BIODIESEL FUEL MIXTURES

Provided herein are biodiesel fuel mixtures having improved properties for reducing NOx emissions as well as total particular matter emissions, CO emissions, and total hydrocarbon emissions.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 120 as a continuation of U.S. patent application Ser. No. 16/050,872, titled “BIODIESEL FUEL MIXTURES,” filed Jul. 31, 2018 that claims the benefit of U.S. Provisional Application No. 62/539,027, filed Jul. 31, 2017, the entire contents of the aforementioned applications being incorporated herein by reference in their entireties.

BACKGROUND

Biodiesel, an alternative diesel fuel created from the esterification of fats and fatty acids, continues to gain significant interest as a renewable energy source. The biodiesel market is expected to reach 6,453 million liters in the U.S. by 2020 and 45,291 million liters globally. See GlobalData, Global Biodiesel Market Analysis and Forecasts to 2020, Accessed May 26, 2012 and Fuel Processing Technology 106 (2013) 526-532. Biodiesel is an attractive alternative fuel source worldwide because it operates in conventional engines, does not require special storage, has less odor offensive exhaust, and has a higher flash point, thereby making it a safer energy source than conventional diesel fuel.

Despite these advantages, a major impediment to the wide-spread committed use of biodiesel has been the observed increase in NOx emissions. For example, for 100% biodiesel, NOx emissions can increase by 13% or more. See Ener Conver and Manag, 50, (2009), 14-34. Excessive NOx emission causes smog, ground level ozone, and acid rain. See Journal of Scientific & Industrial Industry Research, Vol. 73, March 2014, 177-180. This is a significant drawback, particularly since governmental agencies continue to impose new legislation on “cleaner air” and mandate higher emission standards for motor vehicles. Thus, a rising concern is that biodiesel may not be able to meet these heightened requirements.

The need therefore remains for biodiesel fuels which do not negatively impact NOx emission, as well as other criteria pollutants such as particulate matter, total hydrocarbons and carbon monoxide.

SUMMARY

Provided herein are biodiesel fuel mixtures comprising a first biodiesel fuel, a second biodiesel fuel, a base petroleum diesel fuel, and an additive. The disclosed biodiesel fuel mixtures comprise a cetane number of 45 to 70 and have no negative impact on NOx emissions. Indeed, the disclosed mixtures decrease NOx emission by 1 to 7%. See e.g., Table 12. The disclosed mixtures also decrease total particular matter emissions, CO emissions, and total hydrocarbon emissions. See e.g., Table 12.

Process for manufacturing the disclosed biodiesel fuel mixtures are also provided.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a graphic representation of torque and speed commands for the transient cycle for heavy-duty engines.

FIG. 2 is a schematic of sampling system used for transient emission measurements.

FIG. 3 shows the engine performance maps for screening tests.

FIG. 4 shows the engine performance maps for screening tests at 3000 ppm additive.

FIG. 5 shows the engine performance maps for screening tests at 2000 ppm additive.

FIG. 6 illustrates additive concentration vs. NOx results.

FIG. 7 shows a comparison of B20 blends.

FIG. 8 shows a comparison of B20 blends with 3000 ppm A1

FIG. 9 shows a comparison of B20 blends with 3000 ppm additive.

 DETAILED DESCRIPTION

In a first embodiment, provided herein are biodiesel fuel mixtures comprising a first biodiesel fuel, a second biodiesel fuel, a base petroleum diesel fuel, and an additive, wherein the biodiesel fuel mixture has a cetane number of 45 to 70.

In a second embodiment, provided herein are biodiesel fuel mixtures comprising from 5 wt. % to 20 wt. % of at least one biodiesel; from 80 wt. % to 95 wt. % of a base petroleum diesel fuel; and an additive, wherein the biodiesel fuel mixture has a cetane number of 45 to 70.

1. Definitions

The term “biodiesel” means a fuel derived from vegetable oils or animal fats. Biodiesel includes fuels comprising mono-alkyl esters of long-chain fatty acids derived from the transesterification of fats obtained from vegetable oils or other fatty acids such as animal fats or waste cooking oils as well as fuel resulting from hydrotreating vegetable oils, animal fats or mono-alkyl esters of long-chain fatty acids. In one aspect, the biodiesel used herein comprises fatty acid methyl esters (FAMEs) derived from the transesterification of vegetable oil with methanol.

“Petroleum diesel fuel” and “base petroleum diesel fuel” are used interchangeably and refer to a combustible petroleum distillate used as fuel for diesel engines. Petroleum diesel fuel is typically formed from the fractional distillation of crude oil between 200 ° C. and 350 ° C. at atmospheric pressure, resulting in a mixture of carbon chains comprising between 8 and 21 carbon atoms per molecule.

The term “no negative impact” as in, wherein the mixture has no negative impact on NOx emissions, means that there is no statistically significant increase in the amount of NOx emission using the disclosed biodiesel fuel mixture when compared to petroleum diesel fuel in the same engine. Statistical significance is based from the known one-sided Student's t-statistics as set for in Snedecor and Cochran, Statistical Methods (7th edition). Pg 91, Iowa State University Press, 1980, e.g., a cut-off value of 0.5 or less.

2. Fuel Mixtures

In a third embodiment, the additive in the biodiesel fuel mixtures described herein is present in an amount of 0.050 to 0.400 vol. %, 0.060 to 0.350 vol. %, 0.070 to 0.320 vol. %, 0.075 to 0.300 vol. %, 0.075 vol. %, 0.150 vol. %, 0.225 vol. %, or 0.300 vol. %, wherein the remaining features are as described above in the first or second embodiment.

In a fourth embodiment, the at least one biodiesel in the fuel mixtures described herein is present in an amount of 5 wt. %, 10 wt. %, 15 wt. %, or 20 wt. %, wherein the remaining features are as described above in the first, second, or third embodiment.

