Process and plant for producing stabilized diesel emulsions
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- MARCHETTO SIMONE
- Filing Date
- 2026-01-13
- Publication Date
- 2026-08-06
Smart Images
Figure IB2026050252_06082026_PF_FP_ABST
Abstract
Description
[0001] “Process and plant for producing stabilized diesel emulsions”
[0002] DESCRIPTION
[0003] Technical field of the invention
[0004] The present invention relates to a process and a plant for producing stabilized diesel fuel emulsions. In particular, the present invention relates to diesel fuel emulsions with a fluid to be dispersed, typically but not exclusively water, thermodynamically stable having an improved combustion efficiency and consequently a reduction of micro / macro particulate matter, reduction of CO, NOx and CO2 emissions.
[0005] Known art
[0006] For example, water-diesel emulsions are known that comprise a diesel fuel, water (more preferably demineralized water) or an aqueous solution of a low molecular weight alcohol and / or a water-soluble reagent, and a surfactant system which comprises a balanced mixture of one or more hydrophilic surfactants and one or more lipophilic surfactants, wherein the diesel fuel composition can for example contain up to 25 percent by weight of aqueous phase with an aqueous phase / surfactant ratio of at least 2 / 1. The water-diesel emulsions, such as thermodynamically stable fluids, are useful in reducing exhaust emissions (such as nitrogen oxide (NOx), carbon dioxide (CO2), carbon monoxide (CO), sulfur oxide (SOx), hydrocarbons (HC), soot, and micro-macro particulate matter (PM)) from diesel cycle internal combustion engines.
[0007] In the above-mentioned technical field, the Applicant has noted that the wide variety of diesel-water emulsion compositions known in the art have poor stability and low performance, in particular due to the conditions to which the emulsions are exposed. Emulsions are generally unstable and tend to de-emulsify at both high and low temperatures. For example, if particles are pre-absorbed at the interfaces of water droplets by emulsion at room temperature, the subsequent increase in temperature leads to a progressive increase in sedimentation and coalescence as the particles dissolve and dissociate from the interfaces.Furthermore, the addition of even very small amounts of salt, for example through exposure to air or water containing salt, causes serious de-emulsification problems. Another drawback of known emulsions is given by the high concentrations of surfactants required for their formation.
[0008] In this context, the Applicant therefore has noted the need to propose a process and a plant that allow to overcome the above-mentioned drawbacks and to produce stabilized diesel fuel emulsions better than those currently known, in particular with reference to their stability and their performance in terms of reducing the pollutants produced by combustion.
[0009] The Applicant has found that, in the field of industrial diesel emulsion production, it is possible to produce significant quantities of a stable and consistent over time emulsion by adopting a modular structure and recovering errors that occur during the process using a mitigation technique.
[0010] According to a first aspect, the present invention refers to a process for producing stabilized diesel fuel emulsions. The process comprises: arranging N emulsion modules, producing M batches of emulsion sequentially in each of the N emulsion modules from diesel fuel, additive, and a fluid to be dispersed for a total of N x M batches of emulsion. The N emulsion modules are started one after the other with a lag time less than a processing time of each batch of emulsion. The process comprises also: sequentially discharging the batches of emulsions into a common discharge line as soon as each processing time is completed.
[0011] In an optional aspect, during the production of the N x M batches of emulsion, the process comprises: monitoring at least one of: properties of emulsion, diesel fuel, dispersion fluid, additive of each of the M batches of emulsion; parameters and / or working logics of each of the N modules of emulsion; recognizing an error and identifying the relative emulsion modulus; wherein the error is a deviation from reference properties, parameters and / or work logics; correcting the error while the other emulsion modules continue to produce.
[0012] According to a second aspect, the present invention refers to an apparatus for producing stabilized diesel fuel emulsions. The apparatus comprises: N emulsion modules, each comprising a main tank having a diesel fuel inlet, a fluid to be dispersed inlet, an additive inlet, and an emulsion outlet. The module comprises also mixing devices operationally active within said main tank. A diesel fuel charging line is connected to the diesel fuel inlet of each main tank and to a diesel fuel source, afluid to be dispersed charging line is connected to the fluid to be dispersed inlet of each main tank and to a fluid to be dispersed source, an additive charging line is connected to the additive inlet of each main tank and to an additive source. An emulsion discharge line connects, optionally in parallel, the emulsion outlets of the main tanks. The apparatus comprises an electronic control unit operationally connected to the N emulsion modules. The electronic control unit is configured / programmed for implementing the following procedure: producing M batches of emulsion sequentially in each of the N emulsion modules for a total of N x M batches of emulsion, starting the N emulsion modules one after the other with a lag time less than a processing time of each batch of emulsion; sequentially discharging the batches of emulsions into a common discharge line as soon as each processing time is completed.
