US20030226312A1 - Aqueous additives in hydrocarbonaceous fuel combustion systems - Google Patents

Aqueous additives in hydrocarbonaceous fuel combustion systems Download PDF

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Publication number
US20030226312A1
US20030226312A1 US10/165,462 US16546202A US2003226312A1 US 20030226312 A1 US20030226312 A1 US 20030226312A1 US 16546202 A US16546202 A US 16546202A US 2003226312 A1 US2003226312 A1 US 2003226312A1
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United States
Prior art keywords
fuel
combustion
metal compound
aqueous additive
additive
Prior art date
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Abandoned
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US10/165,462
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English (en)
Inventor
Joseph Roos
Lawrence Cunningham
Gregory Guinther
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Afton Chemical Intangibles LLC
Original Assignee
Ethyl Corp
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Priority to US10/165,462 priority Critical patent/US20030226312A1/en
Application filed by Ethyl Corp filed Critical Ethyl Corp
Assigned to ETHYL CORPORATION reassignment ETHYL CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CUNNINGHAM, LAWRENCE JOSEPH, GUINTHER, GREOGRY H., ROOS, JOSEPH W.
Assigned to BANK OF AMERICA, N.A., AS COLLATERAL AGENT reassignment BANK OF AMERICA, N.A., AS COLLATERAL AGENT NOTICE OF GRANT OF SECURITY INTEREST Assignors: ETHYL CORPORATION
Priority to CA002428726A priority patent/CA2428726A1/en
Priority to AU2003204383A priority patent/AU2003204383A1/en
Priority to EP03012742A priority patent/EP1378560A3/en
Priority to MXPA03004990A priority patent/MXPA03004990A/es
Assigned to ETHLYL CORPORATION reassignment ETHLYL CORPORATION RELEASE OF SECURITY INTEREST Assignors: BANK OF AMERICA, N.A.
Assigned to CREDIT SUISSE FIRST BOSTON, CAYMAN ISLANDS BRANCH reassignment CREDIT SUISSE FIRST BOSTON, CAYMAN ISLANDS BRANCH GRANT OF PATENT SECURITY INTEREST Assignors: ETHYL CORPORATION
Priority to ARP030102039A priority patent/AR040173A1/es
Priority to BR0302096-7A priority patent/BR0302096A/pt
Priority to CNA03138689XA priority patent/CN1467267A/zh
Publication of US20030226312A1 publication Critical patent/US20030226312A1/en
Assigned to SUNTRUST BANK, AS ADMINISTRATIVE AGENT reassignment SUNTRUST BANK, AS ADMINISTRATIVE AGENT SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ETHYL CORPORATION
Assigned to SUNTRUST BANK, AS ADMINISTRATIVE AGENT reassignment SUNTRUST BANK, AS ADMINISTRATIVE AGENT ASSIGNMT. OF SECURITY INTEREST Assignors: CREDIT SUISSE FIRST BOSTON, CAYMAN ISLANDS BRANCH
Assigned to AFTON CHEMICAL INTANGIBLES LLC reassignment AFTON CHEMICAL INTANGIBLES LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ETHYL CORPORATION
Abandoned legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • F01N3/2066—Selective catalytic reduction [SCR]
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L1/00—Liquid carbonaceous fuels
    • C10L1/10—Liquid carbonaceous fuels containing additives
    • C—CHEMISTRY; METALLURGY
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    • C10L10/00—Use of additives to fuels or fires for particular purposes
    • C10L10/02—Use of additives to fuels or fires for particular purposes for reducing smoke development
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
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    • C10L10/00—Use of additives to fuels or fires for particular purposes
    • C10L10/06—Use of additives to fuels or fires for particular purposes for facilitating soot removal
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
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    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/023—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles
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    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/023—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles
    • F01N3/029—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles by adding non-fuel substances to exhaust
    • F01N3/0293—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles by adding non-fuel substances to exhaust injecting substances in exhaust stream
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2896—Liquid catalyst carrier
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M25/00—Engine-pertinent apparatus for adding non-fuel substances or small quantities of secondary fuel to combustion-air, main fuel or fuel-air mixture
    • F02M25/022—Adding fuel and water emulsion, water or steam
    • F02M25/0228—Adding fuel and water emulsion
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23K—FEEDING FUEL TO COMBUSTION APPARATUS
    • F23K5/00—Feeding or distributing other fuel to combustion apparatus
    • F23K5/02—Liquid fuel
    • F23K5/08—Preparation of fuel
    • F23K5/10—Mixing with other fluids
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
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    • C10L1/00—Liquid carbonaceous fuels
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    • C10L1/1233—Inorganic compounds oxygen containing compounds, e.g. oxides, hydroxides, acids and salts thereof
