hydrocarbon-water dispersion

Figure 2 shows the schematic representation of a dispersion system. The entire system is divided into three different areas: the coarse disperser, the fine disperser and the ultrafine disperser.

The main component of the system is the ultrasonic acoustic flow unit (UADA).

A UADA is always designed for a specific flow rate (6 m ³ /h; 20 m ³ /h and 100 m ³ /h).

The structure of the UADA module is in Figure 7 The module consists of inlet, pre-sound chamber, sound chamber, ultrasonic chamber and outlet. The acoustic plate, in Figure 8 shown, is located in the pre-sound chamber and is made up of the axial ring chamber and tangential vortex grooves. In the sound chamber there are vortex tubes, which filled with conical vortex bodies. The vortex tubes open into the ultrasound chamber, which is connected to the drain.

To protect the dispersion system, filters are installed between the coarse and fine dispersers and after the ultrafine disperser.

Coarse dispersant: In the area of coarse dispersant ( Figure 3 ) the system consists of at least two supply lines for two different media, each with a heat exchanger, an adjustment device for the media ratio and a pre-mixer. The temperature of the media can be regulated via the system's control technology.

The media ratio is automatically set and monitored using control technology. This is transferred to the fine disperser area of the system. The coarse disperser is the precursor to the fine disperser.

Fine dispersant: The Fine dispersant area in Figure 4 consists of two pumps (primary pressure and vacuum pump), the UADA enclosed by these pumps and the associated control technology. The fine disperser is followed by the ultrafine disperser.

Ultrafine dispersant: The ultrafine dispersant, in Figure 5 shown, consists of a heating device, two pumps (primary pressure and vacuum pump) and the UADA enclosed by them.

The design of the heating device (heating cartridge) consists of a flow-through heating jacket with an integrated screw-in heating element.

The results are evaluated using an online viscometer via three measuring points after the coarse disperser, fine disperser and ultrafine disperser.

Recirculation: A branch is provided behind the measuring section, which allows the dispersion to be guided in an inner circuit over the UADA units during the start-up and shut-down process of the system. The control enables a smooth switchover from the inner recirculation to production.

The dispersion system is used to mix at least two different pre-tempered media. The first step involves rough physical pre-mixing. The second step involves fine dispersion based on hydrodynamic and super cavitation. In the final step, the dispersion is thoroughly refined by combining thermo-, hydrodynamic and super-cavitation.

Separation plant for the production of a phase-forming dispersion

In the event of an accident on the water, the system is used to separate the media.

The facility, as in Figure 6 shown, consists of two pumps (primary pressure and vacuum pump), the UADA enclosed by these pumps and the associated control technology.

The system is fed by a collection tank in which the damaged dispersion is located. Behind the system is the separation tank, which is connected to at least two tanks (e.g. oil and water tank) for at least two already separated media. The quality control (purity control) then takes place in the tanks.

The separation system is used to separate the water-hydrocarbon mixture at accident sites and is constructed identically to the fine dispersion area.

Example 1

The principle of dispersion generation is based on a mixture of fuel and water being pressed through special nozzles in a specially developed UADA (ultrasonic acoustic flow unit). The resulting flow speeds promote the formation of cavitation. The result is a very fine-droplet, stable dispersion that is flammable.

The UADA module can be manually shut off on the inlet side using manual shut-off valves and on the outlet side using manual shut-off valves. In addition, the following safety shut-off valves are installed at the inlet, which automatically shut off the system in the event of a serious fault. Safety valves are installed at the outlet, which separate the modules from the tank farm in the event of a serious fault.

The safety shut-off valves automatically separate the UADA module from the rest of the system in the event of an emergency stop, fire, power failure and unforeseen critical operating conditions.

The UADA module begins behind the fuel supply line in which the temperature and volume flow of the reactant are measured. The continuing fuel line is equipped with a check valve that prevents backflow to the reactant storage. A temperature sensor is also installed after the recirculation line to monitor the pour point and flash point. A filter is then installed to keep dirt particles away from the system. A pressure sensor is installed in front of and behind the filter to detect an excessive pressure drop. If this increases too high, the filter must be replaced or cleaned. A heat exchanger with a bypass is then installed. This is intended to adjust the temperature in the inlet and bring it to the desired values (the current safety margins must be observed for the flash and ignition point temperatures). This adjusted temperature is continuously checked by the temperature sensor.

In the subsequent premixer, the oil stream is roughly premixed with the water component.