In a fifth embodiment, the base petroleum diesel fuel in the fuel mixtures described is present in an amount of 80 wt. %, 85 wt. %, 90 wt. %, or 95 wt. %, wherein the remaining features are as described above in the first, second, third, or fourth embodiment.

In a sixth embodiment, the at least one biodiesel is a mixture of 12-15 wt. % of a first biodiesel fuel and 6-8 wt. % of a second biodiesel fuel, wherein the remaining features are as described above in the first, second, third, fourth, or fifth embodiment.

In a seventh embodiment, the biodiesel fuel mixtures described herein have a cetane number of 45 to 65, wherein the remaining features are as described above in the first, second, third, fourth, fifth, or sixth embodiment. Alternatively, the biodiesel fuel mixtures described herein have a cetane number of 45 to 60, 45 to 55, 55 to 65, 50 to 60, 48 to 51, or 58 to 60, wherein the remaining features are as described above in the first, second, third, fourth, fifth, or sixth embodiment.

In an eighth embodiment, the biodiesel fuel mixtures described herein comprise 25% or less of aromatics by volume, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, or seventh embodiment. Alternatively, the biodiesel fuel mixture described herein comprise 20% or less of aromatics by volume, 15% or less of aromatics by volume, 12% or less of aromatics by volume, 10% or less of aromatics by volume, or 20% to 25% aromatics by volume, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, or seventh embodiment.

In a ninth embodiment, the biodiesel fuel mixtures described herein comprise less than 7% polycyclic aromatics by weight, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, or eighth embodiment. Alternatively, the biodiesel fuel mixtures described herein comprise less than 5% polycyclic aromatics by weight or 4.5% to 5.5% polycyclic aromatics by weight, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, or eighth embodiment.

In a tenth embodiment, the weight ratio of total aromatics to polycyclic aromatics in the biodiesel fuel mixtures described herein is 5:1, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, or ninth embodiment. Alternatively, the weight ratio of total aromatics to polycyclic aromatics in the biodiesel fuel mixtures described herein is 4:1, 3:1, or 2:1, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, or ninth embodiment.

In an eleventh embodiment, the sulfur content in the biodiesel fuel mixtures described herein is less than 15 ppm, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, or tenth embodiment. Alternatively, the sulfur content in the biodiesel fuel mixtures described herein is less than 10 ppm, less than 5 ppm, less than 1.0 ppm, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, or tenth embodiment.

In a twelfth embodiment, the nitrogen content in the biodiesel fuel mixtures described herein is from 0 to about 800 ppm, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, or eleventh embodiment. Alternatively, the nitrogen content in the biodiesel fuel mixtures described herein is from 50 ppm to about 600 ppm, from about 100 to about 400 ppm, from about 200 to about 800 ppm, from about 10 to about 600 ppm, and from about 250 to about 300 ppm, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, or eleventh embodiment.

In a thirteenth embodiment, the fatty acid methyl ester content in the biodiesel fuel mixtures described herein is 15 to 25% or 19 to 21%, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, or twelfth embodiment.

In a fourteenth embodiment, the viscosity at 40° C. in the biodiesel fuel mixtures described herein is 1.9 to 4.1 centistokes, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, or thirteenth embodiment.

In a fifteenth embodiment, the additive in the biodiesel fuel mixtures described herein is present in an amount of 500, 1000, 1500, 2000, 2500, 3000, 3300, 4000, 5000, 6000, 7000, 8000, 9000 or 10,000 ppm, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth, or fourteenth embodiment. Alternatively, the additive is present in an amount of 3300 ppm or 3000 ppm, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth, or fourteenth embodiment.

In a sixteenth embodiment, the additive in the biodiesel fuel mixtures described herein is selected from an amine-based antioxidant, a phenol-based antioxidant, or a nitrated alkyl-based antioxidant, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth, fourteenth, or fifteenth embodiment. Alternatively, the additive is selected from 2-ethylhexyl nitrate (2-EHN); di-tert-butyl peroxide (DTBP); tertiary butylhydroquinone (TBHQ); N,N-di-sec-butyl-1,4-phenylenediamine (DTBP), N,N′-diphenyl-1,4-phenylenediamine (DPPD); and N-phenyl-1,4-phenylenediamine (NPPD), wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth, fourteenth, or fifteenth embodiment. In another alternative, the additive is 2-ethylhexyl nitrate, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth, fourteenth, or fifteenth embodiment.

In a seventeenth embodiment, the biodiesel fuel mixtures described herein have no negative impact on NOx emissions, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth, fourteenth, fifteenth, or sixteenth embodiment.

In an eighteenth embodiment, the biodiesel fuel mixtures described herein decrease NOx emissions of an engine by 1 to 7%, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth, fourteenth, fifteenth, sixteenth, or seventeenth embodiment. Alternatively, the biodiesel fuel mixtures described herein decrease NOx emissions of an engine by 2 to 7%; by 3 to 7%; or by 5 to 7%, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth, fourteenth, fifteenth, sixteenth, or seventeenth embodiment. In one alternative, the biodiesel fuel mixtures described herein comprise NOx emissions equivalent to those of a reference fuel having the following specifications: sulfur (15 ppm maximum), aromatics (10 vol % maximum), polycyclic aromatics (10 wt % maximum), nitrogen (10 ppm maximum), unadditized cetane number (48 minimum), API gravity (33-39), flash point (130° F. minimum), viscosity @40° C., cSt (2.0-4.12), IBP (340 to 420° F.), 10% (400 to 490° F.), 50% (470 to 560° F.), 90% (550 to 610° F.), and EP (580 to 660° F.).

In a nineteenth embodiment, the biodiesel fuel mixtures described herein decrease total particular matter emissions of an engine by 20 to 25%, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth, fourteenth, fifteenth, sixteenth, seventeenth, or eighteenth embodiment.