    • C10L1/125—Inorganic compounds oxygen containing compounds, e.g. oxides, hydroxides, acids and salts thereof water
    • C—CHEMISTRY; METALLURGY
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    • C10L1/1266—Inorganic compounds nitrogen containing compounds, (e.g. NH3)
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    • C10L1/14—Organic compounds
    • C10L1/18—Organic compounds containing oxygen
    • C10L1/1811—Organic compounds containing oxygen peroxides; ozonides
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    • C10L1/18—Organic compounds containing oxygen
    • C10L1/182—Organic compounds containing oxygen containing hydroxy groups; Salts thereof
    • C10L1/1828—Salts thereof
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    • C10L1/188—Carboxylic acids; metal salts thereof
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    • C10L1/222—Organic compounds containing nitrogen containing at least one carbon-to-nitrogen single bond
    • C10L1/2227—Organic compounds containing nitrogen containing at least one carbon-to-nitrogen single bond urea; derivatives thereof; urethane
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    • C10L1/2431—Organic compounds containing sulfur, selenium and/or tellurium sulfur bond to oxygen, e.g. sulfones, sulfoxides
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    • C10L1/305—Organic compounds compounds not mentioned before (complexes) organo-metallic compounds (containing a metal to carbon bond)
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    • F01N2250/00—Combinations of different methods of purification
    • F01N2250/02—Combinations of different methods of purification filtering and catalytic conversion
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    • F01N2430/00—Influencing exhaust purification, e.g. starting of catalytic reaction, filter regeneration, or the like, by controlling engine operating characteristics
    • F01N2430/04—Influencing exhaust purification, e.g. starting of catalytic reaction, filter regeneration, or the like, by controlling engine operating characteristics by adding non-fuel substances to combustion air or fuel, e.g. additives
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    • F01N2570/04—Sulfur or sulfur oxides
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
    • F01N2570/08—Phosphorus
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
    • F01N2570/14—Nitrogen oxides
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2610/00—Adding substances to exhaust gases
    • F01N2610/02—Adding substances to exhaust gases the substance being ammonia or urea
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
    • F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the present invention relates to an additive for protecting or improving operation of combustion exhaust after treatment systems.
  • the additive contains one or more metal compounds that are soluble in aqueous solutions.
  • the additive can be introduced in an embodiment into a combustion chamber as part of an emulsion or dispersion with the fuel, or it may be injected as the emulsion or dispersion, or alone as an aqueous stream introduced into the combustion exhaust. Therefore, the additive will protect emission control devices (catalysts and traps) from degradation. In another embodiment of the invention, the methods will reduce combustion exhaust emissions.
  • Catalytic systems are capable of reducing NO x as well as oxidizing CO and HC.
  • a reducing environment for NO x treatment is required which necessitates a richer than chemically correct engine air-fuel ratio.
  • a two-bed converter may be used in which air is injected into the second stage to oxidize CO and HC. While efficient, this procedure results in lower fuel economy.
  • TWC's Three way catalysts
  • Diesel compression ignition systems raise a different set of challenges for emissions control.
  • Strategies for reducing particulate and HC include optimizing fuel injection and air motion, effective fuel atomization at varying loads, control of timing of fuel injection, minimization of parasitic losses in combustion chambers, low sac volume or valve cover orifice nozzles for direct injection, reducing lubrication oil contributions, and rapid engine warm-up.
  • NO x is removed from diesel exhaust by either selective catalytic reduction, the use of lean NO x catalysts such as those comprised of zeolitic catalysts or using metals such as iridium, or catalyzed thermal decomposition of NO into O 2 and N 2 . It is known to use an aqueous urea solution in selective catalyst reduction (“SCR”) systems.
  • SCR selective catalyst reduction
  • Diesel particulate traps have been developed which employ ceramic or metal filters. Thermal and catalytic regeneration can burn out the material stored. New particulate standards currently under review may necessitate such traps. Fuel composition, including sulfur and aromatic content, and the burning of lubricant can contribute to increased particulate emissions. Catalysts have been developed for diesels, which are very effective in oxidizing the organic portion of the particulate.
