AU2011289250A1

AU2011289250A1 - Process and apparatus for the preparation of combustible fluid

Info

Publication number: AU2011289250A1
Application number: AU2011289250A
Authority: AU
Inventors: Gary J. Bethurem
Original assignee: Individual
Current assignee: Individual
Priority date: 2010-08-12
Filing date: 2011-08-12
Publication date: 2013-04-04
Also published as: US20120037510A1; CA2812080A1; WO2012021850A1; CN103492614A; EP2603619A1; EP2603619A4

Abstract

A fuel and hydrogen generator includes electrolysis in a first closed vessel containing a bath of water, electrolyte and sufficient liquid hydrocarbon fuel to serve as an oxygen barrier. The hydrogen produced in the first closed vessel is introduced into a second closed vessel having a bath of water, electrolyte and liquid hydrocarbon fuel in an amount volumetrically equal to the water. Electrodes extend through the liquid hydrocarbon fuel to the water to conduct electrolysis. Makeup water and liquid hydrocarbon fuel is supplied to both closed vessels as needed. The bath in the second closed vessel is recirculated to entrain all constituents within the bath and to cool the bath to ambient temperature. Gas is drawn off of the bath in the second closed vessel though vacuum with constituents then fractionally liquefied to create a reformed liquid hydrocarbon fuel and to separate the fuel from the gaseous hydrogen.