In a twentieth embodiment, the biodiesel fuel mixtures described herein decrease CO emissions of an engine by 15 to 25%, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth, fourteenth, fifteenth, sixteenth, seventeenth, eighteenth, or nineteenth embodiment.

In a twenty-first embodiment, the biodiesel fuel mixtures described herein decrease total hydrocarbon emissions of an engine by 15 to 25%, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth, fourteenth, fifteenth, sixteenth, seventeenth, eighteenth, nineteenth, or twentieth embodiment.

In a twenty-second embodiment, the engine used to test the properties of the biodiesel fuel mixtures described herein is a diesel engine such as a Detroit Diesel Corporation Series 60 heavy duty diesel engine or a Cummins ISM 370 diesel engine, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth, fourteenth, fifteenth, sixteenth, seventeenth, eighteenth, nineteenth, or twenty-first embodiment.

In a twenty-third embodiment, the biodiesel fuel mixtures, and accompanying properties and features are as described below in the exemplification section, wherein the remaining features are as described above in the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, thirteenth, fourteenth, fifteenth, sixteenth, seventeenth, eighteenth, nineteenth, twenty-first, or twenty-second embodiment.

EXEMPLIFICATION

The following starting fuels and additives were blended at various concentrations. Table 1 provides codes for the six additives and Table 2 lists the fuel codes corresponding to each fuel blend and the concentrations.

TABLE 1 Component % Additive Code 2-EHN DTBP PDA A1, A7 100 0 0 A2 91 0 9 A3 91 9 0 A4 0 100 0 A5 82 9 9 A6 0 0 100

TABLE 2 Concentration, %a Fuel Base Code Fuel Biodiesel 1 Biodiesel 2 Biodiesel 3 Additive/Conc. F1 — 100  — — — F2 — — 100  — — F3 — — — 100  — F4 100 — — — — F5 80 13 7 — — F6 80 — — 20 — F7 80 — — 20 3000 F8 80 13 7 — 3000 F9 80 13 7 — 1000 F10 80 13 7 — 2000 F11 80 13 7 — 1500 F12 80 13 7 —  3300b F13 80 13 7 —  3300c F14 80 13 7 — 2500 aConcentrations for fuel in percentage, concentration for additive in ppm, additive A1 1000 unless indicated bAdditive A3 cAdditive A2

Fuel blends were tested using procedures similar to the one outlined in Title 13 California Code of Regulations Section 2882 “Aromatic Hydrocarbon Content of Diesel Fuel.” The actual screening plan is shown in Table 3. For screening, Alternative 3 was the Title 13 protocol selected. For the first two days of testing, duplicate tests with only a single “prep” were used to quickly move through a large number of fuels. After the first day of testing, the B100 blend with F1 (35 percent) and F2 (65 percent) was selected as the B100 for all subsequent testing. On the final two days of testing, the Alternative 3 procedure was followed to screen a 3000 ppm and 2000 ppm additive, respectively. The test results are reported below in Table 3.

The heavy-duty EPA transient cycle is described by means of percent of maximum torque and percent of rated speed for each one-second interval over a test cycle of 1199 seconds duration. To generate a transient cycle, an engine's full power curve is obtained from an engine speed below curb idle speed to maximum no-load engine speed. Data from this “power curve,” or engine map, are used with the specified speed and load percentages to form a transient cycle. A graphic presentation of the speed and torque commands which constitute a transient cycle is given in FIG. 1 for illustration purposes.

In general, a transient test consists of a cold-start transient cycle and a hot-start transient cycle. The same engine command cycle is used in both cases. For the cold-start, the diesel engine was operated over a “prep” cycle, and then allowed to stand overnight in an ambient soak at a temperature between 68° F. and 86° F. The cold-start transient cycle begins when the engine is cranked for cold start-up. Upon completion of the cold-start transient cycle, the engine is stopped and allowed to stand for 20 minutes. After this hot-soak period, a hot-start cycle begins with engine cranking. In order to determine how well the engine follows the transient command cycle, engine performance was compared to engine command, and several statistics were computed. These computed statistics must be within tolerances specified in the CFR. In addition to statistical parameters, the cycle work actually produced should be between 5 percent above and 15 percent below the work requested by the command cycle. Emissions measurements included total hydrocarbon (THC), carbon monoxide (CO), oxides of nitrogen (NO), carbon dioxide (CO2), and total particulate matter (PM).