  • Organometallic manganese compounds for example methylcyclopentadienyl manganese tricarbonyl (MMT®), available from Ethyl Corporation of Richmond, Va., is known for use in gasoline as both an emissions-reducing agent and as an antiknock agent (see, e.g. U.S. Pat. No. 2,818,417). These manganese compounds have been used to lower deposit formation in fuel induction systems (U.S. Pat. Nos. 5,551,957 and 5,679,116), sparkplugs (U.S. Pat. No. 4,674,447) and in exhaust systems (U.S. Pat. Nos. 4,175,927; 4,266,946; 4,317,657, and 4,390,345.
  • MMT® methylcyclopentadienyl manganese tricarbonyl
  • Organometallic iron compounds such as ferrocene
  • octane enhancement U.S. Pat. No. 4,139,319
  • Diesel-fueled engines produce NOx due to the relatively high flame temperatures reached during combustion.
  • the reduction of NOx production can include the use of catalytic converters, using “clean” fuels, recirculation of exhaust, and engine timing changes. These methods are typically expensive or too complicated to be commercially used.
  • the present invention provides refiners with flexibility in complying with the objective of lowering particulate emissions by allowing refiners to reduce sulfur to a certain level above the regulated level, and yet still obtain the benefits of improved exhaust emissions control technology performance obtained by using fuels containing lower levels of sulfur.
  • the invention includes an aqueous additive containing a water-soluble metal compound or metal ion source.
  • the additive may be introduced into the combustion chamber as part of an emulsion with the fuel, or it may be injected as the emulsion, or introduced alone as an aqueous stream into the combustion exhaust after the combustion chamber, or introduced into the catalytic converter.
  • a hydrocarbonaceous fuel product comprises a hydrocarbonaceous fuel and an aqueous additive that comprises a water-soluble metal compound.
  • the metal compound or metal ion may be an inorganic metal compound or an organometallic compound.
  • the elemental or ionic metal can be one or more of the following group: sodium, potassium, magnesium, calcium, barium, strontium, titanium, cerium, chromium, molybdenum, manganese, iron, rubidium, cobalt, rhodium, nickel, palladium, platinum, copper, and silver compounds, and mixtures thereof.
  • the inorganic metal compound can be selected from the group consisting of fluorides, chlorides, bromides, iodides, oxides, nitrates, sulfates, phosphates, carbonates, hydrides, nitrides, and mixtures thereof.
  • the organometallic compound is selected from the group consisting of alcohols, aldehydes, ketones, esters, anhydrides, sulfonates, phosphonates, chelates, phenates, crown ethers, carboxylic acids, amides, and mixtures thereof. Particularly useful are organometallic compounds containing one or more carbonyl groups, ethers or poly ethers, and other organic ligands able to coordinate with or bond with a metal, metal compound, or metal ion.
  • Oxygenates are also useful in the fuel product of the present invention including water, biodiesel, alcohols, esters, ethers, ketones, polyols, glymes and mixtures thereof.
  • an aqueous additive to be used in connection with a hydrocarbonaceous fuel product comprises a water-soluble metal compound.
  • an additive of the present invention may include a metal compound that is an inorganic metal compound or an organometallic compound. The metal is selected from the group of metals noted herein.
  • the additives of the present invention form a stable compound with combustion byproducts, such as sulfur, phosphorus, lead, zinc or soot, which could otherwise poison or adversely impact an after treatment system.
  • the stable compound formed can be readily removed from the exhaust system by, for example, capture within a particulate trap.
  • an aqueous additive for a hydrocarbonaceous fuel is adapted to be injected into a hydrocarbonaceous combustion exhaust stream.
  • the aqueous additive contains, in an embodiment, a water-soluble metal compound.
  • the aqueous additive contains a water-dispersed metal compound.
  • the metal compound may be an inorganic metal compound or an organometallic compound.
  • the metal may be selected from the group already noted herein.
  • the inorganic metal compounds and organometallic compounds may also be selected from the groups already disclosed herein.
  • the aqueous additive may further include ammonia, urea, a precursor thereof, or a mixture thereof.
  • the invention includes a method of enhancing performance durability of a catalytic emissions control system in a hydrocarbonaceous fuel combustion system containing a catalytic device.
  • the catalytic device has a transition metal, noble metal, alkali or alkaline earth metal element, or combinations thereof (catalytic elements).
