WO2021148673A1

WO2021148673A1 - System and 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

Info

Publication number: WO2021148673A1
Application number: PCT/EP2021/051598
Authority: WO
Inventors: Dimitrij Bieren; Jürgen Gärtner; Kerstin SELKA; Sergej Nikolaeviz TUMAKOV
Original assignee: Raptech Eberswalde Gmbh
Priority date: 2020-01-23
Filing date: 2021-01-25
Publication date: 2021-07-29
Also published as: EP4093535A1

Abstract

The present invention relates to a system for producing a stable hydrocarbon-water fine dispersion or an unstable water-hydrocarbon separation dispersion, comprising at least one unit for producing a stable hydrocarbon-water dispersion in the fine disperser from at least medium 1 as a hydrocarbon-containing medium and medium 2 as water, wherein said unit comprises: at least one first pump for a first increase in pressure in the inflow of the hydrocarbon-water coarse dispersion; at least one ultrasonic acoustic flow machine for producing a hydrocarbon-water dispersion by means of hydrodynamic cavitation, and at least one second pump for generating a negative pressure for establishing the cavitation regime in the ultrasonic acoustic flow machine; at least one heating apparatus upstream of the second pump for generating the thermocavitation; at least one second ultrasonic acoustic flow machine for producing a stable hydrocarbon-water dispersion by means of combining thermo- and hydrodynamic cavitation and at least one third pump for generating a negative pressure for establishing the cavitation regime in the second ultrasonic acoustic flow machine. The present invention further relates to a method for producing a stable hydrocarbon-water fine dispersion or an unstable water-hydrocarbon separation dispersion using a system of this kind.

Description

Plant and process for the production of a stable hydrocarbon-water dispersion for the improvement of the combustion processes and a water-hydrocarbon dispersion which can be easily separated into at least two phases in the context of the cleaning process of disaster sites

The present invention relates to a plant for producing a stable hydrocarbon-water dispersion and a method for producing such a dispersion using thermal cavitation and supercavitation

The present invention relates to a plant for the production of a water-hydrocarbon dispersion which can easily be separated into at least two phases, as well as a process for the production of this dispersion 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 a mixture that is as homogeneous as possible. The size of the water droplets in the dispersion is decisive for the stability.

In the separation process (cleaning process), the proportion of water is significantly larger compared to the stable hydrocarbon-water dispersion. It results in an easily separable dispersion. This physical property is more promising for the natural ecosystem as opposed to the use of dispersants.

Various devices for generating such oil-water emulsions are known from the literature. For example, reference is made to EP 674941 B1, DE 4137179 C2 or DE 4139782 A1, in each of which devices for mixing oil and water to form an emulsion are described.

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

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

There is great interest in the industry in innovative approaches to the development of a cost-effective process and a plant for the production of 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, the use of additives such as emulsifiers being dispensed with.

There are two different UADA versions: without and with an integrated premixer. The first version does not contain an integrated premixer for mixing the media. In the second version, the media are mixed with one another directly in the pre-mixer of the UADA body, which is integrated in the pre-sonic camera.

In the present invention, the first embodiment is used. More information on the two modifications can be found in patent RU 2130503 C1, RU 2462301 C1 and the patent for the useful technical model RU 134076 U1. The technical description of the UADA body and the acoustic panel are shown in FIGS.

In one embodiment of the present system, upstream of the at least one unit for producing a hydrocarbon-water dispersion, at least one premixing unit for producing a coarse dispersion from the at least one medium 1 and medium 2 is connected upstream.

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 premixer or coarse disperser is covered in claim 3.

The coarse disperser is the preliminary stage of the fine disperser (claim 2) or ultrafine disperser (claim 5).

The object of the present invention is achieved with a system having the features of claim 1.

Correspondingly, according to a first aspect, a plant for the production of a stable hydrocarbon-water fine dispersion or a water-hydrocarbon separating dispersion (a water-hydrocarbon dispersion easily separable into at least two phases, or unstable separating dispersion) is provided, the plant having at least one unit to produce 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 has at least one premixer (coarse disperser), at least one first pump, for increasing pressure in the feed of the hydrocarbon-water mixture into the ultrasonic acoustic flow unit (UADA as part of the fine disperser); at least one ultrasonic acoustic flow unit (UADA) for the production of 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 at least medium 1 as a hydrocarbon-containing medium and medium 2 as water (fully demineralized water), this unit having at least one first pump for increasing the pressure in the inlet hydrocarbon-water mixture in the ultrasonic acoustic flow unit (UADA as one part of the separating 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 present system according to the invention 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 separating disperser consisting of a UADA module and a pump upstream of the UADA and a pump downstream of the UADA.