Description

WO 2012/021850 PCT/US2011/047662 PROCESS AND APPARATUS FOR THE PREPARATION OF COMBUSTIBLE FLUID BACKGROUND OF THE INVENTION [00011 The field of the present invention is hydrocarbon refining. [0002] Electrolysis of water to generate hydrogen and oxygen is well known. Also known are HHO generators which use electrolysis to transform water into its component parts but not to separate the hydrogen and oxygen once released. Such devices have been employed to directly feed internal combustion engines to improve combustion. In modern engines, oxygen sensors are used to control air fuel mixture as they sense variations in oxygen. Even though the oxygen introduced from an HHO generator is in a stoichiometric ratio with the hydrogen also introduced, the oxygen sensor does not account for the added combustible hydrogen and senses an excess of oxygen. As a result, the tuning of the engine must be amended to account for the introduction of hydrogen with the additional oxygen from such a generator. Further, as a stoichiometric mixture of oxygen and hydrogen is explosive with a threshold input of energy, such generators are typically employed to immediately feed combustion so that the explosive mixture is not accumulated. The HHO supplied to the intake of internal combustion engines for boosting the operation of liquid hydrocarbon fuels is intended to operate in various ways to increase performance, increase efficiency and/or reduce exhaust pollutants. Mixed results have led to further study without yet establishing a compelling need to commercialize such devices. 10003] Hydrocarbon liquid fuels employed in internal combustion engines range broadly with the most conventional fuels being gasoline, diesel and kerosene. These 1 WO 2012/021850 PCT/US20111/047662 liquids are blended hydrocarbons of various molecular weight and configuration. The size and configuration of such molecules can affect burn rate and exhaust products. Additives have been employed to modify those effects. SUMMARY OF THE INVENTION [00041 The present invention is directed to the creation of reformed fuel from liquid hydrocarbon fuel such as gasoline, diesel and kerosene that appears to burn cleaner and provide substantial energy for combustion in an internal combustion engine with a lighter blend of hydrocarbons. [00051 In a first separate aspect of the present invention, a process for the preparation of combustible fluid includes conducting electrolysis in a bath consisting essentially of water, electrolyte and liquid hydrocarbons with removal of the gas from the bath during electrolysis and adding makeup water and liquid hydrocarbons to effect a continuous process. In implementing this process, the volumetric ratio of hydrocarbon fuel to water may range from about 6:1 down to a very small ratio with only a small amount of hydrocarbon fuel to define an oxygen barrier above the water. Different ratios can impact the final blend of resulting hydrocarbon constituents. [00061 In a second separate aspect of the present invention, a process for the preparation of combustible fluid includes conducting electrolysis in a bath consisting essentially of water, electrolyte and liquid hydrocarbons. The process further includes the circulation of the liquid phase to maintain intermediate products in suspension for further processing. The electrolysis contemplates electrodes of opposite polarity extending into the hydrocarbons and to the water in the bath. Both regulation of the voltage across the electrodes and the recirculation may be used to maintain ambient 2 WO 2012/021850 PCT/US2011/047662 temperatures in the bath. Neutral electrodes may additionally be used to match impedance with the power source to gain efficiency. [0007] In a third separate aspect of the present invention, a plurality of baths consisting essentially of water, electrolyte and liquid hydrocarbons are arranged serially with different ratios of liquid hydrocarbon fuel to water. Serial association of the baths are understood to impact the ratio of products derived. [00081 In a fourth separate aspect of the present invention, a fuel generator employs a closed vessel, water, liquid hydrocarbon fuel, electrolyte and electrodes of opposite polarity extending into the hydrocarbons and water in the vessel. The electrolysis causes the transformation of water and liquid hydrocarbon fuel into hydrogen and reformulated fuel. A vacuum pump in communication with the gas space in the closed vessel removes products which can be volatilized without significantly volatilizing the original liquid hydrocarbon fuel. [0009] In a fifth separate aspect of the present invention, any of the foregoing aspects may be combined to greater result. [0010] Accordingly, it is an object of the present invention to provide a novel process for the generation of reformulated hydrocarbon fuel. Other and further objects and advantages will appear hereinafter. 3 WO 2012/021850 PCT/US2011/047662 BRIEF DESCRIPTION OF THE DRAWING [0011] The drawing is a schematic of the process and apparatus of one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [00121 Turning to the schematic, a first closed vessel 10 includes an arrangement of anodes and cathodes 12 in a cavity 14. Neutral electrodes may also be used to match the impedance with the power source to maximize efficiency as may be empirically determined. The electrodes employed in the preferred embodiment are plates 12 of alternating polarity extending across the cavity 14. Stainless steel has been used but more exotic metals are known to increase plate longevity. Electrical feeds 16 conventionally communicate with the electrodes 12. This first closed vessel 10 contains a bath in the cavity 14 consisting essentially of water, electrolyte, and a thin layer of liquid hydrocarbon fuel. The electrolyte may be introduced as potassium hydroxide. The fuel may be any combustible hydrocarbon which would be liquid in the environment of the bath, most typically gasoline, diesel fuel or kerosene. The layer of liquid hydrocarbon fuel is sufficient to form an oxygen barrier above the water. Less than one quarter inch is sufficient in most cases. The electrodes 12 extend through the hydrocarbon layer to the water. 100131 The electrolysis is driven by a power source which may be a battery, 110 AC or other voltage source which is rectified as needed. The system operates well at 19 volts, drawing about 3 amps for the closed vessel 10. The power is subjected to the voltage being pulsed on and off to reduce the generation of heat in the bath. 4 WO 2012/021850 PCT/US2011/047662 [0014] For feedstock, makeup water is introduced through a port 18 and liquid hydrocarbon fuel is made up through a port 20. Gas generated within the closed vessel 10 is drawn off through a port 22 located above the level of liquid. [0015] A second closed vessel 24 is coupled with the closed vessel 10 through the port 22 by which the closed vessel 24 receives gas generated from the first vessel 10 at a port 26. The closed vessel 24 includes a cavity 28 with electrodes 30 of alternating polarity extending through the hydrocarbon fuel and to the water in a bath consisting essentially of water, electrolyte and liquid hydrocarbon fuel. The electrodes 30 in this embodiment are stainless steel plates extend through the hydrocarbon fuel and to the water in the bath. More exotic metals will likely improve longevity as noted above. The port 26 is located below the bath in the closed vessel 24 to introduce the hydrogen into the electrolysis process. The same electrolyte may be employed in the second bath but the liquid hydrocarbon fuel is at a much higher volumetric ratio with the water than in the first bath. Efficiency in the preferred embodiment appears to be maximized with a ratio of about 6 to 1. Again, power to the electrolysis process is as described above for the first closed vessel 10 with 19 volts drawing about 3 amps in the closed vessel 24 with the power pulsed. Each of these parameters is subject to empirical tuning to maximize efficiency in the environment of each reactor vessel. [0016] During the electrolysis process in the second closed vessel 24, the liquid contained therein is recirculated from a port 32 through a recirculation pump 34 to a tank 36. The tank 36 has the ingredients of the second bath including some intermediate hydrocarbon material which is to be circulated with the water back into the 5 WO 2012/021850 PCT/US2011/047662 bath. From the tank 36, recirculation continues through a heat exchanger 38 and back into the bath of the second closed vessel 24 through a port 40. [0017] As feedstock, a water tank 42 feeds makeup water to the tank 36 as electrolysis lowers the quantity of water in the system. A hydrocarbon fuel tank 44 also makes up liquid fuel ingredients as needed. Solenoids 46 and 48 control the water tank 42 and fuel tank 44, respectively. The same sources may be used to provide feedstock to the first closed vessel, as shown in the schematic. [00181 A further port 50 located above the liquid level within the second closed vessel 24 draws gas into a safety bubbler 52 and then to a vacuum pump/compressor assembly 54. The vacuum pump/compressor assembly 54 draws a vacuum on the closed vessel 24 and compresses a fraction of the gasified product into liquid delivered to a tank 56. The vacuum drawn is moderated. At start-up, foaming is an issue and operation of the vacuum pump/compressor 54 is delayed. Once the bath has been operating for a while, foaming decreases and a vacuum can be drawn. As the bath is a blend of liquid hydrocarbons, the level of vacuum will impact the constituents volatilized. A maximum of 10 pounds per square inch below atmospheric has been used. This avoids volatilizing any of the feedstock water at the bottom of the bath or flashing off the feedstock liquid hydrocarbon fuel before it has been subjected to a time of residence in the bath. The degree of vacuum can be used to vary the residence time of the volatile hydrocarbons in the second bath, which is understood can impact the final mix as may be desired. The compressor side is unable to liquefy the hydrogen generated during this process, which is separately conveyed to a second tank 58. Of course, each of these fractionated products may be directed to other devices for processing or use. 6 WO 2012/021850 PCT/US2011/047662 [0019] Looking to the process directly, the bath in the first closed vessel 10 is subjected to electrolysis and, being principally water, generates hydrogen and oxygen. Power is directed to the electrolysis process such that overheating does not occur, as discussed above. The hydrogen passes through the port 22 above the liquid level and from the vessel 10. Because of the thin layer of liquid hydrocarbon fuel on the surface of the water in the closed vessel 10, oxygen is prevented by this barrier from escaping from the bath. [0020] The hydrogen from the closed vessel 10 is fed to the second closed vessel 24 into the port 26. The second vessel 24 conducts electrolysis in an environment with the bath containing much larger ratios of liquid hydrocarbon fuel to water with an electrolyte and with the hydrogen gas delivered from the closed vessel 10. The electrolysis is accomplished by the electrodes 30 of alternating opposite polarity which extend through the hydrocarbon fuel to the water. The electrolysis process is run on a cycle of about 50% on and 50% off. Efficiency appears to be maximized at around this 50% power supply cycle and the controls keep temperature within the bath down. It has been found that cycling the power such that the electrodes 30 are charged about 50% of the time creates a greater efficiency of operation. [00211 To further maintain temperature and to retain all components of the process entrained in the bath, the constituents of the bath are recirculated through the pump 34 and tank 36. Cooling is included in this recirculating flow by the heat exchanger 38. It is advantageous to maintain the bath at ambient temperature. The intermediate hydrocarbon material is circulated with the water back into the bath as this 7 WO 2012/021850 PCT/US2011/047662 appears to ultimately convert dark hydrocarbon material, intermediate in the conversion process, into the desired volatile hydrocarbons. [0022] Gas is drawn off above the bath in the second closed vessel 24 by the vacuum pump/compressor 54 through the safety bubbler 52, compressed and then cooled again if necessary to create a stable liquid at atmospheric pressure. The hydrogen gas is naturally fractionated from the hydrocarbon fuel thus derived. As noted above, the vacuum is regulated to not gasify the feedstock water and allow residence time for the liquid hydrocarbon fuel. The operation of electrolysis in the second vessel 24 reduces the hydrocarbons to a lighter blend of constituents in the resulting liquid fuel. By controlling residence time in the second bath, the resulting blend of hydrocarbon constituents volatized is understood to vary in weight. [0023] Thus, a gas and fuel generator and the process of using same to generate reconstituted liquid hydrocarbon fuel has been disclosed. While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore is not to be restricted except in the spirit of the appended claims. 8