  • the fuel combustion system produces at least one combustion byproduct.
  • the method includes supplying a fuel comprising an aqueous additive that includes a water-soluble metal compound to the fuel combustion system.
  • the metal compound complexes with at least one combustion byproduct.
  • the metal compound is supplied in an effective amount to complex with at least one fuel combustion byproduct. All of the foregoing reduce the adverse impact of the fuel combustion byproduct on the emissions control system(s).
  • the fuel may be, but is not limited to, a spark-ignition fuel, a compression-ignition fuel, or a combustion chamber fuel.
  • the metal compound may be an inorganic metal compound or organometallic compound as described herein.
  • the invention includes a method of enhancing performance durability of catalytic emissions control systems for after treatment of an exhaust stream from a hydrocarbonaceous fuel combustion system.
  • the fuel combustion system contains a catalytic device having a transition metal, noble metal, alkali or alkaline earth metal element, or combinations thereof (catalytic elements).
  • the combustion system produces at least one byproduct.
  • the method comprises injecting an aqueous additive comprising a metal compound into the exhaust stream.
  • the metal compound complexes with at least one combustion byproduct.
  • the metal compound is supplied in an effective amount to complex with at least one fuel combustion fuel byproduct, whereby the impact of the byproduct on the emissions control system is reduced.
  • the metal compound may be an inorganic or organometallic compound.
  • the additive may contain ammonia, urea, precursors thereof, or a mixture thereof.
  • a catalytic emissions control system for the after treatment of a combustion process exhaust stream comprises an exhaust passageway for the passage of an exhaust stream containing exhaust byproducts from the combustion of a hydrocarbonaceous fuel.
  • the system also includes at least one catalytic material having catalytic activity, with a catalytic material being located within the exhaust passageway and contacting the exhaust stream.
  • the exhaust stream contains a water-soluble metal compound which complexes with at least one of the exhaust byproducts and reduces the impact of the byproduct on the catalytic material, wherein the fuel comprises an aqueous additive that includes the water-soluble metal compound.
  • a catalytic emissions control system for the after treatment of a combustion process exhaust stream comprises an exhaust passage way for the passage of an exhaust stream containing exhaust byproducts from the combustion of a hydrocarbonaceous fuel.
  • the system also includes at least one catalytic material having catalytic activity, and the catalytic material is located within the exhaust passage way and contacts the exhaust stream.
  • the exhaust stream has an aqueous additive streamed into it, the additive comprising a water-soluble metal compound which complexes with at least one of the exhaust byproducts and reduces the impact of the byproduct upon the catalytic material.
  • the additives of the present invention are inorganic or organometallic compounds metal compounds soluble or dispersable in aqueous solutions. At least one of the metals in the additive promotes the oxidation of carbon particulate matter. This would include additives containing sodium, potassium, magnesium, calcium, barium, strontium, titanium, cerium, chromium, molybdenum, manganese, iron, rubidium, cobalt, rhodium, nickel, palladium, platinum, copper, and silver.
  • the metal(s) Upon introduction into the exhaust stream, the metal(s) is/are released and are collected at least in part in a particulate filter. The metal or metals come into contact with the carbon fraction of the particulate, accelerate the carbon oxidation reactions, and aid in particulate trap regeneration.
  • the exhaust system may contain other aftertreatment systems in addition to the particulate filter.
  • hydrocarbonaceous fuel combustion systems that may benefit from the present invention include all internal combustion engines that burn, for example, gasoline, diesel, or similar type fuels. It also refers to coal-burning power plants, wood-burning cogeneration plants, waste burners, burner operations, or any other combustion of a hydrocarbonaceous fuel product.
  • combustion chamber herein is meant any and all devices, machines, engines, incinerators, stationary burners and the like which can combust or in which can be combusted a hydrocarbonaceous fuel.
  • hydrocarbonaceous fuel herein is meant one or more fuels selected from the group consisting of gasoline, bitumen, crude oil, residual fuel oil, bunker oils, middle distillate fuel, diesel fuel, biodiesel, biodiesel-derived fuel, synthetic diesel fuel, coal, coal slurry, methanol, ethanol, methane, home heating oil, lignocellulosics, wood chips, wood pulp, sawdust, leaves, bushes, lawn clippings, paper, urban waste, industrial waste, and farm waste, and mixtures thereof.