The object of the present invention is also achieved with a method having the features of claims 1 and 2, FIGS. 3 and 4.

In one embodiment, a plant 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 (fully demineralized water) and at least one unit a heating device for initiating thermal cavitation, at least one first pump, for increasing the pressure in the inflow of the fine dispersion into the ultrasonic acoustic flow unit (UADA as part of the ultrafine disperser); at least one ultrasonic acoustic flow unit (UADA) for the production of 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 of at least one premixer (coarse disperser), at least a heating device for initiating thermal cavitation, at least one first pump, for increasing the pressure in the inflow of the fine dispersion into the ultrasonic acoustic flow unit (UADA as part of the ultrafine disperser); at least one ultrasonic acoustic flow unit (UADA) for the production of 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 present system 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 (claims 8 and 8) 9) 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.

The object of the present invention is also achieved with a method having the features of claim 4, FIG. 5.

In one embodiment of the present system, upstream of the at least one unit for the production of a stable hydrocarbon-water ultrafine dispersion from at least medium 1 as a hydrocarbon-containing medium and medium 2 as water (fully demineralized water) and this unit at least one premixer (coarse disperser) At least one first pump for increasing the pressure in the inlet hydrocarbon-water mixture in the ultrasonic-acoustic-flow-through unit (UADA as 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 thermal cavitation, at least one second pump for increasing the pressure in the inflow of the fine dispersion into the ultrasonic acoustics -Flow-through unit (UADA as 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 (claim 7).

The present system thus comprises in a third aspect a combination of a coarse disperser, a fine disperser and a downstream ultrafine disperser. The object of the present invention is also achieved with a method having the features of claim 6, FIG. 2.

The basis of the present system and 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 by means of cavitation. The principle of dispersion generation using the system according to the invention 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 one another. The further steps in the production of a hydrocarbon-water dispersion by means of cavitation take place in at least one or two UADA modules. In a first UADA module, supercavitation, as an individual case of hydrodynamic cavitation, takes place in the other, second UADA module, thermal and supercavitation. The two UADA modules are connected one behind the other.

The size of the water droplets in the dispersion is varied by the type and intensity of the cavitation. Stronger cavitations result in a smaller diameter of the enclosed drop. The present process enables the production of a hydrocarbon-water dispersion with a droplet size in the range from 10 to 100 μm. The stability of the dispersion increases with decreasing droplet diameter.

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

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

Three different levels of fineness of the droplets are achieved with the present system (claim 21):

Droplet diameter in the coarse dispersion larger than 1 mm. Droplet diameter in the fine dispersion smaller than 1 mm and larger than 100 μm Droplet diameter in the ultrafine dispersion less than 100 pm

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

The developed process can be built up in two or three procedural stages. On the one hand, there is 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, a coarse dispersion of the pre-tempered medium 1 as a hydrocarbon-containing medium and the pre-tempered medium 2 as water is provided by mixing medium 1 and medium 2 in at least one pre-mixing unit (coarse disperser) before the fine dispersion is made (claim 13).

Accordingly, a method for producing a hydrocarbon-water dispersion (fine dispersion), or a water-hydrocarbon dispersion (separating dispersion) that can easily be separated into at least two phases is provided, the method being carried out in particular in a plant described above and comprising the following steps :

- Fierstellen a hydrocarbon-water fine dispersion, or a water-hydrocarbon separating dispersion in an ultrasonic acoustic flow unit (UADA), in which the cavitation is not actively introduced, but arises due to the currents in the UADA (claim 12).

For the setting, 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 (claim 11).

In the UADA module, three speed ranges of the flow are built up one after the other: pre-sonic, sonic and ultrasonic speed.

The pre-sonic velocity is a transversal deformation of currents through the formation of vortex-ring currents. In the range of the speed of sound, the resulting flow becomes so great that cavitation occurs. Furthermore, long-chain entangled hydrocarbons are torn apart thermomechanically. The inflow is accelerated tangentially in the radial direction, in which the chamber flows are sheared against one another and the relative speed is thus doubled. The high speed creates the vapor bubbles and the displaced eddy currents balance each other out. This creates constant, stable eddies that are separated according to hydrodynamic properties.

