Fuel additive

Abstract

A composition and method for improving the performance, and thus, also the fuel economy, of an internal combustion engine by introducing a fuel additive into the engine's fuel supply to enhance fuel lubricity. The composition can feature a mixture of esters, glycol ether, and a solvent. The mixture of esters can include adipate esters, azelate esters, dodecanedioate esters, sebacate esters, or phthalate esters. Esters that may be used to create the composition can include a mixture of two or more adipate esters such as, for example, an adipic acid ester, a glutaric acid ester, and a succinic acid ester. The composition can further feature a smoke suppressant that can be an organometallic soap. The organometallic soap can be an iron salt of a fatty acid such as, for example, ferrocene. The composition can be used as a combustion modifier fuel additive and as a lubricating oil.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of and claims the priority from U.S. nonprovisional patent application Ser. No. 11/846,994 filed Aug. 29, 2007. The foregoing application is incorporated in its entirety herein by reference.

FIELD OF THE INVENTION

The invention relates to compositions and methods for improving engine performance. More particularly, the invention relates to compositions and methods for improving engine performance by increasing the lubricity of fuel and for lubricating two or more parts in frictional contact.

BACKGROUND

Current government regulations related to hydrocarbon fuels require low sulfur content. Certain chemical processes can be used to reduce the overall sulfur content of commercially available fuels so as to decrease the environmental impact of fossil fuel combustion. The removal of sulfur compounds from fuels has resulted in a corresponding decrease in the incidence of acid rain, acidic fogs and other environmentally harmful pollution-linked weather phenomena. However, the presence of sulfur in fuels also imparts a beneficial lubricating effect to the fuel that reduces friction within a combustion engine. Sulfur compounds present in fuel impart a lubricating effect to the exposed wearing surfaces of an internal combustion engine which are exposed to frictional forces. The lubricity of the fuel is directly linked to engine performance, and therefore, also to fuel efficiency. Removal of sulfur-containing compounds from fuel sources increases the degree of frictional wearing experienced by exposed surfaces of the internal combustion engine and its parts. While providing a benefit to the environment in some regards, the elimination of sulfur-containing compounds from modern fuels has decreased the lubricity of these fuels, which has caused a corresponding decline in engine performance and fuel efficiency of automobile engines and other internal combustion engines. These effects may increase the amount of fossil fuels used by consumers, and therefore, may contribute to further increases in the amount of fuel combustion by-products that are released into the atmosphere as airborne emissions. Increases in the amount of emissions released by automobiles may be linked to the occurrence of smog, global warming, and other environmental harm.

Fuel additives have also incorporated solvents intended to clean the internal surfaces of internal combustion engines. These conventional fuel additives often include hazardous synthetic compounds that are not biodegradable and which actually increase the amount of pollution released into the environment as a byproduct of fossil fuel combustion. Due to the toxicity of their ingredients, the use of such conventional fuel additives may offset any advantages obtained through burning of a biofuel (e.g., ethanol or bio-diesel) as a fuel source.

Soy-based and petroleum-based lubricants used as fuel additives and as lubricating oils have only a limited period of time for effectiveness when used. As a result of the short effective life of conventional lubricants, they are not ideal for use as fuel additives to provide lubricity in internal combustion engines or to be used as lubricating oils on moving parts. Conventional lubricants and solvents are often composed of toxic compounds that pose hazards to the environment and its inhabitants.

SUMMARY

The invention relates to a composition that can be used as a fuel additive that can function as a combustion modifier and as a lubricating oil. The composition is created from a mixture of ingredients that can include one or more esters, glycol ether, and a solvent. The composition can also feature a smoke suppressant. The smoke suppressant can be an organometallic soap such as, for example, a metal salt of an alkanoic acid. In one embodiment, the organometallic soap can be ferrocene. The glycol ether and metallic smoke suppressants of the composition can act to reduce smoke and soot emissions produced by fuel combustion. The ingredients of the composition can be bio-based compounds produced from grains. The composition can be used as a combustion modifying fuel additive and as a lubricant on metals, alloys, elastomer materials, plastics, coatings, finishes, and seals.

As a fuel additive, the composition provides several advantages when added to the fuel supply of a combustion engine. The fuel additive acts as a solvent. The fuel additive can improve the performance of the engine. The fuel additive can also improve fuel economy (or fuel mileage) and reduce emissions that are harmful to the environment. Once mixed with the fuel supply introduced into a combustion engine, the fuel additive can improve engine performance by enhancing the lubricity of the fuel. The fuel additive affects these improvements in engine performance due, in part, to its lower volatility, excellent lubricity, and its detergent and dispersant qualities. Many of these engine performance-enhancing characteristics are connected to the polarity of the ester molecules present in the composition.

The composition's ester molecules exhibit an intermolecular attraction, which is connected to the polarity of the ester molecules. This intermolecular attraction requires more energy in the form of heat to overcome the linkages between molecules so that the esters can change state from a liquid to a gas. At a given molecular weight or viscosity, the esters have a low vapor pressure that imbues the composition with a higher flash point and lower rate of evaporation, properties that are beneficial for a lubricant. Lubricants that evaporate quickly have little time to impart their lubricating properties to an engine. The non-evaporative nature of the composition extends its usefulness as a lubricant by ensuring that its lubricating effects last longer than what is characteristic for a petroleum or soy-based lubricant. The compositions of the invention can include esters that exhibit the formation of many linkages between ester molecules so that the flash point of the composition remains high and its volatility is low to allow the composition more time to lubricate the engine parts.

