PURIFIER AND REFINER FOR PETROLEUM PRODUCT

Abstract

The present invention is an apparatus that separates fuel from other foreign constituents, such as water and organic and inorganic solids and then presents the purified fuel to a catalyst to enhance the fuels performance qualities. Although the present invention pertains to any fuel filter, water/fuel separator and filter less fuel purifier in combination with a catalyst, a preferred embodiment is described herein which uses no moving parts to purify the fuel and house the refining process elements. In the present invention a fuel and all its non fuel constituents enters a container through an input port at one end of a longitudinal chamber which is contained within an essentially closed volume. The chamber forces the fuel downward forcing heavier constituents to settle to the bottom of the container and lighter fuel to rise. On the path to the output of the container the fuel is made to contact a catalyst.

Description

FIELD OF THE INVENTION

[0001] The present invention relates to purifying fuel by separating the fuel from water and other contaminants and further refining the purified fuel by the introduction of a catalyst.

BACKGROUND OF THE INVENTION

[0002] Reliable internal combustion engines and power generation performance require fuels free from contaminants such as water and organic and inorganic solids. For example, a diesel fuel that contains water can freeze fuel lines when ambient temperatures drop below 32 degrees Fahrenheit. Fuel that contains water also reduces the efficiency of engine performance since at least some energy is dissipated in the process of heating the water and not in combustion. In many instances water particulate contribute to engine failure, specifically in engines that utilize dispensing nozzles and injectors to atomize fuel for the combustion chambers. Solid particulate in fuel also decreases the performance and increases the wear due to frictional forces on the internal engine parts. The machinery that most benefits from devices that can remove water and other constituents for the fuel are gasoline and diesel driven engines, generators and fuel oil burners. Diesel driven boats, automobiles and trucks, stationary generators and fuel oil burners all burn distillate fuel oils and can benefit most from devices that can remove foreign constituents. Many devices exist for separating fuel from foreign constituents, however, most of these are expensive and rely on filter media and other moving components. For example, marine power vessel applications use centrifugal separators for improving the quality of fuel oils. A centrifuge is a machine that subjects fuel and its foreign constituents to a centrifugal force. A continuous centrifuge passes fuel and its foreign constituents in a steady stream through part of the centrifuge apparatus where it is subjected to centrifugal forces and continuously discharges separated components. With little difference in principles of operation these machines perform the function of clarifying fuel, separating fuel constituents and purifying fuel so as to remove water, organic matter and solids from the fuel.

[0003] Centrifuges having moving parts are expensive to build and require costly maintenance, yet the larger marine vessels require the less costly low grade fuel to be cleansed to a degree that justifies the expense. For less demanding applications there are several products that offer some level of separation based on conventional filtration made of fine mesh or paper. These are lower cost apparatuses that require frequent filter changes. Although this invention is drawn to any centrifuge, another solution, which is addressed hereinbelow, does not contain any moving parts or removable filters, but relies on the forces produced by external fuel pumps in combination with various plates, baffles, weirs and ports as fuel passes through the fuel system.

[0004] The advantages of having purified the fuel are to reduce wear on moving parts, reduce carbon deposits, improve exhaust emissions and increase combustion efficiency and performance. The purification of the fuel can be especially beneficial, if the fuel is to be brought into contact with a catalyst, since the contaminates tend to eventually coat the catalysts and cause them to become ineffective.

[0005] Petroleum is a complex liquid solution of gases, liquids and solids comprised of long molecular hydrocarbon chains. The size of the molecules determine the grade of the fuel which ranges from: gas, having between one and five carbon atoms per molecule, to the usual fuel oils, having between five and 18 carbon atoms per molecule to paraffins and pitch or asphalt which number as many as 20 or more carbon atoms per molecule. In fact, the crude oil remaining after the volatile hydrocarbons have been removed are mainly comprised of paraffins and asphalt. These heavier components are generally undesirable in a mixture designed for combustion engines.