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

The ultrasonic velocity occurs after the currents meet and the energy of the currents in the confined volume is concentrated. With the help of the concentrated energy, the energy-mass exchange is promoted and the physical-chemical conversion is accelerated. The dispersion formed is discharged from the module through the drain.

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

The steam pressure of water must be undercut with the operating pressure by means of hydrostatic pressure and temperature setting (steam pressure curve) by increasing the speed (energy conversion / kinetic pressure component). This results from the vapor pressure curve for water as shown in FIG.

The type, strength and form of cavitation in the UADA is influenced by the pressure ratio between the pre-pressure and the negative pressure in the fine disperser or in the separating disperser. The more pronounced the cavitation, the smaller the diameter of the droplets in the dispersion,

- where 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. 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 at least one further ultrasonic acoustic flow unit (UADA ) for the production of a hydrocarbon-water ultrafine dispersion by means of a combination of thermodynamic and hydrodynamic cavitation,

- this unit combining hydrodynamic cavitation with thermal cavitation to increase the effectiveness and stability (claim 19).

The conditions for the initiation of thermocavitation are created in a low-pressure, elevated temperature meat sausage device. Due to the local heating in the meat peeling device, small vapor bubbles are created on the surface, which are released by the flow and collapse again in the liquid as a result of a drop in temperature. This thermal cavitation catalyzes the hydrodynamic cavitation in the downstream UADA and thus intensifies the mixing of the dispersion.

The procedural insert is set up in such a way that there is negative pressure in the meat processing device. For the initiation of the ultrasonic cavitation in the downstream UADA, there is a renewed pressure build-up and pressure reduction behind the UADA.

The combination of thermodynamic and hydrodynamic or super cavitation creates better conditions for producing the ultra-stable and ultra-fine dispersion.

The type, strength and form of cavitation in the UADA is influenced by the pressure ratio between the pre-pressure and the negative pressure in the ultrafine disperser. The more pronounced the cavitation, the smaller the diameter of the droplets in the dispersion,

- where 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.

The ultrafine dispersion can be achieved technologically either after the coarse dispersion or after the fine dispersion.

The object of the present invention is also achieved with a method having the features of claims 2 and 5. The cavitation process used in the developed system in an ultrasonic acoustic flow unit (UADA) is known from the patents RU 2130503 C1, RU 2462301 C1 and the patent for the useful technical model RU 134076 U1 and enables the production of a stable dispersion Fuel and water. In the present system, this UADA is expanded in combination with heat exchangers and pressure boosting devices, so that the stability of the hydrocarbon-water dispersion formed is significantly increased. The heat exchangers installed in the present system allow a separately temperature-controlled 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, there are control or metering valves in the hydrocarbon and water addition, which allow the mixing ratio to be changed.

The technology developed is used to produce a long-term stable dispersion of water and hydrocarbons. The long-term stability is significantly influenced by the droplet size. With a drop size of less than 100 μm, a stability of at least 1 year up to 7 years can be achieved. For example, the stability of bunker oils is increased, which means that the use of additives can be dispensed with. 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.

Due to the fine droplets in the dispersion, the fuel can be burned more optimally, as these evaporate suddenly in the combustion chamber and the combustion of the fuel takes place more homogeneously due to the increase in surface area to volume. Fewer soot particles are produced during combustion. The efficiency of the combustion, based on the primary energy introduced, is increased, with the fuel being converted almost entirely into energy.

In addition, the pollutants are decimated when the dispersion is burned compared to when the pure fuel is burned. With a water content of more than 10%, the combustion temperature is reduced, which in turn can minimize _{the emission of pollutants such as NO x.}

The development of the present additive-free process for the cost-efficient elimination of oil disasters by means of the production of the separating dispersion makes an enormous contribution to nature and species protection. Oil pollution of the environment, especially the oceans Crude oil or mineral oil products from damaged oil tankers or platforms can be cleaned using this technology and the associated system and the separated hydrocarbons can be recycled. media

The present method allows the mixing of at least two different types of media. In the present system, 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 are processed (claim 15).

The media used are summarized in Table 1.

Medium 1 Medium 2

Table 1: Media for producing the hydrocarbon-water dispersion

Medium 1 (as the main medium) denotes the hydrocarbon-containing, oil-containing component which, in combustion processes, corresponds to over 60 wt% of the dispersion. When using the process 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 corresponds to less than 40 wt% of the dispersion in combustion processes. 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 version, normal tap water or so-called brackish water can also be used. Premixing / coarse dispersion

As stated above, the fine disperser can be preceded by a premixing unit.