TABLE 3 Step Description 1 Install engine. Perform emission instrument calibrations as required. Calibrate torquemeter and check signal conditioning systems. Validate CVS gaseous and particulate sampling systems using propane recovery techniques 2 Change oil and filters. Operate engine for 5 hours with CARB equivalent fuel to break-in the oil, Check engine condition using in-house, low sulfur emissions type fuel, and note fault codes if any. Bring engine oil level to “full”. 3 Perform fuel change procedure to operate on Fuel R (F4). Change filter, purge fuel supply, etc. 4 Warm up engine, and operate at rated speed and load, then check performance. 5 Conduct transient “full-throttle” torque map from low- to high-idle. Compute and store resulting transient command cycle. 6 Run a 20-minute practice or conditioning transient cycle, and adjust dynamometer controls to meet statistical limits for transient cycle operation. 7 Soak the engine for 20-minutes. Run three hot-start transient tests with a 20-minute soak between each. For each individual hot-start test, determine THC, CO, NOx, CO2, and PM. 8 Change fuel to F5. Repeat Steps 6 and 7. Soak the engine for 20- minutes. Run two hot- start transient tests with a 20-minute soak between each. For each individual hot-start test, determine THC, CO, NOx, CO2, and PM. 9 Change fuel to F6. Repeat Steps 6 and 7. Soak the engine for 20- minutes. Run two hot- start transient tests with a 20-minute soak between each. For each individual hot-start test, determine THC, CO, NOx, CO2, and PM. 10 Change fuel to F7. Repeat Steps 6 and 7. Soak the engine for 20- minutes. Run two hot- start transient tests with a 20-minute soak between each. For each individual hot-start test, determine THC, CO, NOx, CO2, and PM. 11 Change fuel to F8. Repeat Steps 6 and 7. Soak the engine for 20- minutes. Run two hot- start transient tests with a 20-minute soak between each. For each individual hot-start test, determine THC, CO, NOx, CO2, and PM. 12 Change fuel to F9. Repeat Steps 6 and 7. Soak the engine for 20- minutes. Run two hot- start transient tests with a 20-minute soak between each. For each individual hot-start test, determine THC, CO, NOx, CO2, and PM. 13 Change fuel to F10. Repeat Steps 6 and 7. Soak the engine for 20- minutes. Run two hot-start transient tests with a 20-minute soak between each. For each individual hot-start test, determine THC, CO, NOx, CO2, and PM. 14 Change fuel to F11. Repeat Steps 6 and 7. Soak the engine for 20- minutes. Run two hot- start transient tests with a 20-minute soak between each. For each individual hot-start test, determine THC, CO, NOx, CO2, and PM. 15 Change fuel to F4. Repeat Steps 6 and 7. Soak the engine for 20- minutes. Run two hot-start transient tests with a 20-minute soak between each. For each individual hot-start test, determine THC, CO, NOx, CO2, and PM. 16 Change fuel to F8. Repeat Steps 6 and 7 except that the fuel filters should be dumped, and the engine should be run for 20 minutes at rated speed and load prior to Step 7. Soak the engine for 20-minutes. Run two hot-start transient tests with a 20-minute soak between each. For each individual hot-start test, determine THC, CO, NOx, CO2, and PM. 17 Change fuel to F13. Repeat Steps 6 and 7 except that the fuel filters should be dumped, and the engine should be run for 20 minutes at rated speed and load prior to Step 7. Soak the engine for 20-minutes. Run two hot-start transient tests with a 20-minute soak between each. For each individual hot-start test, determine THC, CO, NOx, CO2, and PM. 18 Change fuel to F12. Repeat Steps 6 and 7 except that the fuel filters should be dumped, and the engine should be run for 20 minutes at rated speed and load prior to Step 7. Soak the engine for 20-minutes. Run two hot-start transient tests with a 20-minute soak between each. For each individual hot-start test, determine THC, CO, NOx, CO2, and PM. 19 Change fuel to F5. Repeat Steps 6 and 7 except that the fuel filters should be dumped, and the engine should be run for 20 minutes at rated speed and load prior to Step 7. Soak the engine for 20-minutes. Run two hot-start transient tests with a 20-minute soak between each. For each individual hot-start test, determine THC, CO, NOx, CO2, and PM. 20 Change fuel to F14. Repeat Steps 6 and 7 except that the fuel filters should be dumped, and the engine should be run for 20 minutes at rated speed and load prior to Step 7. Soak the engine for 20-minutes. Run two hot-start transient tests with a 20-minute soak between each. For each individual hot-start test, determine THC, CO, NOx, CO2, and PM. 21 Change fuel to F4. Repeat Steps 4 through 8. 22 Change fuel to F8. Repeat Steps 4 through 8. 23 Change fuel to F4. Repeat Steps 4 through 8. 24 Change fuel to F10. Repeat Steps 4 through 8.

For this screening work, a 1991 DDC Series 60 heavy-duty diesel engine was mounted in a transient-capable test cell. This engine had an inline, six cylinder configuration rated for 365 hp at 1800 rpm. It was turbocharged and used a laboratory water-to-air heat exchanger for a charge air intercooler. Table 4 lists the engine specifications and features.

TABLE 4 Engine Parameter Comment Make Detroit Diesel Model Series 60, 6067GU60 Engine Displacement and Configuration 12.7 L, I-6 Emission Family MDD12.7FZAK Rated Power 365 bhp at 1800 rmp Electronic Control Module DDEC-II Aspiration Turbocharged

For emission testing, the exhaust was routed to a full flow constant volume sampler (CVS) that utilized a positive displacement pump (PDP), as illustrated in FIG. 2. Total flow in the tunnel was maintained at a nominal flow rate of about 2000 SCFM. Sample zone probes were connected to the main tunnel. These probes were used to collect samples for total particulate (PM) and for the gaseous emissions: NON, THC, CO, and CO2. The NOx was analyzed using a chemiluminescent (CL) analyzer, the THC used a flame ionization detector (FID), and CO and CO2 was performed using separate non-dispersive infrared (NDIR) detectors. Probes for background gas measurement were connected downstream of the dilution air filter pack, but upstream of the mixing section. Background concentrations were determined for all emissions, and the tunnel THC background was also determined before and after each test. This engine produced emission results less than or equivalent to the standards for that model year. Table 5 compares the 1991 emission standards, the average reference fuel emission results, and the percent of standard for these tests. The engine did not exceed 110 percent of the applicable emission standards for a 1991 model engine.

TABLE 5 Transient Emission, G/HP-HR Test Number THC CO NOx PM 1991 Standard 1.3 15.5 5.0 0.25 Reference Fuel 0.1 2.4 4.5 0.19 % of Standard 7 16 90 75

FIG. 3 shows a graphical representation of the torque map data for the screening tests, and FIGS. 4 and 5 show the torque map data for the tests with 3000 ppm and 2000 ppm of the additive, respectively. Table 6 gives all of the emission results for THC, CO, NOx, PM, and brake specific fuel consumption (BSFC) obtained for each of the tests. This table groups the tests by fuels and additives rather than in the order that the tests were performed. The average, standard deviation, and coefficient of variation for each set of hot-start transient tests are also included for each fuel. FIG. 6 shows the NOx emissions versus additive concentration with trend lines for a possible shift in baseline.