[0006] Precombustion treatment catalysts have been show to break down the heavier undesirable long chain hydrocarbon chains into smaller chains with greater combustion qualities. These may take the form of liquid or solid formed catalysts which interact with the fuel. At least one class of catalysts referred to as oxidation catalysts can provide improved combustibility reactions at ambient temperatures.

[0007] Traditional oxidation catalysts are of two general types: noble metals and non-precious metals. some combinations of the two general types also have been found to exhibit low temperature catalytic activity. Commercially available catalysts manufactured from rhenium and manganese, heterogeneous metal alloys comprised of tin, antimony, lead and mercury, and others containing soluble platinum group metal compounds have shown to improve the performance of the combustion engine.

[0008] When carbon-containing fuels, such as gasoline and diesel fuel oil are burned in the presence of air, nearly all the carbon combines with oxygen to form carbon dioxide, CO2, but amounts of CO carbon monoxide form, as well, depending on the air available. Carbon monoxides are not desirable in the combustion process. In platinized tin-oxide catalysts the material catalyzes as a result of a reaction of the carbon monoxide CO and the dioxide molecule O2. If the tin surface is exposed to a mixture of CO and O2, it quickly becomes covered by CO, since CO molecules can absorb on vacant surface sites. The presence of tin-oxide alters this affect since only the O2 molecule is absorbed, whereas the CO does not. Therefore it is critical that the fuel be as free from foreign constituents such as large amounts of water, carbons, sediment, oxides and non combustion organic solids as possible. It stands to reason that catalyst type treatments are more efficient when the reaction is effectuated is free from all but trace amounts of water (which incidently are useful in some catalytic reactions) and other impurities. By combining the features of a fuel purifier with such a catalyst the benefits to a combustion engine are greatly enhanced.

SUMMARY OF THE INVENTION

[0009] The present invention is an apparatus and a method that purifies fuel by filtering it from foreign constituents and thereafter passing the fuel through a refining process that improves its combustible efficiency.

[0010] The principle of operation of the embodiment described herein relies on the fact that a centrifugal force is produced by any moving mass that is compelled to depart from a rectilinear path it may be following. Therefore any liquid substance channeled into a rotary motion will assume an angular acceleration and corresponding angular momentum. When the substance impinges on a barrier it will change its direction to conserve its momentum under well known laws of physics. Substances and particles that are relatively heavy compared to other such substances and particles will deflect into different directions upon encountering the barrier. These centrifugal forces can be created through the motorized spinning of a channel through which the fuel enters or can be generated by virtue of the manner in which the fuel is drawn through various pipes and nozzles under the pressure of a pump.

[0011] The invention herein disclosed utilizes as one element an apparatus that separates free water and contaminants from fuel. Heavy contaminates will separate from the fuel based on altering the path of the fluid while under going changes in acceleration, velocity, pressure and position. For example, centrifugal forces aid in the separation of the foreign constituents from the fuel since heavier particles are cast in one direction and lighter constituents in another.

[0012] In the present invention the fuel is drawn through the fuel system and the filtering element under pressure provided by a pump. In one embodiment, the fuel and all its non fuel constituents under the force of a pump enters an orifice at one end of a longitudinal chamber which is contained within a large essentially closed volume, having an input port and one or more ports to connect the output of purified fuel or ports to remove the collected water and impurities. The longitudinal chamber causes the fuel to enter the chamber at one orientation and exit in an orthogonal direction to force the fuel to assume a curvilinear trajectory as it progresses through the chamber towards a distal end where it exits through an orifice constriction or nozzle. The narrowing of the cross section of the chamber from its proximal end to its distal end results in a increase in the velocity of the fuel through the longitudinal chamber. Upon exiting a nozzle, the fluid discharges into a relatively large separating chamber within a cylindrical housing. The nozzle focuses fuel so that it impinges or is forced into a generally concave inner surface of the cylindrical separating chamber whereupon the fluid assumes a generally circular motion.