[0013] In an optional aspect, during the production of the N x M batches of emulsion, the electronic control unit is also configured / programmed for: monitoring at least one of: properties of emulsion, diesel fuel, dispersion fluid, additive of each of the M batches of emulsion; parameters and / or working logics of each ofthe N modules of emulsion; recognizing an error and identifying the relative emulsion module; wherein the error is a deviation from reference properties, parameters and / or work logics; correcting the error while the other emulsion modules continue to produce.
[0014] Preferably, the fluid to be dispersed comprises water or an aqueous solution and / or ammonia and / or methanol and / or similar ions, or substances that contribute to improve the combustion efficiency and / or reduce harmful emissions.
[0015] Preferably, the aqueous solution comprises ammonia and / or methanol.
[0016] The apparatus of the second aspect is configured for implementing the method of the first aspect and / or the method of the first aspect can be implemented in the apparatus of the second aspect.
[0017] The Applicant considers that the present invention allows to produce stable diesel fuel emulsions, with characteristics constant over time and capable of providing high performance in terms of reducing the pollutants produced by the combustion of the emulsions themselves.
[0018] The Applicant has verified that the redundancy of the emulsion modules, the sequence of batch production in each module and their time lag allow to mitigate any errors in one or more modules and therefore guarantee the production of anemulsion quantity provided with the characteristics highlighted above (stability and performance).
[0019] The Applicant has verified that the module wherein the error occurs is retrieved while the other modules continue to produce, so that the production does not stop and the effect of the error on the final quantity of the emulsion produced by the apparatus is negligible.
[0020] The Applicant has further verified that the process is very quick, economic and can be used for the production on a large industrial scale.
[0021] The present invention, in at least one of the above-mentioned further aspects, can have one or more of the preferred characteristics hereinafter described.
[0022] In an aspect, N is equal to or greater than two. In an aspect, N is equal to or less than ten. Preferably, N is equal to five.
[0023] In an aspect, M is equal to or greater than two. In an aspect, M is equal to or lower than twenty. Preferably, M is equal to thirteen.
[0024] In an aspect, the N emulsion modules are identical to each other.
[0025] In an aspect, while the error is corrected, the related emulsion module continues to produce.
[0026] In an aspect, while the error is corrected, the related emulsion module is stopped. The Applicant has verified that, even if the emulsion module is stopped, the partial time overlap with the other modules allows to not stop the production.
[0027] In an aspect, the production of each batch of emulsion comprises: a step of charging diesel fuel in a main tank of a respective emulsion module, a step of charging fluid to be dispersed in the main tank, a step of charging additive in the main tank, a step of mixing and a step of discharging emulsion from the main tank.
[0028] In an aspect, with respect to a batch of emulsion in a first emulsion module, an immediately subsequent batch of emulsion in a second emulsion module is started at the end of the steps of diesel fuel charging, fluid to be dispersed charging and additive charging in the first emulsion module.
[0029] In an aspect, a processing time of each batch of emulsion comprises a diesel fuel charge time in the main tank, a fluid to be dispersed charge time in the main tank, an additive charge time in the main tank, a mixing time and an emulsion discharge time from the main tank.
[0030] In an aspect, the lag time is equal to the sum of the diesel fuel charge time, the fluid to be dispersed charge time and the additive charge time.In an aspect, the production of each batch of emulsion comprises: charging the diesel fuel into the main tank of the respective emulsion module, charging the fluid to be dispersed in a first auxiliary tank belonging to the same emulsion module; charging the additive in a second auxiliary tank belonging to the same emulsion module.
[0031] Then, the production of each batch of emulsion comprises: charging the additive into the main tank by transferring it from the second auxiliary tank to said main tank, charging the fluid to be dispersed in the main tank by transferring it from the first auxiliary tank to said main tank.
[0032] In an aspect, the charging of the additive in the main tank is performed before the charging of the fluid to be dispersed in the main tank.
[0033] In an aspect, the charging of the additive in the main tank and the charging of the fluid to be dispersed in the main tank are performed at the same time.
[0034] In an aspect, the production of each batch of emulsion comprises: mixing the emulsion comprising the diesel fuel, the fluid to be dispersed and the additive in the main tank.
[0035] In an aspect, it is provided to refill the first auxiliary tank with the fluid to be dispersed for a subsequent batch of emulsion while the emulsion is mixed in the main tank. In an aspect, it is provided to refill the second auxiliary tank with the additive for a subsequent batch of emulsion while the emulsion is mixed in the main tank.
[0036] The Applicant has verified that in this way times and continuity of the production are optimized.