TABLE 6 FUEL TRANSIENT EMISSIONS, g/hp-hr BSFC, WORK, CODE RUN # CO2 CO THC NOX PM lb/hp-hr hp-hr F4 1308 531.7 2.5 0.10 4.521 0.177 0.371 24.61 1309 531.4 2.5 0.10 4.501 0.194 0.371 24.60 1310 531.2 2.5 0.10 4.506 0.192 0.371 24.60 Average 531.4 2.5 0.10 4.509 0.187 0.371 24.61 Std. Dev. 0.247 0.0 0.00 0.010 0.010 0.000 0.002 F4 1340 529.7 2.5 0.09 4.475 0.189 0.370 24.60 1341 530.0 2.5 0.09 4.487 0.185 0.370 24.61 Average 529.9 2.5 0.09 4.481 0.187 0.370 24.60 Std. Dev. 0.232 0.0 0.00 0.008 0.003 0.000 0.002 F4 1362 531.8 2.4 0.08 4.553 0.180 0.371 24.49 1363 532.8 2.4 0.08 4.560 0.180 0.371 24.49 1364 533.4 2.4 0.08 4.565 0.184 0.372 24.49 Average 532.7 2.4 0.08 4.559 0.181 0.372 24.49 Std. Dev. 0.808 0.0 0.00 0.006 0.002 0.000 0.003 F4 1370 529.4 2.5 0.09 4.463 0.184 0.370 24.69 1371 529.6 2.4 0.09 4.474 0.180 0.370 24.69 1372 530.7 2.5 0.09 4.483 0.179 0.371 24.69 Average 530.2 2.5 0.09 4.478 0.180 0.370 24.69 Std. Dev. 0.759 0.1 0.00 0.006 0.001 0.001 0.001 F5 1312 532.0 2.3 0.10 4.601 0.162 0.380 24.57 1213 532.1 2.2 0.10 4.607 0.154 0.380 24.59 Average 532.1 2.3 0.10 4.604 0.158 0.380 24.58 Std. Dev. 0.086 0.1 0.00 0.004 0.005 0.000 0.011 F5 1355 531.0 2.2 0.08 4.595 0.151 0.379 24.55 1356 533.1 2.2 0.08 4.630 0.146 0.381 24.56 Average 532.0 2.2 0.08 4.613 0.148 0.380 24.55 Std. Dev. 1.476 0.0 0.00 0.025 0.003 0.001 0.01 F6 1315 532.1 2.2 0.09 4.622 0.157 0.380 24.57 1316 532.1 2.2 0.09 4.620 0.158 0.380 24.58 Average 532.1 2.2 0.09 4.621 0.157 0.380 24.58 Std. Dev. 0.026 0.0 0.00 0.001 0.001 0.000 0.008 F7 1318 531.3 2.0 0.08 4.420 0.154 0.379 24.61 1319 530.8 2.0 0.08 4.416 0.149 0.379 24.60 Average 531.0 2.0 0.08 4.418 0.151 0.379 24.61 Std. Dev. 0.350 0.0 0.00 0.003 0.004 0.000 0.004 F9 1324 526.1 2.2 0.08 4.390 0.150 0.376 24.63 1325 527.6 2.2 0.08 4.403 0.149 0.377 24.63 Average 526.8 2.2 0.08 4.397 0.149 0.376 24.63 Std. Dev. 1.080 0.0 0.00 0.009 0.000 0.001 0.00 F11 1330 529.4 2.1 0.08 4.419 0.151 0.378 24.60 1331 529.0 2.0 0.08 4.419 0.146 0.378 24.60 Average 529.2 2.1 0.08 4.419 0.148 0.378 24.60 Std. Dev. 0.291 0.1 0.00 0.000 0.004 0.000 0.004 F10 1327 529.2 2.0 0.08 4.405 0.150 0.378 24.60 1328 529.5 2.1 0.08 4.401 0.144 0.378 24.60 Average 529.3 2.1 0.08 4.403 0.147 0.378 24.60 Std. Dev. 0.206 0.1 0.00 0.002 0.004 0.000 0.004 F10 1374 533.2 2.1 0.07 4.449 0.142 0.381 24.68 1375 533.9 2.0 0.07 4.459 0.147 0.381 24.69 1376 533.7 2.1 0.07 4.459 0.149 0.381 24.70 Average 533.6 2.1 0.07 4.455 0.146 0.381 24.69 Std. Dev. 0.362 0.1 0.00 0.006 0.004 0.000 0.012 F14 1358 534.7 2.2 0.07 4.483 0.148 0.382 24.53 1359 534.5 2.1 0.07 4.485 0.146 0.382 24.55 Average 534.6 2.1 0.07 4.484 0.147 0.382 24.54 Std. Dev. 0.104 0.0 0.00 0.001 0.001 0.000 0.012 F8 1321 528.7 2.0 0.08 4.356 0.143 0.377 24.63 1322 529.9 2.0 0.07 4.337 0.143 0.375 24.64 Average 529.3 2.0 0.08 4.347 0.143 0.376 24.64 Std. Dev. 0.865 0.0 0.00 0.013 0.000 0.001 0.009 F8 1346 528.7 2.0 0.08 4.386 0.142 0.378 24.57 1347 529.9 2.0 0.07 4.402 0.143 0.378 24.56 Average 529.3 2.0 0.08 4.394 0.142 0.378 24.56 Std. Dev. 0.865 0.0 0.00 0.012 0.001 0.001 0.009 F8 1366 535.1 2.1 0.07 4.473 0.148 0.382 24.46 1367 534.8 2.0 0.07 4.480 0.147 0.382 24.47 1368 534.8 2.1 0.07 4.472 0.149 0.382 24.48 Average 534.9 2.1 0.07 4.475 0.148 0.382 24.47 Std. Dev. 0.147 0.1 0.00 0.004 0.001 0.000 0.006 F13 1349 531.7 2.0 0.07 4.409 0.150 0.380 24.54 A2 1350 532.5 2.0 0.07 4.415 0.152 0.380 24.55 Average 532.1 2.0 0.07 4.412 0.151 0.380 24.54 Std. Dev. 0.539 0.0 0.00 0.004 0.002 0.000 0.01 F12 1352 528.0 2.1 0.07 4.389 0.152 0.377 24.58 A2 1353 529.2 2.1 0.07 4.411 0.147 0.378 24.59 Average 528.6 2.1 0.07 4.400 0.149 0.378 24.59 Std. Dev. 0.0805 0.0 0.00 0.016 0.004 0.001 0.01