Claims

1. A process for the preparation of combustible fluid, comprising conducting electrolysis in a bath consisting essentially of water, electrolyte and liquid hydrocarbon fuel; removing gas from above the bath during electrolysis; providing makeup water and liquid hydrocarbon fuel during the electrolysis.

2. The process of claim 1 further comprising conducting electrolysis in a second bath consisting essentially of water, electrolyte and a second amount of liquid hydrocarbons; introducing the gas removed from the first bath during electrolysis to the water in the second bath; removing gas from above the second bath during electrolysis; providing makeup water and liquid hydrocarbon to the second bath during the electrolysis.

3. The process of claim 1 or claim 2 wherein removing gas from at least one of the first bath and the second bath includes drawing gas with a vacuum pump, the vacuum being low enough to separate volatile components from the feedstock water.

4. The process of claims I or 2 wherein at least one of the electrolysis in the first bath and the second bath is being conducted between electrodes of opposite polarity extending into the hydrocarbon fuel and to the water.

5. The process of claims 1 or 2 further comprising fractionally liquefying gas removed from above at least the first bath; and 9 WO 2012/021850 PCT/US2011/047662 separating hydrogen there from.

6. The process of claims 1 or 2 further comprising maintaining at least the first bath at ambient temperature by at least recirculating liquid from said bath and cooling the recirculating liquid to ambient temperature or by pulsing the voltage for the electrolysis on and off to maintain temperature.

7. The process of claims 1 or 2 wherein the amount of liquid hydrocarbon fuel in at least one of the first bath and the second bath is sufficient to form an oxygen barrier above the water in said bath.

8. A fuel generator comprising a closed vessel; water, liquid hydrocarbons and electrolyte in the closed vessel; electrodes of opposite polarity extending into the hydrocarbons and water in the closed vessel; and, a vacuum pump in communication with gas space in the closed vessel above the water and hydrocarbons.

9. The fuel generator of claim 8 further comprising, a second closed vessel; water, liquid hydrocarbons and electrolyte in the second closed vessel; electrodes of opposite polarity extending into the hydrocarbons and water in the second closed vessel, a vacuum pump in communication with gas space in the second closed vessel above the water and hydrocarbons; and, 10 WO 2012/021850 PCT/US2011/047662 a radiator in communication with the vacuum pump for at least the first closed vessel.

10. The fuel generator of claim 8 or 9 wherein the amount of liquid hydrocarbon fuel in at least one of the first bath and the second bath is sufficient to form an oxygen barrier above the water in said bath. 11