[0013] The fuel which has a lower specific gravity than either water or solid constituents such as sand and sediment flows away from the concave barrier and is swept into the current of the fuel flow as it makes it way under pressure to an output port where it will be forced to contact a catalyst before it is fed to other potential filters and eventually to one or more fuel tanks or combustion engines or boilers.

[0014] The heavier specific gravity components such as free water and sediment do not have the kinetic energy to remain in the current stream and tend toward a sump, the lowest gravitational potential, at the bottom of the large container.

[0015] In the present invention the degree of separation or filtration can be increased by employing filter media, rotating separation surfaces, separating chambers, settling chambers or multiple stages of the aforementioned process. Once the separation occurs the remaining fluid is forced into contact with a catalyst. Only lighter constituents, such as fuel remain in the current stream flowing toward the output port.

[0016] The insertion of a metal alloy catalyst which the fuel is made to contact, such as is described in U.S. Pat. No. 5,580,359 will improve the combustibility of the purified fuel. In one theory as to how the catalyst acts to refine fuel, it is postulated that the type catalysts utilized in the preferred embodiment cleave high molecular weight organic molecules to form lower molecular weight molecules which are susceptible to greater combustion efficiencies. The smaller molecules essentially accelerate the combustion process producing less unburned carbon monoxide and hydrocarbons and increase fuel efficiency. Other metal alloy catalysts have other theories associated with their catalytic mechanisms. In the extant theories it is suggested that surface contact by the fuel is an important consideration. The greater the contact the greater the efficiency of the catalyst. Fuel free from contaminants provides a greater opportunity for fuel to contact the catalyst surface.

[0017] A catalyst suited for these purposes may be formed by casting, extruding, cutting or shaping to have the shape of a mesh, plate, ball or other two or three dimensional shape. The catalyst may be used to form the materials such as plates and container material. As such the catalyst may also be embedded in the surface of either metals, plastics or engineered resins that are used in manufacturing the purifier component of the apparatus. Essentially, the catalyst may be formed from plastics or metals subjected to one or more processes know by those skilled in the art of metal or plastic processing to impregnate, alloy, embed, laminate or plate the catalyst onto the internal surfaces of the apparatus. The object of the materials and its geometric shape is to allow the greatest number of hydrocarbon molecules to contact the catalyst on its path to the tank, engine, or boiler. In the present invention a generally pancake-like shape is encapsulated between two monel mesh plates which are inserted into the path of the purified fuel.

[0018] The insertion of the catalyst can be effectuated anywhere in a fuel purifier. For example, the internal chambers of the separator can be formed from the catalyst material. It can be formed into or become part of the internal surface or the purifier housing itself. It may also be utilized to coat the various surfaces of the settling chambers or diverters. In the present embodiment, after the separation of water and other impurities take effect, the catalyst, by way of example, is placed in the area of the output of the second diverter chamber where the fuel has been for a second time diverted and channeled in a generally downward position relative to the point the fluid first rose after a first separation.

[0019] The invention herein disclosed addresses both an apparatus and method that separates relatively immiscible liquids and solids, such as fuels and heavy petroleum products which have a specific gravity of less than one (1), from water and other constituents and particulate matter generally having a specific gravity equal to or greater than one (1). The purified fuel thereafter contacts the surface of one or more catalyst elements which produces an electrochemical reaction by virtue of the composition and properties of the metal alloy catalyst.

[0020] In summary, the invention comprises a fuel purifier having an input port and an output port and a catalyst whereby lighter constituents remain in the current stream contact the catalyst before the fluid flows through the output port. The catalyst can exist as a separate pellet-like material form or can be made from one of a group of processes utilizing metal or plastic impregnation, alloying, embedding, laminatation or plating of the catalyst material onto one or more surfaces of the separator.

[0021] Essentially the invention comprises a container an apparatus comprising a container having an input port in fluid communication with an output port, a means for creating forces on a stream of fluid such the heavier constituents separate from lighter constituents which contact a catalyst before discharging through the output port.