Two different biodiesels were used. F3 was blended at a concentration of 20 percent biodiesel in the base fuel, F4 to make F6. The other B20 (20 percent biodiesel and 80 percent diesel) blend was a combination of F1 at a concentration of 35 percent and F2 at a concentration of 65 percent. See Table 2. The blend of these two biodiesels was then mixed with the base fuel to make a second B20 blend (F5). FIG. 7 compares the emission results for both biodiesels when blended at a concentration of 20 percent biodiesel. F5 produced slightly less NOx than the single component biodiesel blend.

The two B20 blends were then mixed with the additive (A1) at a concentration of 3000 ppm. F8 was the B20 blend with a combination of F1 at a concentration of 35 percent and F2 at a concentration of 65 percent, and F7 was the B20 blend with F6 (See Table 2). FIG. 8 compares the emission results for the two B20 blends with the additive at 3000 ppm. F8 produced slightly less NOx than the single component biodiesel blend.

Two additional additives were blended with F8 at a concentration of 3300 ppm. The two additives were A2 and A3. The fuel codes were F13 and F12, respectively. FIG. 9 compares the emission results for these two additive blends.

Tables 7 and 8 show the statistical approach for comparing the emission results with additive A7 at 3000 ppm and 2000 ppm, respectively. With this approach, the average emissions from the three (3) individual tests with the candidate fuel, Fuel C (Xc), were compared to the average emission results for three (3) individual tests with the reference fuel, Fuel R (XR), by using the one-sided t distribution. The average term for the reference fuel for each emission was adjusted by the tolerance, (1 percent of the average for NOx and 2 percent of the average for CO and PM) and by a value that included: tolerance, δ and pooled standard deviation, Sp.

Square root of two divided by the number of tests, n, for both reference plus candidate (in this case, n=14, to represent the potential result if the entire seven day test protocol was performed) One-sided upper percentage point of t distribution with a=0.15 and 2n-2 degrees of freedom. The equation for this comparison is XC<XR+δ−(Spx √{square root over (2/η)} xt(a, 2n-2)). See CCR Title 13, Chapter 5—Standards for Motor Vehicle Fuels, Article 3 -Specifications for Alternative Motor Vehicle Fuels. Values presented in Table 7 and 8 were based on a spreadsheet calculation. If the average for the candidate fuel is less than the adjusted average for the reference fuel, then the candidate fuel is comparable or better than the reference fuel.

TABLE 7 Statistical Criteria NOx CO PM Number of Test 14 14 14 Points, na C Average, Xcb 4.475 2.081 0.148 R Average, XRb 4.559 2.364 0.181 Tolerance Level, δc 0.046 0.047 0.004 Pooled std. Dev., Spb 0.005 0.048 0.002 Sqrt of 2/n 0.378 0.378 0.378 Student's t, td 1.058 1.058 1.058 Adjusted R Average, 4.603 2.392 0.184 Adj. XRb,e Is Xc < Adj. XR Yes Yes Yes Percent Reduction, r 2.8 13.0 19.7 aFor alternative 4, n = number of tests (plus reference candidate) bUnits are in g/bhp-hr cTolerance level is 1 percent for NOx and 2 percent for CO and PM One-sided student's t for 2n − 2 degrees of freedom and significance level of 0.15 Adj. XR = XR + δ − (Sp × √{square root over (2)}/η × t(a, 2n − 2)) where t(a, 2n − 2) is 1.055

TABLE 8 Statistical Criteria NOx CO PM Number of Test 14 14 14 Points, na C Average, Xcb 4.455 2.090 0.146 R Average, XRb 4.473 2.475 0.181 Tolerance Level, δc 0.045 0.050 0.004 Pooled std. Dev., Spb 0.008 0.072 0.003 Sqrt of 2/n 0.378 0.378 0.378 Student's t, td 1.058 1.058 1.058 Adjusted R Average, 4.515 2.496 0.183 Adj. XRb,e Is Xc < Adj. XR Yes Yes Yes Percent Reduction, r 1.3 16.3 20.4 aFor alternative 4, n = number of tests (plus reference candidate) bUnits are in g/bhp-hr cTolerance level is 1 percent for NOx and 2 percent for CO and PM One-sided student's t for 2n − 2 degrees of freedom and significance level of 0.15 Adj. XR = XR + δ − (Sp × √{square root over (2)}/η × t(a, 2n − 2)) where t(a, 2n − 2) is 1.055

F5 was used in a further blend as follows.

120 gallons of F4 base fuel used as the untreated diesel blend stock were transferred into a clean tote. 30 gallons of F5 and 1703 ml of 2-ethylhexyl nitrate fuel additive were added. The fuel was blended for one hour with an air-actuated stirrer, and a sample was taken for analysis. The fuel properties for the candidate fuel blend are shown in Table 9 together with the properties for base fuel F4. For the fatty acid methyl ester (FAME), the analysis showed that the concentration was 19.8 percent by volume. The resulting treated candidate fuel, Fuel C, was then identified as F15.