The desalinated (deionized) water is fed from the water treatment plant into the process via separate pipes. The amount of water added is dosed using the control valve. The volume flow and the temperature of the water are measured and recorded. The water can be adjusted to the temperature of the hydrocarbon using the built-in heat exchanger. There is another temperature sensor behind the heat exchanger to monitor the temperature. Before the water reaches the pre-mixer, a check valve is installed to prevent hydrocarbons from entering the water pipe.

The mixture temperature and the resulting pressure are measured behind the pre-mixer in order to detect any deviations in operating conditions. The mixture then goes into the first pressure booster. Here the pressure is increased to up to 2.5 MPa. To ensure precise monitoring of the water content, the humidity is measured in a bypass behind the pump. If there are deviations from the desired water content, the control valve in the water line is used to make adjustments. Before the mixture goes into the first ultrasonic acoustic flow unit (UADA), the temperature and pressure are measured and recorded. The dispersion is produced in this UADA, and the pressure built up by the pressure increase drops completely. The temperature and pressure are measured and recorded behind the UADA. A heating cartridge with a temperature sensor is then installed in order to be able to build up subsequent thermal cavitation behind the UADA.

This is followed by the second pressure increase. An additional function of the second pressure increase is the setting of the negative pressure behind the first UADA. This has a significant influence on the type, strength and form of cavitation in the first UADA. The first UADA works optimally when the pressure behind it is set at 0.05 MPa. The pump of the second pressure increase is equipped with a pressure sensor for monitoring the negative pressure before and a pressure sensor for monitoring the positive pressure after the UADA. This allows the system to be operated in a targeted manner at the required negative pressure and positive pressure. The pressure sensors installed in this section of the line give an alarm before a critical negative or positive pressure occurs. This allows the control system to counteract this event.

This is followed by another pump. This is intended to transport the resulting dispersion further along the measuring section to the storage tanks. This pump is also equipped with pump protection, which again consists of a pressure sensor for monitoring the negative pressure in front of the pump and a pressure sensor for monitoring the positive pressure behind the pump.

Before the measuring section follows, a filter is installed to ensure that no coarse particles get into the measuring section and thus protect the sensitive sensors. Pressure sensors are installed in front of and behind the filter, which allow the differential pressure to be measured in order to detect any blockage of the filter at an early stage. The following data is recorded in the measuring section: the temperature, the pressure, the volume flow.

Behind the measuring section there is a branch that allows the dispersion in the inner circuit to be run via the UADA modules during the start-up and shut-down process. The control valve is installed for this purpose. This enables a smooth switchover from the inner recirculation to production. The control valve is paired with a check valve to prevent mixing of faulty batches during recirculation from the product storage in the line and finished dispersion from the line.

The recirculation line is equipped with a check valve, a pressure sensor and a volume flow monitor.

Example 2: Process for preparing the dispersion

• Example 1: Storage tank, coarse disperser, fine disperser, product tank
• Example 2: Storage tank, coarse disperser, fine disperser, ultrafine disperser, product tank Example 3: Separation process
• Example 3: Collection tank, fine disperser, oil tank and water tank.

Calculation examples

• Produktionszeit = 5 h
  • Medium 1:
    • Ölvorrat 45 m³
    • Bunkeröl IFO 180 - 3,5 %
    • Viskosität 180 mm²/s (DIN EN ISO 3104)
    • Flammpunkt 60 °C
  • Medium 2: Wasservorrat 10 % = 5 m³
• Dispergierungstemperatur T = 50 °C
• Druckeinstellung am Fein-Dispergator / Ultrafein-Dispergator:
  • Vordruck_Minimum = 6 bar (variabel)
  • Unterdruck = 0,5 bar (konstant) $$Druckverh\mathrm{ä}\mathit{ltnis}=\frac{{\mathit{Vordruck}}_{\mathit{vor}\mathit{UADA}}}{{\mathit{Unterdruck}}_{\mathit{nach}\mathit{UADA}}}\ge 12$$
    
  • Druckverhältnis = 12

• Herstellung von 50 m³ einer 10 % igen wasserhaltigen Dispersion
• Temperierung Medium 1 und Medium 2 auf Dispergierungstemperatur
• Einstellung der Durchflussmenge je Medium: Medium 1, Medium 2
• Einstellung der Durchflussmenge Dispersion 10 m³/h
• Grob-Mischung mit Temperatur- und Volumenstromkontrolle
• Feindispergierung mit Druckeinstellung und Temperaturkontrolle, Wassergehaltskontrolle und Nachjustierung (automatisiert)
• Ultrafeindispergierung mit Druck und Temperatureinstellung in der Heizvorrichtung mit Temperaturkontrolle (automatisiert)
• Qualitätskontrolle mittels Viskosität
• Lagerung des temperierten Produktes