In one embodiment of the present 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 exchangers for setting the temperature and, indirectly, the viscosity of the hydrocarbon the medium 1 can be designed as a heat exchanger with a bypass.

Medium 1 and medium 2 are heated to temperatures between 30 and 90 ° C., preferably between 40 and 80 ° C., and introduced into the premixer. Thus, at least two different preheated media are mixed with one another in the coarse dispersion (claim 14). The prerequisite for the optimal production of the coarse dispersion are identical absolute inlet 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 present system, 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. To monitor the degree of filter occupancy, a pressure sensor is installed upstream of the filter and a pressure sensor is installed downstream.

As mentioned above, at least one heat exchanger for adapting 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 desalinated and deionized water. Devices (e.g. sensors) for measuring the volume flow and the temperature of the water are preferably provided upstream and downstream of the heat exchanger in the water pipe.

The premixing apparatus already mentioned above is used to premix the components described above. This mixing apparatus is designed for media of different viscosity. With the help of a static mixer, the water is laminated into the oil flow Layers introduced. 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 behind the premixer.

The temperature-controlled mixture with the preset volume or percentage is then passed to the next stage for fine dispersion after coarse dispersion.

Feindisoeroieruna

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

As stated above, the at least one fine disperser comprises at least one first pump for a first pressure increase in the feed 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, before entering at least one first ultrasonic acoustic flow unit (UADA), to pressures of up to 2.5 MPa, preferably to pressures between 0.1 MPa and 2 MPa, particularly preferably between 1 MPa and brought to 1.5 MPa using a first pump. The pre-pressure built up before the first UADA can, for example, be between 0.6 and 2.5 MPa (claim 16).

The pump used for this can be used for high-volume refueling processes or for continuous low-volume 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 h and 60 m ³ / h. Typical volume flows can be, for example, 6 m ³ / h; 20 m ³ / h and 100 m ³ / h.

In a further preferred embodiment, the system has a device arranged downstream of this first pump for measuring the water content in the coarse hydrocarbon-water dispersion. This device for measuring the humidity can be designed in the form of a bypass, and allows in the event of deviations a readjustment of the water content of the desired water content, e.g. via a control valve from the water pipe.

The setting of the water content is preferably automated, which enables inline and more precise water metering as well as regulation of the volume flow and the temperature. These are prerequisites for a consistent quality of the dispersion to be produced. Furthermore, the amount of water in the fuel can be varied easily. 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 set and measured variably. The water content is important for the later use and properties of the combustion and is in a range from 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-through unit (UADA).

According to the invention, the fine dispersion is produced in an ultrasonic acoustic flow unit (UADA) in that the cavitation is not actively introduced, but rather arises due to the currents in the UADA.

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

This influences the type, strength and form of cavitation in the UADA. The more pronounced the cavitation, the smaller the diameter of the droplets in the dispersion. After the fine dispersion, further monitoring and possible readjustment of the water content can take place, 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, the present case is a two-stage process for producing the stable hydrocarbon-water dispersion by coarse dispersion (premixing to produce the mixture) and fine dispersion, with a determination of the procedural regime of the ultrasonic-acoustic flow-through units making a significant contribution .

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

Ultra fine dispersion

As already described above, downstream of the at least one unit for producing a stable hydrocarbon-water dispersion in the fine disperser, at least one unit for producing a stable hydrocarbon-water dispersion in the ultrafine disperser can be arranged, this unit at least a second Ultrasonic acoustic flow unit (UADA) for producing a stable hydrocarbon-water ultrafine dispersion by means of a combination of thermal and hydrodynamic cavitation (claim 17).

In one embodiment, the ultrafine disperser comprises at least one meat device for heating the fine dispersion flowing under negative pressure, at least one pump (downstream) for generating the negative pressure in the meat 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 setting the negative pressure, which leads to the setting, variation and control of the cavitation regime.

Accordingly, a three-stage process for producing the ultra-stable hydrocarbon-water dispersion by large-scale dispersion, fine dispersion and ultra-fine dispersion can be provided, with the recording of the procedural regime of the ultrasonic-acoustic flow-through units making 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

- 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

Preprint _before UADA

Pressure ratio uit _ra fein-Disp _er g _a t _or ~ jt]> 12

Under pressure _{according to UADA}

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 heater.

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) (claim 18).

For the production of 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 heater. 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 as a result of a drop in temperature. This thermal cavitation intensifies the hydrodynamic cavitation in the downstream UADA and thus supports the mixing of the dispersion.