TABLE 9 F4 Base Fuel Value F15 Candidate Fuel Value Sulfur, ppm 0.9 Sulfur, ppm 1.56 Nitrogen, ppm 1.7 Nitrogen, ppm 284.4 Cetane number 49.3 Cetane number 59.1 API Gravity 35.8 API Gravity 34.4 Flash Point, ° F. 197.5 (91.8) Flash Point 190 (88) (° C.) Viscosity @ 40° C., 3.00 Viscosity @ 40° C., 3.14 cSt cSt IBP, ° F. 400 IBP, ° F. 409 10%, ° F. 451 10%, ° F. 461 50%, ° F. 490 50%, ° F. 521 90%, ° F. 592 90%, ° F. 629 EP, F. 636 EP, F. 644 FAME Content, % — FAME Content, % 19.8

Fuel tests were performed utilizing Alternative 3 outlined above and in outlined in Title 13 California Code of Regulations Section 2882. Table 10 provides the testing protocol that was used. F4 is referred to as “Fuel R” for Reference Fuel and F15 is referred to as “Fuel C” for Candidate Fuel.

TABLE 10 Step Description 1 Install engine. Perform emission instrument calibrations as required. Calibrate torquemeter and check signal conditioning systems. Validate CVS gaseous and particulate sampling systems using propane recovery techniques 2 Check engine condition using in-house, low sulfur emissions type fuel, and note fault codes if any. Bring engine oil level to “full”. 3 Perform fuel change procedure to operate on Fuel R (F4). Change filter, purge fuel supply, etc. 4 Warm up engine, and operate at rated speed and load, then check performance. 5 Conduct transient “full-throttle” torque map from low- to high-idle. Compute and store resulting transient command cycle. 6 Load dummy sample media, and run a 20-minute practice or conditioning transient cycles, and adjust dynamometer controls to meet statistical limits for transient cycle operation 7 Soak the engine for 20-minutes. Run three hot-start transient tests with a 20-minute soak between each. For each individual hot-start test, determine THC, CO, NOx, CO2, and PM. 8 Perform fuel change, and repeat Steps 3 through 7 with Fuel C. 9 On Day 2 of testing, repeat Steps 4 through 9 starting with Fuel C and ending with Fuel R. 10 On Day 3 of testing, repeat Steps 4 through 9 starting with Fuel R and ending with Fuel C. 11 On Day 4 of testing, repeat Steps 4 through 9 starting with Fuel C and ending with Fuel R 12 On Day 5 of testing, repeat Steps 4 through 9 starting with Fuel R and ending with Fuel C. 13 On Day 6 of testing, repeat Steps 4 through 9 starting with Fuel C and ending with Fuel R. 14 On Day 7 of testing, repeat Steps 4 through 9 starting with Fuel R and ending with Fuel C. 15 Summarize data and prepare the final report.

Table 11 gives the emission results for HC, CO, NOx, PM, and brake specific fuel consumption (BSFC) obtained for each of the tests. The average for each set of triplicate hot start transient tests was also included for each fuel.

TABLE 11 TEST TRANSIENT EMISSIONS, g/hp-hr BSFC, WORK, NUMBER CO2 THC CO NOX PM lb/hp-hr hp-hr R1 538.0 2.437 0.077 4.621 0.183 0.378 24.39 R2 538.1 2.432 0.081 4.620 0.182 0.378 24.39 R3 539.1 2.530 0.083 4.620 0.182 0.378 24.39 Average 538.4 2.466 0.080 4.621 0.183 0.378 24.39 C4 539.6 2.122 0.075 4.540 0.147 0.388 24.35 C5 540.4 2.026 0.071 4.538 0.146 0.389 24.35 C6 540.3 2.026 0.071 4.542 0.148 0.389 24.36 Average 540.1 2.058 0.072 4.540 0.147 0.388 24.35 C7 539.0 2.121 0.070 4.513 0.148 0.388 24.39 C8 539.9 2.061 0.066 4.512 0.149 0.388 24.38 C9 539.5 1.997 0.070 4.523 0.149 0.388 24.38 Average 539.5 2.060 0.069 4.516 0.149 0.388 24.38 R10 539.7 2.485 0.085 4.597 0.188 0.379 24.39 R11 539.9 2.551 0.086 4.600 0.188 0.379 24.38 R12 539.6 2.469 0.087 4.615 0.190 0.379 24.40 Average 539.7 2.502 0.086 4.604 0.189 0.379 24.39 R13 537.1 2.543 0.078 4.567 0.183 0.377 24.41 R14 538.0 2.462 0.079 4.568 0.185 0.378 24.43 R15 538.1 2.438 0.081 4.584 0.184 0.378 24.42 Average 537.7 2.481 0.079 4.573 0.184 0.377 24.42 C16 539.2 2.035 0.068 4.513 0.146 0.388 24.36 C17 538.9 2.059 0.071 4.514 0.149 0.388 24.35 C18 539.9 2.143 0.073 4.526 0.148 0.388 24.35 Average 539.3 2.079 0.071 4.518 0.148 0.388 24.35 C19 532.1 2.045 0.064 4.432 0.129 0.383 24.40 C20 532.9 2.026 0.067 4.436 0.144 0.383 24.40 C21 532.9 2.029 0.069 4.447 0.148 0.383 24.38 Average 532.7 2.033 0.067 4.438 0.141 0.383 24.39 R22 534.6 2.558 0.082 4.553 0.182 0.375 24.38 R23 535.3 2.558 0.085 4.561 0.190 0.376 24.38 R24 535.7 2.496 0.087 4.564 0.186 0.376 24.39 Average 535.2 2.537 0.085 4.559 0.186 0.376 24.38 R25 528.2 2.485 0.077 4.482 0.187 0.371 24.48 R26 529.0 2.564 0.080 4.493 0.187 0.371 24.48 R27 529.3 2.475 0.082 4.502 0.190 0.372 24.48 Average 528.8 2.508 0.080 4.492 0.188 0.371 24.48 C28 532.9 2.155 0.066 4.437 0.151 0.383 24.37 C29 532.9 2.088 0.066 4.440 0.152 0.383 24.37 C30 534.0 2.207 0.068 4.447 0.151 0.384 24.37 Average 533.3 2.150 0.067 4.441 0.151 0.384 24.37