The polarity of the composition's ester molecules also causes the molecules to be attracted to positively-charged metal surfaces. When introduced with the fuel supply into the combustion chamber of an internal combustion engine, the ester molecules are attracted to the metal surfaces inside the engine and form a film or coating. The linkages between ester molecules caused by intermolecular attractive forces renders the film more difficult to penetrate than that of lubricants because of the additional energy required to evaporate the composition. Thus, the composition produces a stronger film with lubricity properties that are enhanced compared to those of conventional lubricating fuel additives. In turn, the additional lubricity imparted to the fuel by the composition decreases energy consumption by the engine by lubricating the internal engine parts which operate more efficiently than when affected by frictional forces that can degrade the engine's performance.

In addition, the polarity of the composition's ester molecules enhances the composition's effectiveness as a detergent and dispersant. The composition's esters provide the composition with solvent properties permitting the composition to be used to dissolve and disperse oil by-products of fossil fuel combustion. By solubilizing the oil by-products, the by-products can be burned away during combustion rather than being deposited on the internal surfaces of the combustion engine as sludge or varnish, which could diminish engine performance. The composition can be used to quickly and effectively clean metallic surfaces by removing dirt and grease. Therefore, the composition also improves engine performance by improving the solvent and detergent properties of the fuel to which it is added, thereby resulting in cleaner engine operation.

As a lubricating oil, the composition exhibits the aforementioned qualities that are advantageous when the composition is used as a fuel additive or as a lubricating oil. Because the composition is bio-based (made from, for example, soy-based products), the composition is safer for use than many conventional lubricating oils and fuel additives that can contain harsh artificial chemicals that are damaging to the environment. In addition to its long-lasting lubrication effects, the composition also exhibits superior water displacement and anti-corrosion properties that can protect metal surfaces against the formation of rust. By forming a lubricating coating over and displacing water (e.g., moisture or condensation) from metal surfaces, the composition is able of preventing corrosion, rust formation, and damaging oxidation effects. The lubricant can be used to lubricate the interface between contacting metal surfaces. The composition can be used as a penetrating lubricant that can be used when assembling parts of various types of equipment, e.g., mechanical inventions such as an engine, and also forms a protective coating over objects, and particularly, over the surface of metallic objects. The lubricating oil can also be used to loosen corroded or rusted fittings that are frozen in place.

The composition also provides advantages in that it is created from non-toxic ingredients that are environmentally friendly. Conventional commercial and industrial fuel additives and lubricants often contain toxic compounds that can damage the environment or which can cause death, illness, or other adverse health effects among humans and other animals exposed to their toxic ingredients. The compositions of this invention can be produced using bio-based ingredients and need not include artificial compounds that can be toxic and harmful to the environment.

The invention also relates to methods for improving engine performance and fuel economy and reducing harmful emissions associated with the combustion of fossil fuels, bio-fuels, and other carbon-based fuels by combustion engines, and particularly, by internal combustion engines.

Because the composition can be created from bio-based sources such as, for example, grains, the composition can be made from renewable resources and reduces the consumption of petroleum and other non-renewable resources. The composition is also as effective as but less expensive to produce than synthetic lubricants and mineral oils. The bio-based formula of the composition also renders the composition biodegradable but resistant to break down at cold temperatures, under heat, and with exposure to heavy loads and moisture.

Yet another advantage of the composition is its load carrying capacity which exceeds that of many conventional lubricants and allows the composition to exhibit exceptional anti-wear and pressure performance.

Still another advantage of the composition is that metallic salts can be included as an environmentally safe ingredient for enhancing the smoke suppressing effects of glycol ethers and to reduce particulate emissions.

Accordingly, the invention can feature a composition for improving engine performance, the composition comprising a mixture of esters, glycol ether, and a solvent.

In another aspect, the invention can feature the mixture of esters including at least two esters selected from among the following: adipate esters, azelate esters, dodecanedioate esters, sebacate esters, and phthalate esters.

In another aspect, the invention can feature the mixture of esters including at least two adipate esters.

In another aspect, the invention can feature the at least two adipate esters including an adipic acid ester, a glutaric acid ester, and a succinic acid ester.

In another aspect, the invention can feature the mixture of esters including dimethyl adipate, dimethyl gluctorate, and dimethyl succinate.

In another aspect, the invention can feature a smoke suppressant. The smoke suppressant can be an organometallic soap.

The invention also features a composition for improving the combustion efficiency of an internal combustion engine in combusting hydrocarbon fuels. The composition can include a hydrocarbon fuel and a combustion modifier. The combustion modifier can be an organometallic soap.

In another aspect, the invention can feature the organometallic soap being selected from among one or more of the following: cerium-2-ethylhexanoate, cerium octoate, cerium stearate, cerium naphthenate, cerium salicylate, cerium carbonate, cerium ammoniate, cerium ureate, cerium nitrate, ferric octoate, ferric-2-ethylhexanoate, ferric stearate, ferric naphthenate, ferric salicylate, ferric carbonate, diborylated ferrocene, n-butyl ferrocene, 1,1′-dimethyl ferrocene, benzoyl ferrocene, iron (III) oxide (Fe₂O₃) iron (II, III) oxide (Fe₃O₄), and combinations thereof.

In another aspect, the invention can feature the organometallic soap including a compound selected from among the following: cerium octoate, cerium ammoniate, cerium ureate, or cerium-2-ethylhexanoate.

In another aspect, the invention can feature the organometallic soap being diborylated ferrocene.

In another aspect, the invention can feature the organometallic soap being the reaction product of 1,1′-bis(ethenyl-4-pyridyl)-ferrocene and -1,1′-binaphthol.