The procedural insert is designed in such a way that there is negative pressure in the heating device. For the initiation of the ultrasonic cavitation in the downstream UADA, a renewed pressure build-up takes place in front of the UADA and the setting of the negative pressure behind the UADA. The synergism of the effect of thermodynamic and hydrodynamic cavitation creates ideal conditions for the production of the stable and ultra-fine hydrocarbon-water dispersion.

As already indicated above, at least one further pump is provided downstream of the second UADA for controlling 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 a pump protection, which consists of a negative pressure sensor in front of and an overpressure sensor behind the pump.

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 clogging of the filter at an early stage.

The aforementioned measuring section is used to record the temperature, pressure and volume flow of the hydrocarbon-water dispersion formed.

A branch is provided behind the measuring section, which makes it possible to guide the dispersion in an inner circle over the UADA modules during the start-up and shutdown process of the system. A built-in control technology enables a smooth switchover from internal recirculation to production. The recirculation line is also equipped with a check valve, a pressure sensor and a volume flow monitor.

With the present method, a stable hydrocarbon-water dispersion with a water droplet size of less than 10 μm 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 the dispersion to be produced).

The ultrafine dispersion can be achieved technologically either after the coarse dispersion or after the fine dispersion. Separation process

In a further fourth aspect of the present invention, the separating disperser (unit constructed identically to the fine disperser, but either without or with a premixer - coarse disperser integrated in the UADA body) has at least one separation tank for separating the easily into at least two phases separable water-hydrocarbon dispersion (separating dispersion) in hydrocarbon and water connected downstream (claim 20).

In this case, a system for separating a water-carbon-hydrogen dispersion is provided, the system comprising the following elements:

- At least one unit for producing a water-hydrocarbon separating dispersion, this unit comprising at least one first ultrasonic acoustic flow-through unit for producing a water-hydrocarbon separating dispersion by means of hydrodynamic cavitation and

- At least one separation tank for separating the water-hydrocarbon separating dispersion into hydrocarbon and water.

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

- Provision of at least one water-hydrocarbon mixture that can be separated into at least two phases (pollution from accident sites) and

- Production of a water-hydrocarbon dispersion easily separable into at least two phases in at least one unit for the production of a water-hydrocarbon separation dispersion, this unit having at least one first ultrasonic acoustic flow-through unit (UADA) for the production of a water-hydrocarbon Separating dispersion by means of hydrodynamic cavitation includes 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 separating dispersion into hydrocarbon and water (claim 10).

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

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

The one-step process for cleaning accordingly comprises the production of the water-hydrocarbon separating dispersion by dispersing it in the separating disperser on the ultrasonic-acoustic flow-through unit, whereby the following applies: Flow unit of the pressure ratio:

_{Form before UADA}

_Dispersion pressure ratio => 12 negative _{pressure according to UADA}

The separating dispersion is stored for subsequent separation until the at least two phases of the original media separate. The phase formation takes place by means of coalescence of the hydrocarbon droplets. This creates the aggregates of the hydrocarbon droplets. According to Stokes's 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 over 60 wt%. The water-hydrocarbon dispersion thus formed shows instability. The mobility of the separation system enables the emergency medium, contaminated water, to be fed directly into the separation disperser for the production of the water-hydrocarbon separation dispersion and then for phase separation. This allows the technology to be used as a separation process at the accident site. An essential aspect of the present system is its modular structure, which enables several combinations in terms of system and process implementation.

Individual modules:

- coarse disperser,

- Fine disperser, consisting of a coarse disperser (premixer), a UADA module and upstream and downstream pumps,

- Ultrafine disperser, consisting of heating device, first pump, UADA module, second pump.

In particular, the fine disperser can be used individually.

Combination of the individual modules:

- fine dispersant;

- Fine disperser with upstream coarse disperser;

- Fine disperser with downstream ultrafine disperser, the structure being as follows: first pump - first UADA - heating device - second pump, second UADA - third pump; i.e. with a combination of fine disperser and ultrafine disperser there is no need for a pump after the first UADA;

- Fine disperser - separation tank.

This results in the following possible process variants:

- one-step process with single use of fine dispersant;

- One-stage process consisting of fine dispersion with upstream coarse dispersion;

- two-stage process consisting of fine dispersion and subsequent fine dispersion;

- One-stage separation process by means of separation dispersion and subsequent phase separation.