  • emission treatment may include a catalytic system to reduce harmful emissions.
  • other emission treatment systems are well known.
  • the present invention contemplates providing a metal compound to an aqueous solution as an additive to a fuel or lubricant composition or, alternatively, directly into the exhaust stream or combustion zone resulting from the combustion process, whereby the useful life of the emission treatment system components will be significantly improved.
  • Preferred metals herein include elemental and ionic sodium, potassium, magnesium, calcium, barium, strontium, titanium, cerium, chromium, molybdenum, manganese, iron, rubidium, cobalt, rhodium, nickel, palladium, platinum, copper and silver, precursors thereof, and mixtures. These metal compounds may be either inorganic or organic. Also effective in the present invention is the generation, liberation or production in situ of one or more of these metals or metal ions.
  • Preferred inorganic metallic compounds in an embodiment of the present invention can include by example and without limitation methylcyclopentadienyl manganese tricarbonyl (MMT® available from Ethyl Corporation), sodium chloride, potassium chloride, titanium dioxide, copper oxide, sodium nitrates, sodium nitrites, and copper and silver halides.
  • MMT® methylcyclopentadienyl manganese tricarbonyl
  • Metallic sulfates and metallic phosphates will be operative in the present invention and may, in certain fuels and combustion applications, not present unacceptable additional sulfur and phosphorus combustion byproducts.
  • Preferred organometallic compounds in an embodiment of the present invention include alcohols, aldehydes, ketones, esters, anhydrides, carboxylic acids and amides.
  • the metal compound is soluble in water.
  • soluble in water or “water dispersed” herein is meant any amount of metal compound dissolved in, dissolvable in, or dispersed in any volume of water. No limitation is known with regard to the solubility or dispersability of the metal compounds effective in the present invention.
  • the metal compound is delivered to the combustion chamber or to the combustion exhaust stream through the organic phase of a fuel emulsion or hydrocarbonaceous fuel.
  • the metal compounds when formulating aqueous additives of the present invention, are employed in amounts sufficient to reduce the impact of poisons, e.g., sulfur, lead, soot and phosphorus, on the emissions control systems. Still further, the metallic compounds are employed in amounts sufficient to reduce combustion emissions all together.
  • the aqueous additive of the invention will contain an amount of the metal compound, ion or precursor thereof sufficient to provide from about 0.001 grams to about 2.0 grams of metal or metal compound per liter of fuel (in the case of a liquid fuel product), and preferably from about 0.01 grams to about 1.0 grams of metal or metal compound per liter of fuel.
  • hydrocarbonaceous fuel can include methane gas that is used, for example, alone or in conjunction with other fuels in an internal combustion engine.
  • methane gas that is used, for example, alone or in conjunction with other fuels in an internal combustion engine.
  • Ethanol, methanol and other alcohols, as well as esters, ethers, ketones, polyols, glymes and other oxygenates are also useful herein as hydrocarbonaceous fuels to which the water-soluble metal compounds can be added for beneficial emission and catalysis results.
  • farm waste including fodder, silage, field and crop residue, animal excrement, and other bioproducts can be utilized as a fuel herein with or without the addition of process aids.
  • process aids To such waste can be added the water-soluble metal compounds of the present invention.
  • the aqueous additive will contain an amount of the metal compound sufficient to provide about 0.001 grams to about 10.0 grams of metal per 100 grams of the solid fuel, preferably about 0.01 to about 1.0 grams of metal per 100 grams of the solid fuel.
  • the metal concentration may be increased to provide the above amounts of metal in the combustion chamber.
  • all internal combustion engines burn some lubricant thereby adding to the combustion byproducts any material carried into the combustion chamber by the lubricant.
  • metal sulfate or phosphate (MSO 4 and MPO 4 ) which is stable in the temperature range of 200-650° C.
  • metal sulfates such as, for instance, MnSO 4
  • free sulfur often does, thereby poisoning the catalyst.
  • the present invention provides novel compositions and methods for providing a substance which competes with the active site (e.g., barium) in the lean-burning exhaust.
  • the metal of the scavenging agent will compete with the metal of the catalyst system for complexing with the potential emissions system poisons (e.g., sulfur) the metals may be suitable for use as scavenging agents.
  • the ability of the metal scavenging agent to compete with the metals of the catalyst for complexing with the catalyst poisons can be determined by monitoring catalyst durability.