In another aspect, the invention can feature the organometallic soap being a mixture of diborylated ferrocene and a compound selected from among cerium-2-ethylhexanoate or cerium octoate.

In another aspect, the invention can feature the organometallic soap being a mixture of diborylated ferrocene and a compound selected from among cerium ammoniate or cerium ureate.

In another aspect, the invention can feature the composition further including a hydrocarbon fuel.

In another aspect, the invention can feature the mixture of esters including at least two esters selected from among the following: adipate esters, azelate esters, dodecanedioate esters, sebacate esters, or phthalate esters.

In another aspect, the invention can feature the mixture of esters including at least two adipate esters.

In another aspect, the invention can feature the at least two adipate esters including an adipic acid ester, a glutaric acid ester, and a succinic acid ester.

In another aspect, the invention can feature the smoke suppressant being an iron salt.

The invention can also feature a composition for improving the combustion efficiency of an internal combustion engine in combusting hydrocarbon fuels. The composition can include a hydrocarbon fuel, a hydrocarbon carrier, and a combustion modifier. The combustion modifier can be the reaction product of 1,1′-bis(ethenyl-4-pyridyl)-ferrocene and -1,1′-binaphthol.

In another aspect, the invention can feature the hydrocarbon carrier including a compound selected from among one or more of the following: biphenyl, naphthol, beta naphthol, naphthol-2, beta-binaphthol, dicyclopentadiene, beta-binaphthol, dicyclopentadiene, and combinations thereof.

In another aspect, the invention can feature the hydrocarbon carrier being beta-binaphthol.

In another aspect, the invention can feature the hydrocarbon carrier being dicyclopentadiene.

Still another method of the invention can be used to introduce into an internal combustion engine a hydrocarbon fuel and a fuel additive. The fuel additive can feature a mixture of esters, glycol ether, and a solvent.

Another method of the invention can include the mixture of esters including at least two adipate esters. The at least two adipate esters can be selected from at least two of the following: an adipic acid ester, a glutaric acid ester, or a succinic acid ester.

Yet another method of the invention can be used to reduce friction between moving parts. The method can include the step of lubricating the at least two parts that are in frictional contact with a lubricant. The lubricant can feature a mixture of esters, glycol ether, and a solvent.

Another method of the invention can feature the at least two parts being metal parts.

Another method of the invention can feature the metal parts being parts of an internal combustion engine.

Unless otherwise defined, all technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. All publications, patent applications, patents and other references mentioned herein are incorporated by reference in their entirety. In the case of conflict, the present specification, including definitions will control.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a chart representing fuel pounds per hour measurements for a control test in which diesel fuel was combusted in an internal combustion engine without the addition of a combustion modifier of the invention.

FIG. 1B is a chart representing measurements of air consumed by fuel combustion for a control test in which diesel fuel was combusted in the internal combustion engine without the addition of a combustion modifier of the invention.

FIG. 2A is a chart representing fuel pounds per hour measurements for an experimental test in which diesel fuel was combusted in an internal combustion engine to which a combustion modifier of the invention was supplied.

FIG. 2B is a chart representing measurements of air consumed by fuel combustion for an experimental test in which diesel fuel was combusted in the internal combustion engine to which a combustion modifier of the invention was supplied.

DETAILED DESCRIPTION

The invention provides compositions that can be used as fuel additives or as lubricating oils. Compositions of the invention can be used to improve the combustion efficiency of an internal combustion engine, and in particular, the internal combustion engine of a vehicle, in combusting hydrocarbon fuels. Compositions of the invention can also be used to reduce friction between two moving parts in frictional contact such as, for example, the moving parts of the internal combustion engine. The composition can feature a mixture of esters, glycol ether, and a solvent.

In other embodiments, the composition can also feature a smoke suppressant. The smoke suppressant can be a combustion modifier. The combustion modifier can be an organometallic soap.

The mixture of esters can include at least two esters that are adipate esters, azelate esters, dodecanedioate esters, sebacate esters, or phthalate esters.

In an exemplary embodiment, the mixture of esters can include at least two adipate esters. In a most exemplary embodiment, the adipate esters can be an adipic acid ester, a glutaric acid ester, a succinic acid ester, or a combination of one or more of these esters.

In one exemplary embodiment, the mixture of esters of the composition can include at least two of dimethyl adipate, dimethyl glutorate, and dimethyl succinate. These esters can be included in the composition in the ratios described below.

In one embodiment, the composition can include, in percentages by weight, about 0.5-7% dimethyl adipate, about 0.5-10% dimethyl glutorate, about 0-7% dimethyl succinate, about 0.5-7% glycol ether, and about 70-95% solvent.

In a more preferred embodiment, the composition can include, in percentages by weight, about 0.5-5% dimethyl adipate, about 1-9% dimethyl glutorate, about 0-5% dimethyl succinate, about 1-5% glycol ether, and about 85-95% solvent.

In a most preferred embodiment, the composition can include, in percentages by weight, about 1-2% dimethyl adipate, about 4-6% dimethyl glutorate, about 0.5-2% dimethyl succinate, about 2-4% glycol ether, and about 88-92% solvent.

In another exemplary embodiment, the composition can include a smoke suppressant and a mixture of esters of the composition featuring at least two of dimethyl adipate, dimethyl glutorate, and dimethyl succinate. For example, in the following embodiments, the smoke suppressant can be the organometallic soap, ferrocene, although any smoke suppressant described herein can be used. These esters and smoke suppressant can be included in the composition in the ratios described below.