The present invention is explained in detail below using an exemplary embodiment with reference to the figures. Show it: Figure 1 vapor pressure curve of water

FIG. 2 shows a schematic representation of a first embodiment of the dispersion plant according to the invention;

Figure 3 is a schematic representation of an embodiment of a coarse

Dispersants;

FIG. 4 shows a schematic representation of an embodiment of a fine disperser;

Figure 5 is a schematic representation of an embodiment of an ultrafine

Dispersants;

FIG. 6 shows a schematic representation of an embodiment of the separating disperser according to the invention;

FIG. 7 shows a detailed representation of an ultrasound acoustic flow unit used according to the invention; and

FIG. 8 is a detailed view of an acoustic panel used in the assembly of FIG.

Plant for the production of a stable hydrocarbon-water dispersion

Figure 2 shows the schematic representation of a dispersion plant. The overall 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 shown in FIG. The module consists of an inlet, pre-acoustic chamber, acoustic chamber, ultrasonic chamber and outlet. The acoustic plate, shown in FIG. 8, is located in the pre-acoustic chamber and is made up of the axial annular chamber and tangential vortex grooves. In the sound chamber there are vortex tubes that are filled with conical vertebral bodies. The vortex tubes open into the ultrasonic chamber, which is connected to the drain.

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

Coarse disperser: In the coarse disperser area (Figure 3), the system consists of at least two feed lines for two different media, each with a heat exchanger, a device for adjusting the media ratio and a premixer. The temperature of the media can be regulated via the control technology of the system.

With the help of the control technology, the media ratio is automatically set and monitored. This is transferred to the fine disperser plant area. The coarse disperser is the preliminary stage of the fine disperser.

Fine disperser: The fine disperser area in Figure 4 consists of two pumps (pre-pressure and vacuum pump), the UADA enclosed by these pumps and the associated control technology. After the fine disperser comes the ultrafine disperser.

Ultrafine disperser: The ultrafine disperser, shown in FIG. 5, consists of a heating device, two pumps (pre-pressure and vacuum pump) and the UADA enclosed by these.

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

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 enables the dispersion to be conducted in an inner circle over the UADA units during the start-up and shutdown process of the system. The control enables a smooth switchover from internal recirculation to production.

The dispersion system is used to mix at least two different preheated media. The first step is the rough physical premixing. The second step involves fine dispersion based on the hydrodynamic and super- Cavitation. In a combination of thermo-, hydrodynamic and super-cavitation, the dispersion is refined in the last step.

Separation systems for the production of a phase-forming dispersion

In the event of a water disaster, the system is used to separate the media.

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

The system is fed by a collecting tank in which the damaged dispersion is located. The separation tank is located behind the system, 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 disaster sites and is constructed identically to the fine dispersion area.

Embodiment example 1

The principle of dispersion generation is based on the fact that a mixture of fuel and water is pressed through special nozzles in a UADA (ultrasonic acoustic flow unit) developed for this purpose. The resulting flow velocities favor the development of cavitation. The result is a very fine, stable dispersion which is flammable.

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

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 educt are measured. The fuel line that continues is provided with a non-return valve that prevents backflow to the educt store. Furthermore, a temperature sensor for monitoring the pour point and flash point is installed after the recirculation line. 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 in order to be able to detect an excessive pressure drop. If this rises too high, the filter must be changed or cleaned. A heat exchanger with bypass is then installed. This should adjust the temperature in the input and bring it to the desired values (the current safety surcharges must be observed for the flash and ignition point temperatures). This adjusted temperature is continuously checked by the temperature sensor.

In the following premixer, the oil flow is roughly premixed with the water content.

The desalinated (deionized) water is fed into the process from the water treatment via separate lines. The addition of water is dosed with 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 with the built-in heat exchanger. There is another temperature sensor behind the heat exchanger for temperature monitoring. Before the water reaches the premixer, a non-return valve is installed to prevent hydrocarbons from entering the water pipe.

After the premixer, the mixture temperature and the resulting pressure are measured in order to identify deviating operating conditions. The mixture then comes into the first pressure increase. Here the pressure is increased to up to 2.5 MPa. For 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, readjustment is carried out via the control valve from the water pipe. Before the mixture enters 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 a 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 for the second pressure increase is equipped with a pressure sensor for monitoring the negative pressure in front of the UADA and a pressure sensor for monitoring the overpressure behind the UADA. This makes it possible to run the system in a targeted manner with the required negative and positive pressure. The pressure sensors built into this section of the route give an alarm before a critical negative or positive pressure arises. The control can thus counteract this event.