  • the metal scavengers of the present invention can reduce the detrimental impact of other poisons such as sulfur, phosphorous, lead, zinc, or soot on emissions control systems of the lean burn combustion systems in one embodiment of the present invention.
  • the metal additive can be water-soluble or dispersable and delivered through an aqueous additive to obtain comparable emissions aftertreatment benefits. Yet, the use of the aqueous additive is beneficial in its ease of handling, expense, ease of preparation, etc. and can be used herein in addition to fuel soluble additives.
  • aqueous additive to enhance the performance and durability of emissions and aftertreatment systems.
  • the instance of incorporating the additive to the fuel to form an emulsion (gasoline, diesel, etc.), dispersion, suspension, or slurry (coal, etc.) can have positive benefits on the emissions from the combustion.
  • the additive may also be injected alone or with liquid fuel directly into the exhaust stream of a combustion process.
  • the additives are inorganic or organometallic compounds metal compounds soluble in aqueous solutions. At least one of the metals in the additive promotes the oxidation of carbon particulate matter. This would include additives containing elemental or ionic sodium, potassium, magnesium, calcium, barium, strontium, titanium, cerium, chromium, molybdenum, manganese, iron, rubidium, cobalt, rhodium, nickel, palladium, platinum, copper and silver.
  • the metal(s) is (are) released and collected, at least in part, in a particulate filter. The metals come into contact with the carbon fraction of the particulate, accelerate the carbon oxidation reactions, and aid in particulate trap regeneration.
  • the exhaust system may contain other aftertreatment systems in addition to the particulate filter.
  • the exhaust system contains at least a particulate trap upstream of a selective catalytic reduction (SCR) system, which is designed to aid in the reduction of exhaust NO x emissions.
  • SCR utilizes in one embodiment urea as a reductant.
  • Urea is typically a solid but to ease handling an aqueous solution, preferably at a concentration of about 32.5% can be used.
  • This solution can form a eutectic with a low crystallization point ( ⁇ 110° C.). In case of crystallization, the eutectic mixture provides an aqueous and solid phase of equal composition. The additive is added to this solution.
  • the urea/additive aqueous solution is, in one embodiment, injected into the exhaust stream after the exhaust stream has left the combustion chamber.
  • the water is vaporized and the urea decomposes to form ammonia (NH 3 ), which reacts with oxides of nitrogen over a catalyst to form N 2 and H 2 O.
  • NH 3 ammonia
  • the metal from the additive is released and collected with the combustion particulate matter in the particulate trap.
  • the metal increases particulate oxidation, thereby promoting trap regeneration.
  • particulate trap regeneration additive By introducing the particulate trap regeneration additive with the reductant in this system, its presence in the particulate trap is assured.
  • a separate additive-dosing tank on the vehicle, as used in some cases (Peugeot) is not needed. Enhanced regeneration does not rely on additive being present in fuel.
  • the metal additive used is one that will form stable metal phosphates. A portion of the metal released in the exhaust interacts to form stable metal phosphates as solid particulate and prevent phosphorus deposition on exhaust catalyst. The use of these additives will protect the SCR catalyst from deterioration due to phosphorus poisoning.
  • the metal additive may be chosen such that at least one of the metals catalyzes the reaction between NH 3 and NO.
  • the metal additive will form very small metal cluster in the exhaust and possess high specific surface area.
  • the high surface area available on the nano sized catalytic sites provided by the metal additive will provide additional activity for NO conversion.
  • the reactants will move with the catalyst through the exhaust stream, increasing residence time in contact with the catalyst.
  • the presence of the catalyst in the exhaust will also help insure that catalyst and reactants are together at optimal conversion temperatures for oxides of nitrogen.
  • the ability to have catalyst present at the time optimal reaction temperatures are reached is advantageous over relying on a catalyst fixed in the exhaust system. This catalyst would be amenable to wide swings in exhaust temperatures occur during transient engine operation.
  • a fuel water emulsion in which the aqueous phase additionally contains a water-soluble additive containing 0.05 weight percent of a divalent Mn compound is used in a diesel engine.
  • the diesel engine operates under fuel lean conditions.
  • the water-soluble manganese additive decomposes to form primarily manganese oxides.
  • Sulfur oxides in the exhaust gas interact with the manganese oxides to form stable manganese sulfate, scavenging the SO 2 and SO 3 from the exhaust as solid particles are captured in the particulate trap or emitted from the exhaust.