In one embodiment, the composition can include, in percentages by weight, about 0.5-7% dimethyl adipate, about 0.5-10% dimethyl glutorate, about 0-7% dimethyl succinate, about 0.5-7% glycol ether, about 0.5-4% smoke suppressant, and about 70-95% solvent.

In a more preferred embodiment, the composition can include, in percentages by weight, about 0.5-5% dimethyl adipate, about 1-9% dimethyl glutorate, about 0-5% dimethyl succinate, about 1-5% glycol ether, about 1-3% smoke suppressant, and about 85-95% solvent.

In a most preferred embodiment, the composition can include, in percentages by weight, about 1-2% dimethyl adipate, about 4-6% dimethyl glutorate, about 0.5-2% dimethyl succinate, about 2-4% glycol ether, about 1.5-2.5% smoke suppressant, and about 88-92% solvent.

In one example of a composition described herein, the composition can include, in percentages by weight, about 1.89% dimethyl adipate, about 5.31% dimethyl glutorate, about 1.8% dimethyl succinate, about 3% glycol ether, and about 89% solvent.

In another example of a composition described herein, the composition can include in percentages by weight, about 2.52% dimethyl adipate, about 7.08% dimethyl glutorate, about 2.4% dimethyl succinate, about 6% glycol ether, about 2.5% ferrocene as the smoke suppressant, and about 79.5% solvent.

In another example of a composition contemplated herein, the composition may include no solvent, glycol ether, or smoke suppressant but can include in percentages by weight, about 4.2% dimethyl adipate, about 11.8% dimethyl glutorate, about 4% dimethyl succinate, about 56% methyl laurate, about 22.4% methyl myristate, and about 0.8% methyl palmitate.

Example 1

Tests were conducted to determine the effectiveness of the composition in improving lubricity of a standard commercial pump diesel fuel that would be used to power a diesel-powered internal combustion engine. The tests were conducted using a high frequency reciprocating rig (HFRR) and ASTM D-6079, the standard test method used to evaluate the lubricity of diesel fuels in an HFRR. As a diesel fuel standard specification for lubricity, the test used ASTM D-975 as a baseline, i.e., 520 microns maximum for the wear scar at 60° C. using the HFRR test method. In an untreated first sample, the test was performed using a commercial pump ultra low sulfur diesel fuel (ULSD). Using the HFRR and standard specification described above, the lubricity using the untreated first sample was determined to be 333 microns. A second sample was prepared by adding one of the compositions described herein above to a commercial pump ultra low sulfur diesel fuel. The test was then performed in the HFRR using this second treated sample, and its lubricity was determined to be 290 microns. The results of these particular tests showed that lubricity of a commercial pump ultralow sulfur diesel fuel were improved significantly by adding the composition to the diesel fuel as opposed to using an untreated diesel fuel.

Hydrocarbon fuels with which the composition can be mixed include, for example, (1) petroleum-derived fossil fuels such as gasoline, diesel, jet fuel, fuel oil, and kerosene; (2) biofuels such as bioethanol, biodiesel, straight vegetable oils (pure plant oils), and waste vegetable oils; and (3) combinations thereof. The composition can also be used in engines that are powered by natural gas.

Example 2

Emissions tests were conducted for one of the compositions described herein above using two internal combustion engines (a V16 Waukesha™ engine and a 2500-hp V16 Caterpillar™ engine, model #3515) powered by natural gas. Both engines burned approximately 10,000 cubic feet (10 M BTUs) of natural gas per hour, and were running at 1,200 rpm. Compared with a control of natural gas and no additive, when the composition described herein was added to the engines as they burned the natural gas, NO_x and other toxic emissions were reduced substantially from 250 ppm to 50 ppm. The test results also showed that fuel consumption was reduced by approximately 18% and engine speed was increased from 1,200 rpm to 1,400 rpm after the composition was added, thereby resulting in significantly better engine improvement.

In some embodiments, the composition may include more than one smoke suppressant. The smoke suppressants can be metallic smoke suppressants such as, for example, metallic salts of alkanoic acid. In an exemplary embodiment, the smoke suppressant can be an iron salt such as, for example, an organometallic soap. In another embodiment, the smoke suppressant can be a barium salt. In embodiments in which the composition is used as a fuel additive, the composition can further include a hydrocarbon fuel.

A composition of this invention may also include a hydrocarbon fuel and a combustion modifier that can be an organometallic soap, but no mixture of esters and no glycol ether. The organometallic soaps described herein below can be used in both compositions that include and those that do not include a mixture of esters and glycol ether.

The smoke suppressant can be an organometallic soap. The organometallic soap may contain ferric iron or cerium (III). The organometallic soap of the combustion modifier can be selected from among the following ferric and cerous organometallic soap compounds: cerium ammoniate, cerium ureate, cerium nitrate, cerium-2-ethylhexanoate, cerium octoate, cerium stearate, cerium naphthenate, cerium salicylate, cerium carbonate, ferric octoate, ferric-2-ethylhexanoate, ferric stearate, ferric naphthenate, ferric salicylate, ferric carbonate, diborylated ferrocene, n-butyl ferrocene, 1,1′-dimethyl ferrocene, benzoyl ferrocene, iron (III) oxide (Fe₂O₃), iron (II, III) oxide (Fe₃O₄), and combinations thereof. Iron (III) oxide (Fe₂O₃) can be derived from natural sources such as the mineral hematite while iron (II, III) oxide (Fe₃O₄) can be derived from natural sources such as the mineral magnetite. The combustion modifier can include 1, 2, 3, 4, 5, or more of the organometallic soaps. The organometallic soap is soluble in fuel products derived from petroleum oil as well as in other hydrocarbon fuels.

