DESCRIPTION of the industrial invention with the title: "Method for a reduction of emissions in combustion processes"
DESCRIPTION
This invention concerns a method for reducing the emissions in combustion processes of internal combustion engines, heat generators, fireboxes, etc, obtained by immission, in the pipe leading to the combustion chamber, of an aerosol coming from a water solution cont ining some diluted ionic species, after appropriate irradiation by a light source in the presence of a photocacalyst.
It is well known that toxic substances are produced in a combustion process, which are then introduced in the atmosphere and constitute a problem for public health. Technologies aiming at reducing emissions of unburnt polluting products have been in the works for a long time. For instance, some technologies operate on the variation of air/fuel ratio, spark advance, phasing of timing, etc. Other technologies either put into effect a thermic post-combustion, by air injection in the exhaust manifold with automatic valves (Exhausted Gas Recirculation, EGR). or use thermic post-co∑nbustion with additional oxidizing catalysts, in traditional engines. In more modern cars, it is compulsory the use of 'lean-bum" engines with very lean mixtures (air/gasoline ratio 20:1) equipped with oxidizing catalysts on exhaust gases for unbumt hydrocarbons. Mostly used are triple effect catalysts (3xcat), which catalyze oxidizing reactions (CO, PAH) and reducing reactions (NOx) in exhaust gases.
The correct working of such catalysts requests necessarily to operate in a narrow interval of air/gasoline ratio, near the stoichiometric interval, but for this purpose it is necessary to make use of an electronic device adjusting the mixture carburation, controlled by an 02 probe, placed in the exhaust manifold.
Anyway, besides costs, wich are anyhow considerable, the technologies suggested do not allow to achieve positive results in variable conditions of engine working, such as, for example, in cold starting imd in congested urban traffic, conditions which, everybody knows, give rise to a quantity of exhaust emission greater than when running. Moreover, worries are rising about the dispersion, in the atmosphere, of heavy metal particles, for instance platinum, which is a component of catalysts.
The addition of particular substances to fuels, especially for boilers, in order to improve the elimination of unbumt products from fuel gases. Mg (magnesium) and Mn (manganese) have been suggested among those substances, in the form of oxides and/or hydroxides, as well as other substances, mostly added in powder or in suspension, capable to reduce acid emissions of SOa and
These additives give problems, especially when used in large quantities. They bring on furs inside boilers and produce great amounts of ashes with consequent necessity to stop the process in order to carry out the cleaning of plants. Moreover, such reagents are expensive and their massive use weighs sensibly on operating costs of thermal plants.
It is also known that gaseous ammonia has already been used in coal thermal plants, in order to reduce NO to nitrogen and water also in the presence of oxigen. It is necessary to mix ammonia with gaseous hydrogen (or methane), to be able to lower the reaction temperature to economically compatible levels.
Other methods of fuel gases conditioning have been suggested, in particular concerning the use of additives with a basis of ammonium phosphate and urea. Specifications which are common to the above mentioned methods, at the state of technics, concern the relatively high concentrations of the additives used, concentrations ranging between hundreds and thousands of parts per million compared to the fuel burned.
It is also known that the energetic yield of fuels (whether gaseous, liquid or fossil, coal included) increases if moderate quantities of steam are introduced in the system, if necessary added with NaCl. This latter technique, however, feels the effects of atmospheric conditions and, in particular, of relative humidity in the air.
In the methods mentioned, the adjustment of the quantity of air, saturated with steam, to be conveyed into the combustion zone is of great importance, above all in engines with variable speed of working. In fact the method brings forth advantages only when the quantity of air sent in is optimal. ,
Now it has been found that, conveying a fraction of the loτ_ into a vessel containing a water solution with some ionic species diluted in k, such as potassium, calcium, magnesium, ammonium, iron, nitrate, bicarbonate, chloride, in quantities ranging between particular values, and irradiating a photocatalyst of the titanium dioxide supported type, bathed in the solution, by means of a light source emitting in the interval of visible UV, and mixing that portion of the air so treated directly with the not-treated co burent air in the pipe leading to the combustion chamber of an internal combustion engine or boiler, the level of toxic emission resulted minimized as to the state of technics and, at the same time, the combustion efficiency increased in a particularly advantageous way.
Therefore the first object of this invention is a method for optimizing the combustion of commercial fuels, reducing the levels of emissions, featuring an optimization obtained by sending directly to the combustion a portion of the comburent air after crossing a vessel containing a photocatalyst bathed in a water solution irradiated by a light source emitting in the interval of visible UV, and containing also the following diluted ionic species: cations: potassium, ammonium, calcium, magnesium, iron anions: nitrate, chloride, bicarbonate, in quantities ranging between particular values.