[0037] In an aspect, for a first batch of emulsion in chronological order of the M batches of emulsion, the steps of charging the diesel fuel in the main tank, charging the fluid to be dispersed in the first auxiliary tank and charging the additive in the second auxiliary tank are performed at the same time.
[0038] In an aspect, each emulsion module comprises a first auxiliary tank operationally coupled to the fluid to be dispersed charging line.
[0039] In an aspect, each emulsion module comprises a second auxiliary tank operationally coupled to the additive charging line.
[0040] In an aspect, each emulsion module comprises two first auxiliary tanks connected to each other in parallel and operationally coupled to the fluid to be dispersed charging line.In an aspect, the electronic control unit is configured for: charging the diesel fuel in the main tank; charging the fluid to be dispersed in the first auxiliary tank; charging the additive in the second auxiliary tank.
[0041] Then, the electronic control unit is configured for: charging the additive into the main tank by transferring it from the second auxiliary tank to said main tank and charging the fluid to be dispersed in the main tank by transferring it from the first auxiliary tank to said main tank.
[0042] In an aspect, the electronic control unit is configured for charging at first the additive in the main tank and then charging the fluid to be dispersed in the main tank.
[0043] In an aspect, the electronic control unit is configured for charging at the same time the additive and the fluid to be dispersed in the main tank.
[0044] In an aspect, the electronic control unit is configured for mixing the emulsion comprising the diesel fuel, the fluid to be dispersed and the additive in the main tank. In an aspect, the electronic control unit is further configured for refilling the first auxiliary tank with the fluid to be dispersed for a subsequent batch of emulsion while the emulsion is mixed in the main tank.
[0045] In an aspect, the electronic control unit is further configured for refilling the second auxiliary tank with the additive for a subsequent batch of emulsion while the emulsion is mixed in the main tank.
[0046] In an aspect, the processing time is between 18 min and 45 min. Preferably, the processing time is equal to 32 min.
[0047] In an aspect, the lag time is between 4 min and 6 min. Preferably, the lag time is equal to 5 min.
[0048] In an aspect, the diesel fuel charge time is between 1 min and 3 min. Preferably, the diesel fuel charge time is equal to 2 min.
[0049] In an aspect, the fluid to be dispersed charge time is between 1 min and 3 min. Preferably, the fluid to be dispersed charge time is equal to 2 min.
[0050] In an aspect, the additive charge time is between 0.5 min and 1.5 min. Preferably, the additive charge time is equal to 1 min.
[0051] In an aspect, the mixing time is between 15 min and 35 min. Preferably, the mixing time is equal to 25 min.
[0052] In an aspect, the emulsion discharge time is between 1 min and 3 min. Preferably, the emulsion discharge time is equal to 2 min.The Applicant has verified that the indicated times allow to optimize the results of the invention in terms of speed and quantity of emulsion produced, stability over time, and performance.
[0053] In an aspect, the mixing devices comprise an agitator placed in the main tank. In an aspect, the agitator is provided with movable wave breakers.
[0054] In an aspect, the mixing devices comprise fixed wave breakers placed in the main tank.
[0055] In an aspect, each of the movable wave breakers and / or fixed wave breakers comprises a series of fins aligned with each other along a respective direction. In an aspect, said respective direction is vertical or forms with a vertical direction an angle other than zero and less than 30°.
[0056] In an aspect, each fin has a first portion and a second portion projecting from the first portion and inclined with respect to said first portion.
[0057] In an aspect, the first portion and the second portion are flat.
[0058] In an aspect, each of the movable wave breakers and / or fixed wave breakers comprises a plate and wherein the fins are obtained along an edge of said plate. In an aspect, the movable and / or fixed wave breakers have also through holes. In an aspect, the movable wave breakers are mounted on a shaft of the agitator. In an aspect, the fixed wave breakers are mounted on an inner wall of the main tank. In an aspect, the fixed wave breakers are mounted on pipeline projecting inside the main tank and terminating with the respective nozzles.
[0059] In an aspect, the movable wave breakers are mounted on pipeline projecting inside the main tank and terminating with the respective nozzles and are free to rotate around said pipeline.
[0060] The Applicant has verified that the wave breakers effectively contribute to the production of stable emulsions.
[0061] In an aspect, each of the N emulsion modules comprises at least a recirculation circuit provided with a respective recirculation pump.
[0062] In an aspect, the pipeline belongs to said recirculation circuit.
[0063] In an aspect, the recirculation circuit comprises a recirculation line connecting the emulsion outlet with a pipeline terminating with a nozzle placed in an upper portion of the main tank.In an aspect, the recirculation circuit comprises a first recirculation line connecting the emulsion outlet with a first pipeline of said pipeline terminating with a first nozzle of said nozzles placed in an upper portion of the main tank.