In an exemplary embodiment, the organometallic soap can be the reaction product of 1,1′-bis(ethenyl-4-pyridyl)-ferrocene and -1,1′-binaphthol.

In one embodiment, the organometallic soap can be diborylated ferrocene only although the combustion modifier preferably also contains a cerous compound for increasing the combustion rate of the fuel in the internal combustion engine. In another embodiment of the composition, the combustion modifier may include only a single ferric iron-containing organometallic soap selected from among those described herein.

In another embodiment, the organometallic soap can be cerium-2-ethylhexanoate only although the combustion modifier preferably also contains a ferric compound for increasing the combustion rate of the fuel in the internal combustion engine by preventing the accumulation of carbon residues on the internal surface of the combustion chamber of the internal combustion engine. In another embodiment of the composition, the combustion modifier may include only a single cerium-containing organometallic soap selected from among those described herein.

In another embodiment, the combustion modifier can include a mixture of one or more ferric compounds selected from among those described herein and one or more cerous compounds selected from among those described herein. The combustion modifier may include the ferric compound or mixture of compounds in a range of about 10 to 100 percent by weight or about 60 to 80 percent by weight and the cerous compound or mixture of compounds in a range of about 10 to 100 percent by weight or about 20 to 40 percent by weight. The combustion modifier can also include the ferric compound or mixture of compounds in a range of about 15 to 85, about 35 to 75, or about 65 to 75 percent by weight and the cerous compound or mixture of compounds in a range of about 15 to 85, about 25 to 65, or about 25 to 35 percent by weight. The combustion rate and combustion efficiency are most improved when the combustion modifier contains about 70 percent by weight ferric compound or compounds and about 30 percent by weight cerous compound or compounds.

In another embodiment, the combustion modifier can include a mixture of n-butyl ferrocene, 1,1′-dimethyl ferrocene, or benzoyl ferrocene and one or more cerous compounds selected from among those described herein. The combustion modifier may include at least one of n-butyl ferrocene, 1,1′-dimethyl ferrocene, or benzoyl ferrocene in a range of about 10 to 100 percent by weight or about 60 to 80 percent by weight and the cerous compound or mixture of compounds in a range of about 10 to 100 percent by weight or about 20 to 40 percent by weight. The combustion modifier can also include at least one of n-butyl ferrocene, 1,1′-dimethyl ferrocene, or benzoyl ferrocene in a range of about 15 to 85, about 35 to 75, or about 65 to 75 percent by weight and the cerous compound or mixture of compounds in a range of about 15 to 85, about 25 to 65, or about 25 to 35 percent by weight. The combustion rate and combustion efficiency are most improved when the combustion modifier contains about 70 percent by weight of at least one of n-butyl ferrocene, 1,1′-dimethyl ferrocene, or benzoyl ferrocene and about 30 percent by weight cerous compound or compounds.

In another embodiment, the combustion modifier can include a mixture of cerium-2-ethylhexanoate and diborylated ferrocene. In this embodiment, the combustion modifier may include diborylated ferrocene in a range of about 10 to 100 percent by weight or about 60 to 80 percent by weight and cerium-2-ethylhexanoate in a range of about 10 to 100 percent by weight or about 20 to 40 percent by weight. The combustion modifier can also include diborylated ferrocene in a range of about 15 to 85, about 35 to 75, or about 65 to 75 percent by weight and cerium-2-ethylhexanoate in a range of about 15 to 85, about 25 to 65, or about 25 to 35 percent by weight. The combustion rate and combustion efficiency are most improved when the combustion modifier contains about 70 percent by weight diborylated ferrocene and about 30 percent by weight cerium-2-ethylhexanoate.

In a preferred embodiment, the combustion modifier can be a mixture of diborylated ferrocene and cerium octoate. In this embodiment, the combustion modifier may include diborylated ferrocene in a range of about 10 to 100 percent by weight or about 60 to 80 percent by weight and cerium octoate in a range of about 10 to 100 percent by weight or about 20 to 40 percent by weight. The combustion modifier can also include diborylated ferrocene in a range of about 15 to 85, about 35 to 75, or about 65 to 75 percent by weight and cerium octoate in a range of about 15 to 85, about 25 to 65, or about 25 to 35 percent by weight. The combustion rate and combustion efficiency are most improved when the combustion modifier contains about 70 percent by weight diborylated ferrocene and about 30 percent by weight cerium octoate. This embodiment of the composition is preferred because of the high combustion efficiency and combustion rate achieved by use of the combustion modifier during testing.

In the most preferred embodiments, the combustion modifier can be a mixture of diborylated ferrocene and cerium ammoniate or a mixture of diborylated ferrocene and cerium ureate. The mixtures of compounds contained in these embodiments of the composition may reduce nitrogen oxide emissions produced by combustion of the fuel. These embodiments of the composition are most preferred because, during testing, these embodiments of the combustion modifier achieved the highest combustion efficiency and combustion rates. The combustion modifier may include diborylated ferrocene in a range of about 10 to 100 percent by weight or about 60 to 80 percent by weight and either cerium ammoniate or cerium ureate in a range of about 10 to 100 percent by weight or about 20 to 40 percent by weight. The combustion rate and combustion efficiency are most improved when the combustion modifier contains about 70 percent by weight diborylated ferrocene and about 30 percent by weight cerium ammoniate or cerium ureate. In other embodiments, the combustion modifier may include diborylated ferrocene in a range of about 15 to 85, about 40 to 60, about 35 to 75, or about 65 to 75 percent by weight with the remainder of the composition including either cerium ammoniate or cerium ureate in a range of about 15 to 85, about 40 to 60, about 25 to 65, or about 25 to 35 percent by weight.