This invention uses a photocatalytic heterogeneous process operating on water and molecular oxygen, present in the air, capable to fulfil both the oxiding and reducing processes with respect to the polluting toxic substances which are present or are produced during the combustion process.
Surprisingly, the air gurgled in the water solution irradiated on the photocatalyst and conveyed into the combustion chamber is capable to favour selectively a more complete oxidation of the produα at present unbumt (CO, PAH, etc.) and to reduce the emission of nitrogen oxides (NOx), of polluting fumes and powders in combustion processes.
The reasons of such behavior are not fully explained yet, but it is possible that the photoexitation with UV-visible light of the photocatalyst surface, for example the semiconductor Tiθ2 , causes a variation in the energetic state of electrons from the valence band to the conduction band, with formation of free electrons and of positive vacancies. In the presence of water and of oxygen from the air, electrons and positive surface sites interact with the ionic and molecular species present. In that way, oxiding and reducing free radicals of H, OH, HO∑ , O2 type, highly reactive, can be generated. Therefore, it is possible that the photocatalitic system of this invention carries out simultaneously both the oxidation phase (by the positive vacancies and the radical oxiding species) and the reduction phase ( by the negative vacancies on the T.O2 surface).
Surprisingly, it has been observed that the effects of this method are magnified by the presence of saline components in the irradiated solution, by a synergic action on the operating performances of this invention. The reasons of this synergy are not clear, but it is possible that the photocatalytic process, in the presence of saline species diluted in the water, may amplify the reactions with the electrons produced by the photocatalysis in order to prevent their ricombination with the positive sites on the Ti02 surface and/or generate other intermediate radical species. These latter may favour the completeness of oxidation reactions in combustion, besides having reducing effects on the photocatalysis, capable of stopping radical reactions (quenching). Such effects are magnified by the presence of basic components (Mg++ ions, Ca++ and HCO3 - ions) capable also to neutralize the normal acidity of exhaust gases.
The method of this invention consists in properly irradiating with a lamp a photocatalyst, for example titanium dioxide, fixed on a suitable fiberglass, ceramic or glass support, on the inside walls of a vessel containing a water solution with some salts diluted in it. A portion of the air is gurgled, directly by aspiration and or using an additional stream of compressed air, through the water solution. The photocatalitic eterogeneous irradiation on the water and the molecular oxygen,
present in the air, produces free radicals highly oxidant, which are dragged directly in the combustion chamber in the form of aerosol by the inspired and/or compressed-air.
The advantages achieved with this invention consist mainly in a greater control of atmospheric pollution, with respect to the previous state of technics. The suggested method contemplates preferentially the use of a film of TiOj immobilized on a proper support and, therefore, in the case of internal combustion engines, it may be mounted also on vehicles equipped with post-combustion catalysts, so remarkably increasing their average life. The method, both in the simplest condition, and in the most complex ones, has a low cos, is easy to realize and requires a very little maintenance.
Another advantage of this invention is that the method here described may be assembled on any combustion system. Therefore it is susceptible of fittings, alterations and variations according to the type of fuel employed, which must be considered within the scope of the inventive concept.
The method of this invention is implemented by the use of conventional devices, which allow an economic and simple contol of the dosage of the air required. The air treated is then mixed to the other comburent air and conveyed directly into the combustion chamber.
The ratios and the concentrations of the different components diluted in the water solution may vary within wide limits. Typically, the values range between a few milligrams per litre and the saturated solution. The relative quantities of the salts in the solutions employed are varied according to the type of fuel used and to the characteristics of the combustion process under discussion.
The aerosol produced is conveyed, at a flow of a few μl per second in internal combustion engines, directly in the intake pipe of the combustion chamber, where also the part of not-treated air is conveyed.
' The field of the radiation emitted by the light source may vary in the range 200-400 urn. Preferably the lamp emits in the range 200-280 nanometres.
The photocatalyst may be supported by several materials. Preferably titanium dioxide is used in a thin layer (5-50 μm) on a fiberglass support.
It has been observed that the TiOa catalyst supported develops a real catalytic action since its activity remains constant also for operating periods of some years.
As an example, the equipment to to be employed may use control systems and devices for the dosage of air in the process, both of pneumatic and/or electric type, already known at the state of art.
According to a favourite, but not restrictive, form of performance of this invention, the water solution is prepared starting with deionized and/or distilled water, in which the following salts, in the quantities reported, expressed in grams/liter, are diluted:
The gurgling vessel may have any shape or size. The shapes and sizes of the scrubber are not part of this invention, they are not new and may be made up by several different types of manufacture.