[0064] In an aspect, the first nozzle is a spraying nozzle.
[0065] In an aspect, a first pump is operationally active on the first recirculation line.
[0066] In an aspect, the recirculation circuit comprises a second recirculation line connecting the emulsion outlet with a second pipeline of said pipeline terminating with a second nozzle of said nozzles placed in an intermediate or lower portion of the main tank.
[0067] In an aspect, a second pump is operationally active on the second recirculation line. In an aspect, a cavitator / mixer is placed on the recirculation line, optionally on the first recirculation line and / or on the second recirculation line, and is configured for generating vortices in the recirculated emulsion.
[0068] In an aspect, the cavitator / mixer comprises a chamber and a plurality of partitions placed in the chamber and each having slots and / or holes for the passage of the recirculated emulsion.
[0069] In an aspect, the first auxiliary tank is connected to the fluid to be dispersed charging line through an upper duct and to the emulsion outlet from the main tank through a lower duct.
[0070] In an aspect, the second auxiliary tank is connected to the additive charging line through an upper duct and to the emulsion outlet from the main tank through a lower duct.
[0071] In an aspect, the transfer of the fluid to be dispersed from the first auxiliary tank to the main tank is generated by the recirculation implemented by the recirculation circuit pump that generates a depression such as to recall the fluid to be dispersed through the upper duct and / or through the lower duct up to the emptying of the first auxiliary tank.
[0072] In an aspect, the transfer of the additive from the second auxiliary tank to the main tank is generated by the recirculation implemented by the recirculation circuit pump that generates a depression such as to recall the additive through the upper duct and / or through the lower duct up to the emptying of the second auxiliary tank. In an aspect, a percentage of diesel fuel is between 70% and 90%.
[0073] In an aspect, a percentage of fluid to be dispersed is between 5% and 28%.
[0074] In an aspect, a percentage of additive is between 0.5% and 2.8%, optionally 1.3%.In an aspect, the additive comprises at least an emulsifier formulated to keep the fluid to be dispersed (such as water or aqueous solution, ammonia or methanol or similar ions) in emulsion in diesel fuel.
[0075] In an aspect, the additive comprises Dodecan-1-ol, ethoxylated, for example Paryol™ WG11 or Paryol™ WG12.
[0076] Further characteristics and advantages will become apparent from the detailed description of a preferred, but not exclusive, embodiment of an apparatus and a process for producing stabilized diesel fuel emulsions according to the present invention.
[0077]
[0078] of
[0079] This description will be provided below with reference to the attached drawings, provided for illustrative purposes only and therefore not exhaustive, in which:
[0080] - figure 1 is a three-dimensional view of an apparatus for producing stabilized diesel fuel emulsions according to the present invention;
[0081] - figure 2 schematically shows a part of the apparatus of figure 1 ;
[0082] - figure 3 shows a sectional view of a component of the apparatus referred to in the preceding figures;
[0083] - figure 4 is a different sectional view of the component of figure 3;
[0084] - figure 5 is a further view of the component of figures 3 and 4;
[0085] - figure 6 is an enlargement of a portion of the component of figure 5;
[0086] - figure 7 is a flow chart of a method for producing stabilized diesel fuel emulsions according to the present invention;
[0087] - figure 8 shows a diagram showing the steps of an example of the method according to the present invention.
[0088] Detailed
[0089]
[0090] With reference to figure 1, with 1, an exemplary embodiment of an apparatus for producing stabilized diesel fuel emulsions according to the present invention has been indicated overall.
[0091] The apparatus 1 comprises five emulsion modules 2 substantially identical to each other and all of them connected to a common diesel fuel source 3, a common water or aqueous solution source 4, and a common additive source 5 via a diesel fuelcharging line 6, a water or aqueous solution charging line 7, and an additive charging line 8.
[0092] Water or aqueous solution is the fluid to be dispersed, i.e., the dispersed phase in the emulsion. The diesel fuel is the dispersing phase. The example shown here refers to water or aqueous solution, but the fluid to be dispersed can also comprise or consist of ammonia or methanol or similar ions, i.e., substances that contribute to improve the combustion efficiency and / or to reduce harmful emissions.
[0093] Respective diesel fuel loading pumps 9, water or aqueous solution charging pumps 10, and additive charging pumps 11 are operationally connected to the diesel fuel charging line 6, the water or aqueous solution charging line 7, and the additive charging line 8. The sources of diesel fuel 3, water or aqueous solution 4, and additive 5 are shown schematically and for simplicity with their respective tanks. Figure 2 shows two of the five emulsion modules 2, and since the emulsion modules 2 are substantially identical to each other, only one will be described in detail below. The emulsion module 2 comprises a main tank 12 that has a diesel fuel inlet 13, a water or aqueous solution inlet 14, an additive inlet 15 placed on an upper portion of the main tank 12 and an emulsion outlet 16 placed on a lower portion of the main tank 12 (can be seen in figure 2). The diesel fuel charging line 6 is connected to the diesel fuel inlet 13.