In an alternate embodiment of the invention, the combustion modifier can include a mixture of diborylated ferrocene and both cerium ammoniate and cerium ureate. In this embodiment, the combustion modifier can include diborylated ferrocene in a range of about 10 to 100 percent by weight or about 60 to 80 percent by weight and a mixture of both cerium ammoniate and cerium ureate in a range of about 10 to 100 percent by weight or about 20 to 40 percent by weight. The mixture of cerium ammoniate and cerium ureate may contain cerium ammoniate in a range of about 0.001 to 99.999 percent by weight and cerium ureate in a range of about 0.001 to 99.999 percent by weight. In other embodiments, the combustion modifier can include diborylated ferrocene in a range of about 15 to 85, about 40 to 60, about 35 to 75, or about 65 to 75 percent by weight with the remainder of the composition including a mixture of both cerium ammoniate and cerium ureate in a range of about 15 to 85, about 40 to 60, about 25 to 65, or about 25 to 35 percent by weight. The combustion rate and combustion efficiency are most improved when the combustion modifier contains about 70 percent by weight diborylated ferrocene and about 30 percent by weight of the mixture of cerium ammoniate and cerium ureate.

Hydrocarbon fuels with which the combustion modifier can be mixed include, for example, (1) petroleum-derived fossil fuels such as gasoline, diesel, jet fuel, fuel oil, and kerosene; (2) biofuels such as bioethanol, biodiesel, straight vegetable oils (pure plant oils), and waste vegetable oils; and (3) combinations thereof.

The combustion modifier may be a solid in the form of a pill, caplet, tablet, powder, bar, block, or amorphous form. The combustion modifier may also be manufactured as a liquid or gel. In one embodiment, the combustion modifier can be manufactured to include nanophase particles of the organometallic soap.

To produce the combustion modifier as a liquid, the organometallic soap can be dissolved in a solvent blend comprising Solvent 142, dibasic ester, and propylene glycol mono-n-butyl ether. Solvent 142 is a heavy hydrotreated petroleum with a flashpoint above 142 degrees Fahrenheit, which includes a mixture of predominantly aliphatic hydrocarbons (for example, paraffins and cycloparaffins) having hydrocarbon chain lengths predominantly in the range of C9 through C12. In other embodiments, the solvent blend may include about 0.1 to 10, about 3 to 7, about 3.5 to 5, or about 4 to 6 percent by weight organometallic soap; about 70 to 90, about 75 to 85, about 77 to 83, or about 80 to 82 percent by weight Solvent 142; about 5 to 15, about 7 to 11, or about 8.5 to 10 percent by weight dibasic ester; and about 1 to 10, about 4 to 6, or about 4.5 to 5.5 percent by weight propylene glycol mono-n-butyl ether. In another embodiment, the solvent blend may include about 2 to 8 percent by weight organometallic soap, about 73 to 89 percent by weight Solvent 142, about 6 to 12 percent by weight dibasic ester, and about 3 to 7 percent by weight propylene glycol mono-n-butyl ether. In an exemplary embodiment, the blend may include about 4 percent by weight organometallic soap, about 81 percent by weight Solvent 142, about 10 percent by weight dibasic ester, and about 5 percent by weight propylene glycol mono-n-butyl ether.

When produced in tablet form, the active ingredients of the combustion modifier compositions may be added to a benign hydrocarbon carrier such as biphenyl, naphthol, beta naphthol, naphthol-2, beta-binaphthol, dicyclopentadiene, or combinations thereof. In exemplary embodiments, the combustion modifiers can contain either beta-binaphthol, dicyclopentadiene, combinations of these two carriers, or either or both of these carriers in combination with biphenyl, naphthol, beta naphthol, naphthol-2, beta-binaphthol, dicyclopentadiene, or mixtures thereof.

The carrier solvent of the combustion modifiers described herein can also be diphenyl carbonate, dimethyl carbonate, or combinations thereof.

In another embodiment, the composition for improving the combustion efficiency of an internal combustion engine in combusting hydrocarbon fuels can include a hydrocarbon fuel, a hydrocarbon carrier, and a combustion modifier. The combustion modifier can be the reaction product of 1,1′-bis(ethenyl-4-pyridyl)-ferrocene and -1,1′-binaphthol. The hydrocarbon carrier can be a compound selected from among one or more of the following: biphenyl, naphthol, beta naphthol, naphthol-2, beta-binaphthol, dicyclopentadiene, beta-binaphthol, dicyclopentadiene, and combinations thereof. In exemplary embodiments, the hydrocarbon carrier can be beta-binaphthol, dicyclopentadiene, or combinations thereof.

Method for Making

The invention features methods for making a combustion modifier that can be introduced into a fuel tank feeding an internal combustion engine to improve the efficiency of fuel combustion in the internal combustion engine. In one step of the method, cerium can be mixed and reacted with a synthetic mono-carboxylic acid and with a salt or ester of a second acid, e.g., 2-ethylhexanoic acid, octoic acid, stearic acid, naphthenic acid, salicylic acid, carbonic acid, or nitric acid. Other cerium-containing compounds can be substituted for the elemental cerium for reaction with the mono-carboxylic acid. Other acids and acid blends, including natural mono-carboxylic acids, can also be used to produce less effective combustion modifier compositions.