The calculation example was based on the following data:

• Production time = 5 h
  • Media1:
    • Oil reservoir 45 m ³
    • Bunker oil IFO 180 - 3.5%
    • Viscosity 180 mm ² /s (DIN EN ISO 3104)
    • Flash point 60 °C
  • Medium 2: Water supply 10 % = 5 m ³
• Dispersing temperature T = 50 °C
• Pressure setting on the fine disperser / ultrafine disperser:
  • Pre-pressure _minimum = 6 bar (variable)
  • Negative pressure = 0.5 bar (constant) $$DruckverH\mathrm{ä}\mathit{ltnis}=\frac{{\mathit{form}}_{\mathit{before}\mathit{UADA}}}{{\mathit{negative\; pressure}}_{\mathit{after}\mathit{UADA}}}\ge 12$$
    
  • Pressure ratio = 12

• Preparation of 50 m ³ of a 10 % aqueous dispersion
• Tempering medium 1 and medium 2 to dispersion temperature
• Setting the flow rate per medium: Medium 1, Medium 2
• Dispersion flow rate setting 10 m ³ /h
• Coarse mixing with temperature and volume flow control
• Fine dispersion with pressure adjustment and temperature control, water content control and readjustment (automated)
• Ultrafine dispersion with pressure and temperature adjustment in the heating device with temperature control (automated)
• Quality control using viscosity
• Storage of the tempered product

Forecasted product:

• Tröpfchendurchmesser in der Grobdispergierung größer als 1 mm
• Tröpfchendurchmesser in der Feindispergierung kleiner als 1 mm und größer als 100 µm
• Tröpfchendurchmesser in der Ultrafeindispergierung kleiner als100 µm

Three different levels of droplet fineness are achieved with the system:

• Droplet diameter in coarse dispersion greater than 1 mm
• Droplet diameter in fine dispersion smaller than 1 mm and larger than 100 µm
• Droplet diameter in ultrafine dispersion smaller than 100 µm

Predicted stability of ultrafine dispersion 5-7 years.

nomenclature

Expression Meaning Dispersant Plant area Dispersing Procedural area Dispersion Finest distribution of one substance in another Dispersion plant Process plant for the production of the dispersion, consists of several plant areas Fine dispersion Dispersion after fine dispersiondispersion Coarse dispersion Dispersion after coarse dispersiondispersion Cavitation Formation and dissolution of vapor-filled liquids Hydrocarbon-water dispersion over 50 wt% hydrocarbon content Media1 oil-containing component Media2 water-containing component Oil tank Tank in which pure oil is stored Collection tank Tank in which contaminated medium is stored Separation system Plant for the realization of the separation process for the separation of the water-hydrocarbon mixture Separation dispersion Dispersion after separation dispersion Ultrafine dispersion Dispersion after ultrafine dispersiondispersion Ultrasonic acoustic flow unit (UADA) Module for generating cavitation negative pressure Pressure after the ultrasonic acoustic flow unit form Pressure before the ultrasonic acoustic flow unit Water-hydrocarbon dispersion Dispersal of medium 1 and medium 2, over 50 wt% water content Water tank Tank in which pure water is stored wt% Mass percent

Claims (9)

1. Method for producing a stable fine hydrocarbon-water dispersion with a hydrocarbon content greater than 50 wt%, comprising the following steps:

   - Production of a stable fine hydrocarbon-water dispersion with a droplet diameter of 100 µm to 1 mm in at least one unit for producing a fine hydrocarbon-water dispersion from at least medium 1, as a medium containing hydrocarbons, and medium 2, as water, with this unit comprising a fine dispersant consisting of at least one initial pump (pump 01) for an initial pressure increase in an afflux of a coarse hydrocarbon-water dispersion from a premixing unit as part of a coarse dispersant, at least one ultrasonic acoustic flow unit (UADA-01) for producing a fine hydrocarbon-water dispersion by means of hydrodynamic cavitation, and at least one second pump (pump 02) for generating negative pressure in the outflow of the fine hydrocarbon-water dispersion formed,

   - whereby the coarse dispersion from medium 1 and medium 2 is provided by mixing medium 1 and medium 2 in the premixing unit, of which there is at least one, in the coarse disperser, and