[0094] The water or aqueous solution charging line 7 is connected to the water or aqueous solution inlet 14 through two first auxiliary tanks 17. The additive charging line 8 is connected to the additive inlet 15 through a second auxiliary tank 18. More in particular, the first auxiliary tanks 17 are connected to each other in parallel, are connected to the water or aqueous solution charging line 7 through an upper duct 19 and are connected to the emulsion outlet 16 through a lower duct 20. The second auxiliary tank 18 is connected to the additive charging line 8 through an upper duct 21 and to the emulsion outlet 16 through a lower duct 22.
[0095] An emulsion discharge line 23 connects in parallel the emulsion outlets 16 of the main tanks 12 of the five modules 2.
[0096] The emulsion module 2 comprises a recirculation circuit defined by a first recirculation line 24 and by a second recirculation line 25. The first recirculation line 24 connects the emulsion outlet 16 with a first pipeline 26 terminating in the main tank 12 with a first spraying nozzle 27 placed in an upper portion of said main tank 12. The second recirculation line 25 connects the emulsion outlet 16 with twosecond pipeline 28 terminating in the main tank 12 with respective second nozzles 29 placed in an intermediate and lower portion of said main tank 12 (figure 13). A first recirculation pump 30 is operationally active on the first recirculation line 24 and a second recirculation pump 31 is operationally active on the second recirculation line 25. A cavitator / mixer 32 is placed on the first recirculation line 24 downstream of the first recirculation pump 30 and is configured for generating vortices in the recirculated emulsion. The cavitator / mixer 32, not shown in detail, is a cylindrical body which delimits within itself a chamber through which the recirculated emulsion flows. The chamber is divided by partitions, each having slots and / or holes for the passage of the recirculated emulsion.
[0097] The emulsion module 2 comprises mixing devices operationally active in the main tank 12. The mixing devices comprise an agitator 33 which comprises a motor 34 placed on a top of the main tank 12, a shaft 35 vertically arranged, operationally connected and moved in rotation by the motor 34 and a rotor 36 mounted on the end of the shaft 35. The rotor 36 shown comprises a horizontal plate provided with tips placed at respective angles (figures 4 and 5).
[0098] The mixing devices comprise also movable wave breakers and fixed wave breakers 37 placed in the main tank 12. The movable wave breakers, not shown, can for example be mounted on the shaft 35 or be mounted on the first pipeline 26 and on the second pipeline 28 and are free to rotate around said pipeline 26, 28. The movable wave breakers mounted on the first pipeline 26 and on the second pipeline 28 are rotated by the movement of the emulsion in the main tank 12. In the embodiment shown in figures, the fixed wave breakers 37 are mounted on an inner wall of the main tank 12 and on the second pipeline 28. As better shown in figures 4, 5 and 6, each of the fixed wave breakers 37 mounted on the inner wall of the main tank 12 comprises a plate 38 constrained to said inner wall and extending inward of the main tank 12. The plate 38 is oriented vertically and a series of fins 39 is formed on one of its edges mutually aligned along a respective direction (figure 6). In particular, the edge of the plate 38 is toothed and each tooth defines a fin 39. The fin 39 has a first portion 39A flat and lying in a same plane of the plate 38 and a second portion 39B flat too, that projects from the first portion 39A and inclined with respect to said first portion 39A. The second portion 39B is connected to the first portion 39A along a side of said first portion 39A directed toward an adjacentwall. The wave breakers 37 have also through holes 39C obtained through the plate 38.
[0099] The wave breakers mounted on the second pipeline 28 have the same structure as those previously described but, being the second pipe inclined with respect to the vertical, the direction along which the fins 39 are mutually aligned is not vertical and forms an angle of less than approximately 30° with the vertical, for example approximately 20°. Furthermore, as visible in figure 6, some second portions 39B are oriented in one direction and others in an opposite direction.
[0100] An electronic control unit 40 is operationally connected to the various elements of apparatus 1 to implement a process for producing stabilized water-diesel emulsions according to the present invention. In particular, the electronic control unit 40 is connected to the diesel fuel loading pump 9, to the water or aqueous solution charging pump 10, to the additive charging pump 11, to motors 34, to the first recirculation pumps 30, to the second recirculation pumps 31 , as well as valves and other devices of known type and not shown in detail here.