In another embodiment, a salt of ammonia or urea or an ester of ammonia or urea may be substituted in place of the salt or ester of the second acid.

In another embodiment of the method, the second acid, e.g., 2-ethylhexanoic acid, may itself be reacted with cerium in place of the salt or ester of the second acid. In this embodiment, if the second acid utilized for the reaction with cerium is a carboxylic acid, such as 2-ethylhexanoic acid, octoic acid, stearic acid, naphthenic acid, or salicylic acid, the addition of a mono-carboxylic acid is not required.

The cerium-containing compound and acid are heated and mixed in a reactor to form a mixture that may include any of the following cerous organometallic soap compounds: cerium-2-ethylhexanoate, cerium octoate, cerium stearate, cerium naphthenate, cerium salicylate, cerium carbonate, cerium ammoniate, cerium ureate, cerium nitrate, and combinations thereof.

In another step of the method, a ferric compound (e.g., ferric octoate, ferric-2-ethylhexanoate, ferric stearate, ferric naphthenate, ferric salicylate, ferric carbonate, diborylated ferrocene, n-butyl ferrocene, 1,1′-dimethyl ferrocene, benzoyl ferrocene, or combinations thereof) can be added to the mixture.

In another step of the method, the mixture is placed under a pressure of about 20 inches of mercury (e.g., 15, 18, 19, 19.5, 19.9, 20, 20.1, 20.5, 21, 22, or 25 inches of mercury) while heat continues to be applied. Then, the mixture is placed under a pressure of about 30 inches of mercury (e.g., 25, 28, 29, 29.5, 29.9, 29.92, 30, 30.1, 30.5, 31, 32, or 35 inches of mercury) while continuing to be heated.

In another step of the method, the mixture undergoes cooling to yield a first mixture.

In another step of the method, a second mixture can be blended from at least two dicarboxylic acids.

In another step of the method, the dicarboxylic acids of the second mixture can be mixed with an alcohol to form a third mixture.

In another step of the method, the third mixture can be heated to produce a fourth mixture that features dicarboxylic acid esters.

In a final step of the method, the first mixture and the fourth mixture can be mixed with glycol ether and a solvent to produce a composition. The composition can be used as a combustion modifying fuel additive, as a lubricant, or as both.

Methods for Using

The invention also features methods for improving the efficiency of fuel combustion in an internal combustion engine. In one embodiment of the method, one or more of the fuel additive compositions described herein is introduced into a fuel tank feeding an internal combustion engine. In an exemplary embodiment of the method, the fuel additive is introduced into the fuel tank of the internal combustion engine through a fuel line.

In another embodiment of the method, the fuel additive may be premixed with the hydrocarbon fuel and subsequently introduced into the fuel tank of the internal combustion engine. In another embodiment of the method, the fuel additive may be introduced into the fuel tank, directly into the combustion chamber, or into both the fuel tank and combustion chamber using a pump or another suitable system for supplying the fuel additive into the internal combustion engine.

The internal combustion engine into which the fuel additive is introduced can be a reciprocating engine (e.g., a diesel engine, a two-stroke engine, a four-stroke engine, a five-stroke engine, a six-stroke engine, a crude oil engine, a hot bulb engine, a controlled combustion engine, or a Bourke engine), a rotary engine (e.g., a Wankel engine), or a continuous combustion engine (e.g., a gas turbine, a jet engine, or a rocket engine). The internal combustion engine may use any suitable form of combustion such as homogeneous charge spark ignition, stratified charge compression ignition, or homogeneous charge compression ignition. In one embodiment, the fuel tank into which the composition is introduced may be part of a vehicle such as an automobile, a truck, a motorcycle, an aircraft, a personal watercraft, a boat, a bus, an all-terrain vehicle (ATV), a motorized go-cart, a motorized bicycle, a tractor, a lawn mower, a locomotive, an engineering vehicle, or a scooter. In another embodiment the fuel tank into which the composition is introduced can be part of a generator.

In one embodiment of the method, the fuel additive can be supplied into the fuel tank in an amount of about 0.01 to 5 grams (e.g., 0.01, 0.05, 0.1, 0.5, 1, 1.5, 2, 3, 4, 4.9, 5, or 5.5 grams) per about 20 gallons of fuel.

In an exemplary embodiment of the method, the fuel additive is supplied into the fuel tank in an amount of about 0.01 to 3 grams (e.g., 0.01, 0.05, 0.1, 0.5, 1, 1.5, 2, 2.9, 3, or 3.5 grams) per about 20 gallons of fuel.

In a preferred embodiment of the method, the fuel additive is supplied into the fuel tank in an amount of about 0.25 to 1 gram (e.g., 0.1, 0.3, 0.5, 0.9, 1, 1.1, or 1.5 grams) per about 20 gallons of fuel.

Example 3

By adding the combustion modifying fuel additive to the fuel in an automobile or other vehicle's internal combustion engine, the combustion efficiency of that internal combustion engine may be significantly improved. During testing, diesel fuel was combusted in an internal combustion engine first without the introduction of the combustion modifier (the control test shown in FIGS. 1A and 1B) and then with the introduction of the combustion modifier (the experimental test shown in FIGS. 2A and 2B). The combustion modifier used in the experimental test was a mixture of 70 percent by weight diborylated ferrocene and 30 percent by weight cerium-2-ethylhexanoate. The fuel pounds per hour combusted by the internal combustion engine was measured and the air/fuel ratio was calculated from the amounts of air and fuel used in a given time period. The internal combustion engine was operated at the same horsepower during both tests and measurements were taken at intervals of about one to two minutes.