This is followed by another pump. This is supposed to transport the resulting dispersion over the measuring section to the storage tanks. This pump is also equipped with a pump protection, which again consists of a pressure sensor for monitoring the negative pressure in front of and a pressure sensor for monitoring the overpressure 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 clogging 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 enables the dispersion in the inner circle to be run over the UADA modules during the start-up and shutdown process. The control valve is built in for this purpose. This enables a smooth switchover from internal recirculation to production. The control valve is paired with a check valve in order to prevent mixing of faulty batches in the event of recirculation from the product store from 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.

Embodiment 2: Method for making 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

The calculation example was based on the following data: Production time = 5 h Medium 1: Oil supply 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 dispersion temperature T = 50 ° C

Pressure setting on the fine disperser / ultrafine disperser: _Minimum pre-pressure = 6 bar (variable)

Negative pressure = 0.5 bar (constant)

Pressure ratio 12

- Positioning 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

- Adjustment of the flow rate dispersion 10 m ³ / h

- Coarse mixing with temperature and volume flow control

- Fine dispersion with pressure setting and temperature control, water content control and readjustment (automated)

- Ultra-fine dispersion with pressure and temperature setting in the heating device with temperature control (automated)

- Quality control by means of viscosity

- Storage of the temperature-controlled product

Predicted Product: Three different levels of fineness of the droplets are achieved with the present system:

- The droplet diameter in the coarse dispersion is greater than 1 mm

- droplet diameter in the fine dispersion smaller than 1 mm and larger than 100 gm - droplet diameter in the ultrafine dispersion smaller than 100 gm

Predicted stability of ultrafine dispersion 5-7 years.

nomenclature

Claims

Expectations

1 . Plant for producing a stable hydrocarbon-water dispersion or an unstable water-hydrocarbon separating dispersion comprising at least one unit for producing a hydrocarbon-water dispersion in the fine disperser or a water-hydrocarbon separating dispersion in the separating disperser from at least one medium 1 as a hydrocarbon-containing medium and medium 2 as water, this unit having at least one first pump for a first pressure increase in the inlet of the hydrocarbon-water mixture; comprises at least one ultrasonic acoustic flow unit (UADA) for producing a hydrocarbon-water dispersion by means of hydrodynamic cavitation, and at least one second pump for generating a negative pressure of the hydrocarbon-water dispersion formed.

2. Plant according to claim 1, characterized in that the at least one unit for producing a stable hydrocarbon-water dispersion in the fine disperser is preceded by at least one premixing unit for producing a coarse dispersion from the at least one medium 1 and medium 2.

3. Plant for producing a coarse dispersion of at least one medium 1 as a hydrocarbon-containing medium and medium 2 as water, characterized in that the at least one premixing unit has at least one heat exchanger for medium 1, at least one heat exchanger for medium 2 and at least one coarse disperser for premixing comprised of medium 1 and medium.

4. Plant for the production of a long-term stable hydrocarbon-water dispersion comprising at least one unit for the production of a hydrocarbon-water dispersion in the ultrafine disperser from at least one medium 1 as a hydrocarbon-containing medium and medium 2 as water, this unit having at least one heating device for the initiation of thermal cavitation by increasing the temperature; At least one first pump, for setting the vacuum in the heating device and at the same time for increasing the pressure in the inflow of the dispersion into the ultrasonic acoustic flow unit (UADA as part of the ultrafine disperser) for the production of long-term stable hydrocarbon-water dispersion using a combination of thermal - and hydrodynamic cavitation; comprises at least one pump for generating a negative pressure of the long-term stable hydrocarbon-water dispersion formed, for building up the cavitation regime in the UADA.

5. Plant according to claims 3 and 4, characterized in that the at least one unit for producing a long-term stable hydrocarbon-water dispersion in the ultrafine disperser is preceded by at least one premixing unit for producing a coarse dispersion from the at least one medium 1 and medium 2.

6. Plant according to one of the preceding claims 2 and 4, characterized in that downstream of the at least one premixing unit for producing a coarse dispersion from the at least one medium 1 and medium 2 is connected upstream, at least one unit for producing a stable hydrocarbon-water dispersion comprises in the fine disperser at least one unit for the production of a long-term stable dispersion in the ultrafine disperser.

7. Plant according to claim 6, characterized in that in the case of an ultrafine disperser connected downstream of the fine disperser, the structure is as follows: first - pump - first UADA - heating device - second pump - second UADA - third pump.

8. Plant according to claim 4, characterized in that the at least one heating device consists of at least one heating cartridge.