[0101] In use and in accordance with the process for producing stabilized water-diesel emulsions according to the present invention, to produce a determined quantity of stabilized water-diesel emulsion, for example 65,000 liters, each of the five emulsion modules 2 is commanded and controlled by the electronic control unit 40 to produce thirteen respective batches of emulsion in sequence, for a total of sixty-five batches, each of 1,000 liters. Furthermore, the electronic control unit 40 starts the five emulsion modules 2 one after the other with a lag time “At” between one emulsion module 2 and the next.
[0102] Hereinafter, the process of processing only one of the emulsion modules 2 will be described, as it is common to all five.
[0103] The electronic control unit 40 activates and controls the diesel fuel charging pump 9 and charges the diesel fuel from the diesel fuel source 3 into the main tank 12. The diesel fuel charging time “td” is, for example, 2 min.
[0104] At the same time, the electronic control unit 40 activates and controls the water or aqueous solution charging pump 10 and charges the water or aqueous solution from the water or aqueous solution source 4, previously prepared, into one of or both the first auxiliary tanks 17. The electronic control unit 40 activates and controls the additive charging pump 11 and charges the additive from the additive source 5, previously prepared, in the second auxiliary tank 18. For example, the additivecomprises Dodecan-1-ol, ethoxylated, such as for example Paryol™ WG11 or Paryol™ WG12.
[0105] The electronic control unit 40 activates and controls the motor 34 to start the mixing of only the diesel fuel present in the main tank 12. The electronic control unit 40 activates and controls the first recirculation pump 30 and the second recirculation pump 31 so as to let the diesel fuel circulate through the first recirculation line 24 and the second recirculation line 25. The diesel fuel exits from the emulsion outlet 16, passes through the first recirculation line 24 and the cavitator / mixer 32, and is returned to the main tank 12 through the first spraying nozzle 27. The diesel fuel exits from the emulsion outlet 16, passes through the second recirculation line 25 and is returned to the main tank 12 through the second nozzles 29.
[0106] The electronic control unit 40 opens and / or closes dedicated valves so that the recirculation of diesel fuel generates a depression that draws the additive present in the second secondary tank 18 through the upper duct 21 and / or the lower duct 22 and feeds it into the main tank 12 until the second auxiliary tank 18 is emptied. An additive charge time “ta” in the main tank 12 is for example equal to 1 min.
[0107] Then, the electronic control unit 40 opens and / or closes dedicated valves so that the recirculation of diesel fuel generates a depression that draws the water or aqueous solution present in the first auxiliary tanks 17 through the upper duct 19 and / or the lower duct 20 and feeds it into the main tank 12 until the second auxiliary tanks 17 are emptied. A water or aqueous solution charge time “tw” in the main tank 12 is for example equal to 2 min.
[0108] In a variant, the additive and the water or aqueous solution are charged simultaneously into the main tank 12.
[0109] By way of example, the percentage of diesel fuel is equal to 50% and the percentage of water or aqueous solution is equal to 10%, a percentage of additive is equal to 0.9%.
[0110] The mixing and circulation are kept for a mixing time “tm”, for example, 25 min. Meanwhile, the first auxiliary tanks 17 are refilled with water or aqueous solution, and the second auxiliary tank 18 is refilled with the additive, ready for the next batch of emulsion.
[0111] At the end of this mixing time, the emulsion is discharged through the emulsion outlet 16 and fed into the emulsion discharge line 23. An emulsion discharge time “tout” is, for example, equal to 2 min.A total processing time “T” for a single batch is therefore, for example, 32 minutes (2 minutes to charge diesel fuel, 2 minutes to charge water or aqueous solution, 1 minute to charge additive, 25 minutes to mix, 2 minutes to discharge emulsion). At the end of a batch processing in an emulsion module 2 is immediately started the processing of a subsequent batch in the same emulsion module 2 and according to the same modes and so on until completing thirteen batches sequentially.
[0112] As above mentioned, the five emulsion modules 2 work in parallel but are temporally offset from each other by the lag time “At”. A first emulsion module 2 of the five is started as above described. After the lag time “At” a second emulsion module 2 of the five is started and afterwards the third, fourth and fifth emulsion module 2, still offset by said lag time “At”.
[0113] The lag time “At” is for example equal to the sum of the diesel fuel charge time “td”, the water or aqueous solution charge time “tw” and the additive charge time “ta” in the main tank 12, i.e. for example equal to 5 min. In other words, with respect to a batch of emulsion in the first emulsion module 2, an immediately subsequent batch of emulsion in the second emulsion module 2 is started at the end of the step of charging diesel fuel, charging water or aqueous solution and charging additive in the first emulsion module 2.