[0022] The method disclosed herein is comprised of purifying fuel by separating fuel from its contaminants, and thereafter catalyzing the fuel.

[0023] An object of the present invention is to separate fuel and water before subjecting the fuel to a catalyst.

[0024] Another object of the present invention is to reduce the cost of conventional fuel purifiers and catalyst products when products and utilized as separate products in-line or in series.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The novel features of the present invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation, together with further objects and advantages thereof, may be best understood by reference to the following description taken in conjunction with the accompanying drawings, in which:

[0026] FIG. 1 is a plan view of the preferred embodiment of the present invention.

[0027] FIG. 2 is a perspective view of the catalyst encapsulated between two plates.

[0028] FIG. 3 is diagram of a centrifuge machine illustrating the separating bowl.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] In FIG. 1 is shown an apparatus 1 of the present invention where a housing 8 is illustrated as a generally cylindrical shaped container with convex ends 9 and 10, although the shape of the ends is not critical. In the preferred embodiment shown in FIG. 1, there is an input port 2 and an output port 40 which is mounted in a vertical plane. Attached to the input port is a longitudinal chamber 3 having a proximal end 12 and a distal end 11, which extends vertically from the input port 2 to a point lower than the input port 2. The location of the lower distal end 11 relative to the proximal end 12 is not critical, however it should be sufficient low to insure the necessary distance that the fluid must travel to attain a forward velocity and impart an angular momentum sufficient to force a separation of the heaviest constituents from the lightest constituents in the fluid.

[0030] As the fuel flows through the fuel system under pressure of a fuel pump (not shown) it enters input port 2 and progresses downward through longitudinal chamber 3, discharging through the longitudinal chamber 3 output orifice 14 where generally heavier than fuel constituents settle into a settling chamber 18. The fuel being discharged impinges a concave barrier 13, in this case the concave inner wall of housing 8, which contact serves to force the fluid into a circular motion whereby, heavier constituents of the fuel are urged in one angular direction and lighter constituents in yet another angular direction. The heavier constituents, those with specific gravities 1 or greater come to rest in the settling chamber 18 and the lighter constituents are forced by the current created by the fuel pump through the volume 25 and into an opening 5 into a chamber 3a formed from two plates, 4 and 4c running axially through the central portion of the housing 8 and diametrically across housing 8. The fluid enters at orifice 5 and exits at orifice 11 a, discharging into an output chamber 26.

[0031] The fuel emerging from the longitudinal chamber 3, discharging through output orifice 11a contacts a pellet-like metal alloy catalyst 30 which sits at the lower end of chamber 26. FIG. 1, of the preferred embodiment shows the catalyst 30 resting on a perforated plate 32 above plate 12. In a second embodiment (not shown) the catalyst 30 rests on plate 12. Perforated plates 34, 35 and 36 serve as a cover and base to contain additional catalysts 30. As the fuel contacts the base of the metal plate 32 it penetrates the perforated sections 38 and contacts the catalyst 30. The fluid sweeps or flows around the catalyst 30 making surface contact with the other like catalyst 30 pellets and flows into the output chamber 26.

[0032] It is believed that the perforated plates as represented by plate 32 through 36 can improve the operation of the catalyst. Therefore, a metal that is empirically determined to improve the performance of the catalyst may be chosen. In the present embodiment monel has been utilized as the chosen metal. This disclosure is intended to cover any plates separating the catalysts.

[0033] The quantity of catalyst 30 pellets required has been empirically established and is determined on the basis of fuel flow and the degree of refinement desired. Typically the number of pellet catalysts 30 would number from 6 to 600 in applications for treating fuel supplied to storage tanks, internal combustion engines, and boilers.

[0034] A ceiling 4a separates the chamber 18 from the output chamber 26. A floor 4b also separates the output chamber 26 from chamber 18, except for an optional fluid communication through a small weep hole or opening 12 to allow water and heavier constituents collected at the output orifice 11a to flow into the chamber 18.