It has been verified that the appliance to accomplish the method of this invention, when applied to internal combustion engines, performs efficiently its action with no need of maintenance for an operating period corresponding to a distance covered of about 15,000 Km. Next it is neccessary to inspect the state of the light source and of the TiOj film, and to refill the vessel with the gurgling solution.
The following examples may be a suitable illustration of this invention, without limiting it.
Example no.1
The appHance was fitted on a car FIAT Tempra 1.4 , gasoline fueled, 14.100 Km covered. The composition of the solution was the same as in Table 1. The source of irradiation was a commercial, low pressure, 60 W, UV lamp, placed in a suitable housing on top the 1 liter cylindrical gurgling vessel, separated from the solution by a quartz glass, transparent to UV rays. A portion of the combustion air was gurgled by aspiration from the engine in the gurgling vessel, where the solution was irradiated; said air was then mixed to the portion of not-treated comburent air.
Table 1
Composition of the gurgling solution used in example no.1
The emissions of carbon oxide (CO), carbon dioxide (C02 ), total hydrocarbons (HC) and nitrogen oxides (Nox) in the exhaust gases, both with and without the appliance, according to the rotation speed of the engine.
The results achieved in the tests are reported in Table 2, columns 1 and 2.
Table 2
Results of the tests carried out on a car FIAT Teropra 1.4 , gasoline fueled, about 14, 100 Km covered, at different rotation speeds of the engine, with and without the appliance. The solution had the composition reported in Table 1.
The data achieved during the tests with the appliance (column 2) show a remarkable reduction in the values of all the parameters examined, as compared to the starting ones (without appliance), for all the speeds of the engine. In particular we can point out that the contents of carbon oxide in the exhaust gases passed from 1.75% to 0.25% at 1500 RPM (columns 1 and 2). That corresponds to a per cent reduction of about 85% CO in emissions. Analogically, we can observe per cent reductions ranging between 40 and 75% with regard to HC, and between 50 and 60% with regard to NOx.
Comparative tests have been carried out during which the same parameters of emissions have been measured, also in the absence of photochemical effect (With the lamp out), and for water only (in the absence of added salts).
Table 2 shows that, in all comparative tests (columns 3, 4 and 5) in which the appliances used contained only distilled not-irradiated water (column 3), distilled irradiated water (column 4) and the saline not-irradiated water solution (column 5), the per cent reduction in the values of tha parameters tested' resulted remarkably lower. That constitutes an evidence of the advantages connected with the synergic of the catalytic effect deriving from the presence of salts diluted in the gurgling water solution of the appliance.
Example no.2
The appliance was fitted on a car FIAT Ritmo DS, gasoil fueled, about 208,000 Km covered. The opacity of the exhaust fumes was measured, both before and after the fitting up of the appliance. For each group of five measurements, after discarding the highest and the lowest, an average of the three remaining measurements was calculated. The average values obtained were the following: opacity of the fumes without appliance = 55%; opacity of the fumes with appliance = 18.2%; per cent reduction obtained β 66.9%.
Example no.3
A further application of the method was aimed to verify the fficiency of the appliance on cars equipped with catalytic muffler. For this purpose, the appliance was fitted on a car FIAT Tempra 1.4 - IE catalyzed, gasoline fueled, about 34,200 Km covered. The results are reported in Table 3.
Table 3
Results of the tests carried out on a car FIAT Tempra 1.4 , gasoline fueled, about 14,100 Km covered, at different rotation speeds of the engine, with and without the appliance. The solution had the composition reported in Table 1.
The data obtained show CO reductions of 60-90% (passing from 0.20-0.40 a 0.01-0.06). Similar is the case with HC and NOx which are reduced of 55-75% and 20-60% respectively. That is evidence of the efficiency of this invention also when the initial values of the emissions are very low. A catalytic muffler therefore receives a remarkably lower quantity of pollutants if this appliance is fitted on the engine. This permits a remarkable extension of the average life of a catalytic muffler, with undoubted economic and environmental advantages.
Example no.4
Measurements were taken on the combustion efficiency and on the reduction of fuel consumption of an industrial boiler STANDARD KESSEL ITALIANA for steam production, with a power of 2,500 Kg/h, gasoil fueled. The results obtained with and without aplliance are reported in Table 4.
Table 4
Results of the measurements taken on the combustion efficiency and on the reduction of fuel consumption of an industrial boiler STANDARD KESSEL ITALIANA for steam production, with a power of 2,500 Kg h, gasoil fueled.
We can observe the appreciable improvement in the combustion efficiency, which passes from 89.2% to 96.7% and the remarkable reduction of about 21% in fuel consumption, with undoubted economic ; advantages.