[0114] In this way, in order to produce the determined quantity of stabilized water-diesel emulsion (65,000 liters), the apparatus 1 requires approximately 8 hours. An example of the above-described sequence of steps is schematized in figure 8. The electronic control unit 40 is also configured and / or programmed for monitoring, through dedicated sensors and / or detectors, not shown, properties of diesel fuel, of water or aqueous solution, of additive and of emulsion of each of the thirteen batches of emulsion of each of the emulsion modules 2 and also of parameters and / or working logics of each of the five emulsion modules 2.
[0115] The electronic control unit 40 is also configured and / or programmed for comparing such properties and / or parameters and / or working logics with reference values or ranges, so as to recognize an error and identify the emulsion module 2 that has generated such error.
[0116] For example, through a real-time density measurement system and an algorithm it is possible to recognize an incorrect percentage of additive and / or aqueous solution. The electronic control unit 40 is also configured and / or programmed for correcting such error and then for retrieving the emulsion module 2 while the other emulsionmodules 2 continue to produce. While the error is corrected and the emulsion module 2 is retrieved, said emulsion module 2 continues to produce or is temporarily stopped.
[0117] List of elements
[0118] 1 apparatus
[0119] 2 module
[0120] 3 diesel fuel source
[0121] 4 water or aqueous solution source
[0122] 5 additive source
[0123] 6 diesel fuel charging line
[0124] 7 water or aqueous solution charging line
[0125] 8 additive charging line
[0126] 9 diesel fuel charging pump
[0127] 10 water or aqueous solution charging pump
[0128] 11 additive charging pump
[0129] 12 main tank
[0130] 13 diesel fuel inlet
[0131] 14 water or aqueous solution inlet
[0132] 15 additive inlet
[0133] 16 emulsion outlet
[0134] 17 first auxiliary tanks
[0135] 18 second auxiliary tank
[0136] 19 upper duct
[0137] 20 lower duct
[0138] 21 upper duct
[0139] 22 lower duct
[0140] 23 emulsion discharge line
[0141] 24 first recirculation line
[0142] 25 second recirculation line
[0143] 26 first pipeline
[0144] 27 first spraying nozzle
[0145] 28 second pipeline
[0146] 29 second nozzles30 first recirculation pump 31 second recirculation pump 32 cavitator / mixer
[0147] 33 agitator
[0148] 34 motor
[0149] 35 shaft
[0150] 36 rotor
[0151] 37 fixed wave breakers
[0152] 38 plate
[0153] 39 fin
[0154] 39A first portion
[0155] 39B second portion
[0156] 40 electronic control unit
Claims
CLAIMS1. Process for producing stabilized diesel fuel emulsions, comprising:- arranging N emulsion modules (2), wherein N is equal to or greater than two; - producing M batches of emulsion sequentially in each of the N emulsion modules (2) from diesel fuel, additive, and a fluid to be dispersed for a total of N x M batches of emulsion; wherein M is equal to or greater than two; wherein the N emulsion modules (2) are started one after the other with a lag time (At) less than a processing time (T) of each batch of emulsion; wherein the fluid to be dispersed comprises water or an aqueous solution and / or ammonia and / or methanol and / or similar ions;- sequentially discharging the batches of emulsions as soon as each processing time (T) is completed into a common discharge line (23);wherein, during the production of the N x M batches of emulsion, the method comprises:- monitoring at least one of: properties of emulsion, diesel fuel, fluid to be dispersed, additive of each of the M batches of emulsion; parameters and / or working logics of each of the N emulsion modules (2);- recognizing an error and identifying the relative emulsion module; wherein the error is a deviation from reference properties, parameters and / or work logics;- correcting the error while the other emulsion modules (2) continue to produce.
2. Process according to claim 1, wherein N is equal to five, and wherein M is equal to thirteen.
3. Process according to claim 1 or 2, wherein the production of each batch of emulsion comprises: a step of charging diesel fuel in a main tank (12) of a respective emulsion module (2), a step of charging fluid to be dispersed in the main tank (12), a step of charging additive in the main tank (12), a step of mixing in the main tank (12), and a step of discharging emulsion from the main tank (12); wherein, with respect to one batch of emulsion in a first emulsion module (2), an immediatelysubsequent batch of emulsion in a second emulsion module (2) is started at the end of the steps of diesel fuel charging, fluid to be dispersed charging and additive charging in the first emulsion module (2).
4. Process according to claim 3, wherein a processing time (T) of each batch of emulsion comprises a diesel fuel charge time (td) in the main tank (12), a fluid to be dispersed charge time (tw) in the main tank (12), an additive charge time (ta) in the main tank (12), a mixing time (tm) in the main tank (12), and an emulsion discharge time (tout) from the main tank (12); wherein the lag time (At) is equal to the sum of the diesel fuel charge time (td), the fluid to be dispersed charge time (tw) and the additive charge time (ta).