In the control test, diesel fuel was burned in an internal combustion engine in the absence of the combustion modifier. Approximately 10.8 to 11.1 fuel pounds per hour of diesel fuel were combusted by the internal combustion engine in the absence of the combustion modifier. The air/fuel ratio for the control test fell within a range of about 52 to about 54.

In the experimental test, the combustion modifier was added to diesel fuel supplied to an internal combustion engine and the fuel pounds per hour was measured and the air/fuel ratio calculated. As shown in FIGS. 1A and 1B, approximately 6.0 to 6.3 fuel pounds per hour were combusted by the internal combustion engine to which the combustion modifier was supplied. The air/fuel ratio in this experimental test fell within a range of about 99 to about 105. The amount of fuel combusted by the internal combustion engine in the presence of the combustion modifier was about 40 percent less than the amount of fuel combusted by the engine during the control test.

In another method of use, one or more of the fuel additive compositions described herein can be used as a lubricant to lubricate two or more parts in frictional contact such as, for example, the moving metal parts of an internal combustion engine. In this usage, the composition acts as a lubricating oil.

Other Embodiments

It is to be understood that while the invention has been described in conjunction with the detailed description thereof, the foregoing description is intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims. Other aspects, advantages, and modifications are within the scope of the following claims.

Claims

1. A composition for improving engine performance comprising:

a mixture of esters;

glycol ether; and

a solvent.

2. The composition of claim 1, wherein the mixture of esters comprises at least two esters selected from the group consisting of: adipate esters, azelate esters, dodecanedioate esters, sebacate esters, and phthalate esters.

3. The composition of claim 1, wherein the mixture of esters comprises at least two adipate esters.

4. The composition of claim 3, wherein the at least two adipate esters comprises an adipic acid ester, a glutaric acid ester, and a succinic acid ester.

5. The composition of claim 1, wherein the mixture of esters comprises dimethyl adipate, dimethyl gluctorate, and dimethyl succinate.

6. The composition of claim 1, further comprising a smoke suppressant, wherein the smoke suppressant comprises an organometallic soap.

7. A composition for improving the combustion efficiency of an internal combustion engine in combusting hydrocarbon fuels, the composition comprising:

a hydrocarbon fuel and a combustion modifier, the combustion modifier comprising an organometallic soap.

8. The composition of claim 7, wherein the organometallic soap is selected from the group consisting of: cerium-2-ethylhexanoate, cerium octoate, cerium stearate, cerium naphthenate, cerium salicylate, cerium carbonate, cerium ammoniate, cerium ureate, cerium nitrate, ferric octoate, ferric-2-ethylhexanoate, ferric stearate, ferric naphthenate, ferric salicylate, ferric carbonate, diborylated ferrocene, n-butyl ferrocene, 1,1′-dimethyl ferrocene, benzoyl ferrocene, iron (III) oxide (Fe2O3), iron (II, III) oxide (Fe3O4), and combinations thereof.

9. The composition of claim 7, wherein the organometallic soap comprises a compound selected from the group consisting of: cerium octoate, cerium ammoniate, cerium ureate, and cerium-2-ethylhexanoate.

10. The composition of claim 7, wherein the organometallic soap comprises diborylated ferrocene.

11. The composition of claim 7, wherein the organometallic soap comprises the reaction product of 1,1′-bis(ethenyl-4-pyridyl)-ferrocene and -1,1′-binaphthol.

12. The composition of claim 7, wherein the organometallic soap comprises a mixture of diborylated ferrocene and a compound selected from the group consisting of: cerium-2-ethylhexanoate and cerium octoate.

13. The composition of claim 7, wherein the organometallic soap comprises a mixture of diborylated ferrocene and a compound selected from the group consisting of: cerium ammoniate and cerium ureate.

14. The composition of claim 7, wherein the composition further comprises a hydrocarbon fuel.

15. The composition of claim 7, wherein the smoke suppressant comprises an iron salt.

16. A composition for improving the combustion efficiency of an internal combustion engine in combusting hydrocarbon fuels, the composition comprising:

a hydrocarbon fuel, a hydrocarbon carrier, and a combustion modifier, the combustion modifier comprising the reaction product of 1,1′-bis(ethenyl-4-pyridyl)-ferrocene and -1,1′-binaphthol.

17. The composition of claim 16, wherein the hydrocarbon carrier comprises a compound selected from among one or more of the group consisting of: biphenyl, naphthol, beta naphthol, naphthol-2, beta-binaphthol, dicyclopentadiene, beta-binaphthol, dicyclopentadiene, and combinations thereof.

18. The composition of claim 17, wherein the hydrocarbon carrier comprises beta-binaphthol.

19. The composition of claim 17, wherein the hydrocarbon carrier comprises dicyclopentadiene.

20. A method comprising the step of:

introducing into an internal combustion engine a hydrocarbon fuel and a fuel additive, the fuel additive comprising: a mixture of esters; glycol ether; and a solvent.

21. The method of claim 20, wherein the mixture of esters comprises at least two adipate esters, and wherein the at least two adipate esters comprises at least two of the following: an adipic acid ester, a glutaric acid ester, or a succinic acid ester.

22. A method of reducing friction between moving parts comprising:

lubricating the at least two parts that are in frictional contact with a lubricant, the lubricant comprising: a mixture of esters, glycol ether, and a solvent.

23. The method of claim 22, wherein the at least two parts comprise metal parts.

24. The method of claim 23, wherein the metal parts comprise parts of an internal combustion engine.