  • a fuel water emulsion in which the aqueous phase additionally contains a water-soluble additive containing 0.05 weight percent of a manganese compound is used in a diesel engine.
  • the diesel engine operates under fuel lean conditions.
  • the water-soluble manganese additive decomposes to form primarily manganese oxides.
  • Sulfur oxides in the exhaust gas interact with the manganese oxide to form stable manganese sulfate scavenging the SO 2 and SO 3 from the exhaust.
  • the manganese oxides effectively tie up the phosphorus in a stable compound and reduce the phosphorus deposition on catalyst systems in the exhaust.
  • the water-soluble manganese compound will aid in the regeneration of a particulate trap if one is present.
  • Embodiments of the present invention include a method of enhancing performance durability of a catalytically-based emissions control system in a lean fuel combustion system containing a catalytic device having a transition metal, alkali or alkaline earth metal element, or combinations thereof (catalytic elements), said combustion system producing at least one byproduct, comprising supplying a fuel to said lean fuel combustion system, said combustion system being provided with a scavenger, said scavenger complexing with at least one combustion byproduct, said scavenger being supplied in an effective amount to complex with the at least one fuel combustion byproduct, whereby the impact of said fuel combustion byproduct on said emissions control system is reduced.
  • the reactants and components are identified as ingredients to be brought together either in performing a desired chemical reaction (such as formation of the organometallic compound) or in forming a desired composition (such as an additive concentrate or additized fuel blend).
  • a desired chemical reaction such as formation of the organometallic compound
  • a desired composition such as an additive concentrate or additized fuel blend
  • the additive components can be added or blended into or with the base fuels individually per se and/or as components used in forming preformed additive combinations and/or sub-combinations.
  • the claims hereinafter may refer to substances, components and/or ingredients in the present tense (“comprises”, “is”, etc.), the reference is to the substance, components or ingredient as it existed at the time just before it was first blended or mixed with one or more other substances, components and/or ingredients in accordance with the present disclosure.
  • the fact that the substance, components or ingredient may have lost its original identity through a chemical reaction or transformation during the course of such blending or mixing operations is thus wholly immaterial for an accurate understanding and appreciation
  • Patentee does not intend to dedicate any disclosed embodiments to the public, and to the extent any disclosed modifications or alterations may not literally fall within the scope of the claims, they are considered to be part of the invention under the doctrine of equivalents.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Health & Medical Sciences (AREA)
  • Organic Chemistry (AREA)
  • Toxicology (AREA)
  • General Chemical & Material Sciences (AREA)
  • Catalysts (AREA)
  • Solid Fuels And Fuel-Associated Substances (AREA)
  • Incineration Of Waste (AREA)
  • Liquid Carbonaceous Fuels (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)
US10/165,462 2002-06-07 2002-06-07 Aqueous additives in hydrocarbonaceous fuel combustion systems Abandoned US20030226312A1 (en)

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US10/165,462 US20030226312A1 (en) 2002-06-07 2002-06-07 Aqueous additives in hydrocarbonaceous fuel combustion systems
CA002428726A CA2428726A1 (en) 2002-06-07 2003-05-14 Aqueous additives in hydrocarbonaceous fuel combustion systems
AU2003204383A AU2003204383A1 (en) 2002-06-07 2003-05-27 Aqueous additives in hydrocarbonaceous fuel combustion systems
EP03012742A EP1378560A3 (en) 2002-06-07 2003-06-04 Aqueous additives in hydrocarbonaceous fuel combustion systems
MXPA03004990A MXPA03004990A (es) 2002-06-07 2003-06-04 Aditivos acuosos en sistemas de combustion de combustibles a base de hidrocarburos.
ARP030102039A AR040173A1 (es) 2002-06-07 2003-06-06 Aditivos acuosos en sistemas de combustion de combustibles a base de hidrocarburos
BR0302096-7A BR0302096A (pt) 2002-06-07 2003-06-06 Aditivos aquosos em sistemas de combustão de combustìvel de hidrocarbonáceo
CNA03138689XA CN1467267A (zh) 2002-06-07 2003-06-09 烃燃料燃烧系统中的水性添加剂

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EP1378560A3 (en) 2004-01-14
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AR040173A1 (es) 2005-03-16
CN1467267A (zh) 2004-01-14
MXPA03004990A (es) 2004-10-15
EP1378560A2 (en) 2004-01-07

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