[0035] In an alternate embodiment the catalyst 30 may be impregnated, alloyed, embedded, laminated or plated onto one or more internal surfaces of the apparatus. The plate 4, plate 4a plate 4b plate 4c may have the catalyst 30 impregnated, alloyed, embedded, laminated or plated onto one or more of each of its two surfaces. Likewise the catalyst 30 may be impregnated, alloyed, embedded, laminated or plated onto the inner surface of the housing 8. In each of these embodiments the objects of the invention would be fulfilled.

[0036] It will be understood by those skilled in the art that additional stages of purification such as provided by chamber 3a, or additional chambers 26 containing catalysts 30 can be utilized to improve the degree of purification and refining.

[0037] FIG. 3 illustrates the pertinent cross section of a centrifuge 50, yet another embodiment of the present invention comprising a container 44 having an input port 46 in fluid communication with an output port 48, a separating chamber 42, a means for creating forces 43 on a stream of fluid 62 such that the heavier constituents 64 separate from the lighter constituents 66 which contact a catalyst 30 before discharging through the output port 48. The separating bowl 58 is made to spin at a high rotational velocity which imparts a centrifugal force on the liquid 62 causing heavier components 64 to separate into one stream and the lighter components 66 to separate into a second stream. The centrifuge 50 contains a catalyst 30 interposed between the output side of a distribution aperture 52 and the discharge end 54 and 56 of a catalyzing chamber 70. It will be apparent that the catalyst can be composed of pellet-like metal alloys separated by monel perforated plate 68 or other sutiable material or made in a form capable of being impregnated, alloyed, embedded, laminated or plated onto the separating bowl 58 surfaces or the internal surfaces of the neutral zone 60 which will also provide the benefits of catalyzing the fuel.

[0038] While preferred embodiments of the invention have been shown and described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will occur to those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention.

Claims

1. An apparatus comprising a container having an input port in fluid communication with an output port, a means for creating forces on a stream of fluid such the heavier constituents separate from lighter constituents which contact a catalyst before discharging through the output port.

2. The apparatus as in

claim 1 including one or more separating chambers or more chambers whereby lighter constituents remain in the stream contacting the catalyst.

3. The apparatus as in

claim 1 including one or more surfaces having the quality of the catalysts.

4. An apparatus comprising a cylindrical container having an input port and an output port; a first diverter chamber attached to the input through which fluid containing differing constituents is discharged from the distal end of said diverter chamber into a settling chamber where the fluid is forced to impinge a concave surface, causing lighter constituents to remain in the current stream flowing toward the output port and heavier constituents to settle in the settle chamber and come to rest in a settling chamber of the container and a catalyst, whereby the lighter constituents remaining in the current stream contact the catalyst before the flowing through the output port.

5. The apparatus as in

claim 4 wherein the settling chamber discharges into a second diverter chamber and channeled in a generally downward position relative to the point the fluid rose after a first separation and contacts the catalyst before the fluid flows through the output port.

6. The apparatus as in

claim 1 wherein the catalyst is made from one of a group of processes utilizing metal or plastic impregnation, alloying, embedding, laminatation or plating of the catalyst material onto the internal surfaces of the apparatus.

7. The apparatus as in

claim 3 wherein the plates separating the catalysts is made from a group of metals having the qualities of substitutional solid solutions such as represented by the metal monel.

8. The method disclosed herein is comprised of separating fuel from its contaminants, and thereafter catalyzing the fuel.

9. The method as in

claim 8 wherein separating fuel from its contaminants includes the steps of creating forces on a fluid, such that when the fluid is forced into a circular motion, heavier constituents settle into a sump and lighter constituents remain in the current stream.

10. The method as in

claim 8 wherein catalyzing said fluid includes the step of contacting a catalyst and thereafter discharging through an output port.