9. Plant according to claim 8, characterized in that the at least one heating cartridge consists of a heating jacket and a screw-in heater.

10. Plant according to claim 1, characterized in that at least one separation tank for separating the hydrocarbon-water dispersion into hydrocarbon and water is connected downstream of the separating disperser.

11. Procedure for setting, varying and controlling the hydrodynamic cavitation in a UADA module by building up a pressure ratio between the pressure upstream of the UADA module (pre-pressure) and the pressure downstream of the UADA module (negative pressure), which is at least 10 lies.

12. A method for producing a stable hydrocarbon-water dispersion or an unstable water-hydrocarbon separating dispersion, in particular in a plant according to one of the preceding claims, comprising the following steps:

- Fierstellen a stable hydrocarbon-water dispersion in at least one unit for the preparation of a hydrocarbon-water dispersion in the fine disperser from at least medium 1 as a hydrocarbon-containing medium and medium 2 as water, this unit having at least one first pump for a first pressure increase in the feed of the hydrocarbon-water coarse dispersion; comprises 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 in the outlet of the hydrocarbon-water dispersion formed

- Or a unit for making a water-hydrocarbon separating dispersion in the separating disperser from at least medium 1 as a hydrocarbon-containing medium and medium 2 as water, this unit having at least one first pump for a first pressure increase in the inlet of the water-hydrocarbon dispersion in a premixing unit in the coarse disperser; comprises at least one ultrasonic acoustic flow unit (UADA) for producing a water-hydrocarbon separating dispersion by means of hydrodynamic cavitation, and at least one second pump for generating a negative pressure in the outlet of the water-hydrocarbon separating dispersion formed,

- where the ratio of the pressure before the UADA (pre-pressure) of the fine or separating disperser and the pressure after the UADA (negative pressure) of the fine or separating disperser is at least 10.

13. The method according to claim 11, characterized in that before the preparation of the dispersion in the fine disperser, a coarse dispersion of medium 1 and medium 2 is provided by mixing medium 1 and medium 2 in at least one premixing unit in the coarse disperser.

14. The method according to claim 12, characterized in that the medium 1 and the medium 2 are introduced into a premixer of the premixing unit at temperatures between 30 and 90 ° C, preferably between 40 and 80 ° C.

15. The method according to any one of claims 11-13, characterized in that the media 1 used have 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.

16. The method according to any one of claims 11-14, characterized in that the hydrocarbon coarse dispersion before entering the ultrasonic acoustic flow unit (UADA) to pressures of 0.5 MPa up to 2.5 MPa, preferably Pressures between 0.6 MPa and 2 MPa, particularly preferably between 1 MPa and 1.5 MPa, can be brought using the first pump of the fine, ultrafine or separating disperser. After exiting the ultrasonic acoustic flow unit (UADA) to pressures of 0.02 MPa up to 0.1 MPa, preferably to a pressure of 0.06 MPa using the second fine, ultrafine or separating pump -Dispergators are brought.

17. The method according to any one of claims 11-15, characterized in that the hydrocarbon-water dispersion after leaving the ultrasonic acoustic flow unit (UADA) of the fine disperser in at least one unit for producing a dispersion in the ultrafine disperser is introduced,

- This unit has at least one heating device for initiating the thermal cavitation by heating the dispersion flowing under negative pressure, produced in the fine disperser, at least one pump for increasing the pressure in the inlet of the heated hydrocarbon-water dispersion; at least one second ultrasonic acoustic flow unit (UADA) and at least one further pump for generating a negative pressure in the discharge of the hydrocarbon-water dispersion formed, for the development of the cavitation regime in the UADA,

18. The method according to claim 16, characterized in that the hydrocarbon-water dispersion, produced in the fine disperser after leaving the fine disperser, first in at least one meat device, in particular a meat cartridge, to up to 80 ° C before entering the at least second ultrasonic acoustic

Flow unit (UADA) is heated.

19. The method according to claim 16 or 17, characterized in that the effects of hydrodynamic cavitation or supercavitation are enhanced by means of upstream thermal cavitation.

20. The method according to claim 11, characterized in that the water-hydrocarbon separating dispersion formed in the separating disperser is introduced into at least one separation tank for separating the hydrocarbon-water dispersion into hydrocarbon and water.

21. Stable hydrocarbon-water dispersion producible in a process according to one of claims 11-17, characterized by a droplet size of less than 100 μm, preferably less than 50 μm, particularly preferably less than 10 μm 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).