Table 12 shows the statistical approach for comparing the emission results. With this approach, the average for each of the triplicate results from the 21 individual tests with the candidate fuel, Fuel C (Xc), were compared to the average for each of the triplicate results for 21 individual tests with the average reference fuel, Fuel R (XR), by using the calculations describe above with XC<XR+δ−(Spx √{square root over (2/η)} xt(a, 2n-2)).

TABLE 12 Statistical Criteria HC CO NOx PM Number of Test 14 14 14 14 Points, na C Average, Xcb 0.082 2.509 4.540 0.187 R Average, XRb 0.068 2.080 4.463 0.147 Tolerance Level, δc 0.002 0.050 0.045 0.004 Pooled std. Dev., Spb 0.003 0.033 0.065 0.003 Sqrt of 2/n 26 26 26 26 Student's t, td 1.058 1.058 1.058 1.058 Adjusted R Average, 0.082 2.546 4.560 0.189 Adj. XRb,e Is Xc < Adj. XR Yes Yes Yes Yes Percent Reduction, r 17.5 18.3 2.1 22.1 aFor alternative 1, n = number of tests (plus reference candidate) bUnits are in g/bhp-hr cTolerance level is 1 percent for NOx and 2 percent for HC, CO, and PM ddf = 2(n − 1) One-sided student's t for 2n − 2 degrees of freedom and significance level of 0.15 Adj. XR = XR + δ − (Sp × √{square root over (2)}/η × t(a, 2n − 2)) where t(a, 2n − 2) is 1.055

As shown, the candidate fuel was found to decrease the NOx emissions by 2.1 percent when compared to the reference fuel. The PM emissions were decreased by about 22 percent and average HC and CO were lower (17.5 and 18.3 percent lower, respectively).

The contents of all references (including literature references, issued patents, published patent applications, and co-pending patent applications) cited throughout this application are hereby expressly incorporated herein in their entireties by reference. Unless otherwise defined, all technical and scientific terms used herein are accorded the meaning commonly known to one with ordinary skill in the art.

Claims

1. A biodiesel fuel mixture comprising:

from 5 wt. % to 20 wt. % of at least one biodiesel;
from 80 wt. % to 95 wt. % of a base petroleum diesel fuel; and
one or more additives, including_from 0.060 to 0.350 vol. % 2-ethylhexyl nitrate; and
1-20% aromatics by volume;
wherein the amount of 2-ethylhexyl nitrate is sufficient to reduce on average total particulate matter, to cause the fuel mixture to have no negative impact on NOx emissions, and to reduce at least one of CO emissions, total hydrocarbon emissions, or NOx emissions of an engine, said emissions being relative to the emissions from the base petroleum diesel fuel without biodiesel and without 2-ethylhexyl nitrate.

2. The biodiesel fuel mixture of claim 1, wherein none of the one or more additives are classified as outside of a Baseline Category and the biodiesel fuel mixture is classified under the Baseline Diesel category per the United States Environmental Protection Agency regulations as defined in 40 CFR § 79.56(1997).

3. The biofuel mixture of claim 1, wherein the base petroleum diesel fuel has:

a maximum sulfur content of 15 ppm,
a maximum polycylic aromatics content of 10 wt. %,
a maximum nitrogen content of 10 ppm,
a minimum cetane number of 48,
an American Petroleum Institute (API) gravity of 33 to 39,
a minimum flash point of 130 ° F., and
a viscosity @ 40 ° C., cSt of 2.0 to 4.12.

4. The biofuel mixture of claim 3, wherein the base petroleum diesel fuel has a distillation profile comprising the following properties:

an initial boiling point of 340 ° F. to 420 ° F.;
T10% (400 to 490 ° F.);
T50% (470 to 560 ° F.);
T90% (550 to 610 ° F.); and
an end point of (580 to 660 ° F.).

5. The biodiesel fuel mixture of claim 1, wherein the mixture decreases CO emissions of an engine by 15 to 25%.

6. The biodiesel fuel mixture of claim 1, wherein the mixture decreases total hydrocarbon emissions of an engine by 15 to 25%.

7. The biodiesel fuel mixture of claim 1, wherein the mixture decreases NOx emissions of an engine by 1 to 7%.

8. The biodiesel fuel mixture of claim 1, wherein the mixture decreases total particulate matter emissions of an engine by 20 to 25%.

9. The biodiesel fuel mixture of claim 1, wherein the fuel mixture comprises 7.5-20% aromatics by volume.

10. The biodiesel fuel mixture of claim 1, wherein the fuel mixture comprises 9-20% aromatics by volume.

11. The biodiesel fuel mixture of claim 1, wherein none of the one or more additives or the biodiesel fuel mixture are classified under an Atypical category per United States Environmental Protection Agency regulations as defined in 40 CFR § 79.56(1997).

Patent History
Publication number: 20220235287
Type: Application
Filed: Apr 18, 2022
Publication Date: Jul 28, 2022
Inventor: Patrick McDuff (Hull, MA)
Application Number: 17/659,552
Classifications
International Classification: C10L 1/10 (20060101); C10L 10/12 (20060101); C10L 1/04 (20060101); C10L 1/02 (20060101); C10L 10/02 (20060101); C10L 1/223 (20060101); C10L 1/18 (20060101); C10L 1/183 (20060101); C10L 1/23 (20060101);