5. Process according to claim 3 or 4, wherein the production of each batch of emulsion comprises:- charging diesel fuel into the main tank (12) of the respective emulsion module (2);- charging the fluid to be dispersed into a first auxiliary tank (17) belonging to the same emulsion module (2);- charging the additive into a second auxiliary tank (18) belonging to the same emulsion module (2); and then- charging the fluid to be dispersed into the main tank (12) by transferring it from the first auxiliary tank (17) to said main tank (12); and then- charging the additive into the main tank (12) by transferring it from the second auxiliary tank (18) to said main tank (12);- mixing the emulsion including diesel fuel, fluid to be dispersed and additive in the main tank (12);wherein the first auxiliary tank (17) is refilled with the fluid to be dispersed for a subsequent batch of emulsion and the second auxiliary tank (18) is refilled with the additive for the subsequent batch of emulsion while the emulsion is mixed in the main tank (12).
6. Apparatus for producing stabilized diesel fuel emulsions, comprising:N emulsion modules (2), each comprising a main tank (12) having a diesel fuel inlet (13), a fluid to be dispersed inlet (14), an additive inlet (15), and anemulsion outlet (16); wherein N is equal to or greater than two; wherein the emulsion module (2) comprises mixing devices operationally active within said main tank (12); optionally said N emulsion modules (2) are identical to each other;a diesel fuel charging line (6) connected to the diesel fuel inlet (13) of each main tank (12) and to a diesel fuel source (3), a fluid to be dispersed charging line (7) connected to the fluid to be dispersed inlet (14) of each main tank (12) and to a fluid to be dispersed source (4), an additive charging line (8) connected to the additive inlet (15) of each main tank (12) and to an additive source (5), an emulsion discharge line (23) connecting the emulsion outlets (16) of the main tanks (12); an electronic control unit (40) operationally connected to the N emulsion modules (2) and configured for implementing the following procedure:- producing M batches of emulsion sequentially in each of the N emulsion modules (2) for a total of N x M batches of emulsion, starting the N emulsion modules (2) one after the other with a lag time (At) less than a processing time (T) of each batch of emulsion (2), wherein M is equal to or greater than two;- sequentially discharging the batches of emulsions in a common discharge line as soon as each processing time (T) is finished.
7. Apparatus according to claim 6, wherein, during the production of the N x M batches of emulsion, the electronic control unit (40) is also configured for:- monitoring at least one of: properties of emulsion, diesel fuel, fluid to be dispersed, additive of each of the M batches of emulsion; parameters and / or working logics of each of the N modules of emulsion (2);- recognizing an error and identifying the relative emulsion module (2); wherein the error is a deviation from reference properties, parameters and / or work logics;correcting the error while the other emulsion modules (2) continue to produce.
8. Apparatus according to claim 6 or 7, wherein each emulsion module (2) comprises: a first auxiliary tank (17) operatively coupled to the fluid to be dispersed charging line (7); a second auxiliary tank (18) operatively coupled to the additive charging line (8); wherein the electronic control unit (40) is configured for:- charging the diesel fuel into the main tank (12);- charging the fluid to be dispersed into the first auxiliary tank (17);- charging the additive into the second auxiliary tank (18); and then- charging the fluid to be dispersed into the main tank (12) by transferring it from the first auxiliary tank (18) to said main tank (12); and then- charging the additive into the main tank (12) by transferring it from the second auxiliary tank (18) to said main tank (12);- mixing the emulsion including diesel fuel, fluid to be dispersed and additive in the main tank (12);wherein the electronic control unit (40) is also configured for refilling the first auxiliary tank (17) with the additive for a subsequent batch of emulsion and for refilling the second auxiliary tank (18) with the fluid to be dispersed for a subsequent batch of emulsion while the emulsion is mixed in the main tank (12).
9. Apparatus according to any one of claims 6 to 8, wherein the mixing devices comprise an agitator (33) placed in the main tank (12) and fixed wave breakers (37) placed in the main tank (12), wherein each of the fixed wave breakers (37) comprises a series of fins (39) aligned with each other along a respective direction and each having a first portion (39A) and a second portion (39B) projecting from the first portion (39A) and inclined with respect to said first portion (39A); wherein each of the fixed wave breakers (37) comprises a plate (38) and wherein the fins (39) are formed along an edge of said plate (38).
10. Apparatus according to any one of claims 6 to 9, wherein each of the N emulsion modules (2) comprises: a recirculation circuit comprising a recirculation line (24, 25) connecting the emulsion discharge line (23) with a pipeline (26, 28) terminating with a nozzle (27, 29) located in an upper portion of the main tank (12); a cavitator / mixer (32) located on the recirculation line (24, 25).