   - whereby the ratio of the pressure upstream of the ultrasonic acoustic flow unit (UADA), i.e., the initial pressure, of the fine dispersant and the pressure downstream of the ultrasonic acoustic flow unit (UADA), i.e. the negative pressure, of the fine dispersant is at least 10.
2. Method for producing an unstable separable water-hydrocarbon dispersion with a water content greater than 50 wt%, comprising the following steps:

   - Production of an unstable separable water-hydrocarbon dispersion that can be separated into at least two phases in a unit for producing a separable water-hydrocarbon dispersion from at least medium 1, as a medium containing hydrocarbons, and medium 2, as water, with this unit comprising a separation dispersant consisting of at least one initial pump (pump 01) for an initial pressure increase in an afflux of a water-hydrocarbon mixture; at least one ultrasonic acoustic flow unit (UADA 01) for producing a separable water-hydrocarbon dispersion by means of hydrodynamic cavitation, and at least one second pump (pump 02) for generating negative pressure in the outflow of the separable water-hydrocarbon dispersion formed,

   - whereby a separation tank for separating the separable water-hydrocarbon dispersion into hydrocarbon and water is connected downstream of the separation dispersant,

   - whereby the water-hydrocarbon mixture, of which there is at least one, that is separable into at least two phases is provided from medium 1 and medium 2; and

   - whereby the ratio of the pressure upstream of the ultrasonic acoustic flow unit (UADA), i.e., the initial pressure, of the separation dispersant and the pressure downstream of the ultrasonic acoustic flow unit (UADA), i.e. the negative pressure, of the separation dispersant is at least 10.
3. Method according to claim 1, characterised by the fact that medium 1 and medium 2 are introduced into a premixer of the premixing unit at temperatures between 30 and 90 °C, preferably between 40 and 80 °C.
4. Method according to one of claims 1-3, characterised by the fact that medium 1 used has a viscosity of 1 mm²/s to 1,000 mm²/s, preferably of 100 mm²/s to 800 mm²/s, in particular, of 300 mm²/s to 500 mm²/s.
5. Method according to one of claims 1-4, characterised by the fact that the coarse hydrocarbon-water dispersion or the water-hydrocarbon mixture is brought to pressures of 0.5 MPa to 2.5 Mpa, preferably to pressures between 0.6 Mpa and 2 Mpa and, particularly preferably, between 1 Mpa and 1.5 Mpa, before entry into the ultrasonic acoustic flow unit (UADA) using the first pump of the fine or separation dispersant unit, and is brought to pressures of 0.02 Mpa to 0.1 Mpa, preferably to pressures of 0.06 Mpa, after exiting the ultrasonic acoustic flow unit (UADA) through the use of the second pump of the fine or separation dispersant unit.
6. Method according to one of claims 1, 3-5, characterised by the fact that, after leaving the ultrasonic acoustic flow unit (UADA) of the fine dispersant unit, the fine hydrocarbon-water dispersion is introduced into at least one ultra-fine dispersant unit for producing an ultra-fine dispersion with a droplet diameter of less than 100 µm,

   - whereby this ultra-fine dispersant unit comprises at least one heating device for initiating thermocavitation by means of heating the dispersion flowing under negative pressure from the fine dispersant unit, at least one pump (pump 02) for increasing the pressure in an afflux of the heated hydrocarbon-water dispersion; at least one second ultrasonic acoustic flow unit (UADA - 02), and at least one further pump (pump 03) for generating negative pressure in the outflow of the hydrocarbon-water dispersion formed for building up the cavitation regimes in the UADA,

   - whereby the ratio of the pressure of the ultra-fine dispersant upstream of the ultrasonic acoustic flow unit (UADA), i.e., the initial pressure, and the pressure of the ultra-fine dispersant downstream of the ultrasonic acoustic flow unit (UADA), i.e., the negative pressure, is at least 12.
7. Method according to claim 6, characterised by the fact that the fine hydrocarbon-water dispersion produced in the fine dispersant, after leaving the fine dispersant, is first heated to up to 80 °C in at least one heating device, in particular, a heating cartridge, before entry into the at least second ultrasonic acoustic flow unit (UADA).
8. Method according to claim 6 or 7, characterised by the fact that the effects of hydrodynamic cavitation or supercavitation are enhanced by means of upstream thermal cavitation.
9. Method according to claim 2, characterised by the fact that the separable water-hydrocarbon dispersion formed in the separation dispersant is introduced into at least one separation tank for separating the hydrocarbon-water dispersion into hydrocarbon and water.

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