High shear process for air/fuel mixing
Abstract
This record has no abstract on file.
Term
2.7 yearsto projected expiry
Projected expiry 2 June 2029, counted from filing; an application has no term until it is granted.
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1 claim: 1 independent, 0 dependent
- 1Patent claims Zastrzeżenia patentowe 1. A method of producing aerated fuels, including:1. Sposób produkcji napowietrzonych paliw, obejmujący: providing a high shear device (40, 200) having at least one toothed set of rotor and stator (220, 230, 240) configured to achieve a tip speed of at least 5 m / s;zapewnienie urządzenia wysokiego ścinania (40, 200), mającego co najmniej jeden zębaty zestaw rotora i statora (220, 230, 240) skonfigurowany do osiągania prędkości końcówki co najmniej 5 m/s;introducing gas and liquid fuel into the high shear device (40, 200);and forming an emulsion from gas and liquid fuel, the gas containing bubbles with an average size less than 5 μm to form an aerated fuel. wprowadzanie gazu i ciekłego paliwa do urządzenia wysokiego ścinania (40, 200);i tworzenie emulsji z gazu i ciekłego paliwa, przy czym gaz zawiera pęcherzyki o średnim rozmiarze mniejszym niż 5 μm to utworzenia napowietrzonego paliwa. 2. The method according to claim The process of claim 1, wherein the emulsion formation further comprises gas bubble formation with an average diameter less than about 1.5 μm in a high shear apparatus (40, 200). 2. Sposób według zastrz. 1, w którym tworzenie emulsji ponadto obejmuje tworzenie pęcherzyków gazu o średniej średnicy mniejszej niż około 1,5 μm w urządzeniu wysokiego ścinania (40, 200). 3. The method according to claim The method of claim 1, wherein the high shear device is configured to achieve a tip speed greater than about 23 m / s. 3. Sposób według zastrz. 1, w którym urządzenie wysokiego ścinania jest skonfigurowane do osiągania prędkości końcówki większej niż około 23 m/s. 4. The method according to claim Wherein the high shear device (40, 200) is configured to create a local pressure of at least about 1000 MPa at the tip. 4. Sposób według zastrz. 1, w którym urządzenie wysokiego ścinania (40, 200) jest skonfigurowane do tworzenie miejscowego ciśnienia co najmniej około 1000 MPa na końcówce. 5. The method according to claim 1 comprising subjecting liquid fuel and gas bubbles to shear at a rate greater than 20,000s-1. 5. Sposób według zastrz. 1 obejmujący poddawanie ciekłego paliwa i pęcherzyków gazu działaniu ścinania o szybkości większej niż 20.000s-1. 6. The method according to claim Wherein the high shear device (40, 200) is configured for an energy consumption of at least 1000 W / m3. 6. Sposób według zastrz. 1, w którym urządzenie wysokiego ścinania (40, 200) jest skonfigurowane na zużycie energii co najmniej 1000 W/m3. 7. The method according to claim The process of claim 1, wherein the emulsion comprises a mixture of liquid fuel and gas above the upper explosion limit (GGW) of the liquid fuel. 7. Sposób według zastrz. 1, w którym emulsja zawiera mieszaninę ciekłego paliwa i gazu powyżej górnej granicy wybuchowości (GGW) ciekłego paliwa. 8. The method according to claim Wherein the emulsion contains foam from aerated fuel. 8. Sposób według zastrz. 1, w którym emulsja zawiera mikropianę z napowietrzonego paliwa. 9. The method according to claim The process of claim 1, wherein the introduction of gas and liquid involves raising the pressure of the liquid fuel, optionally raising the pressure of the liquid fuel means obtaining a pressure every 203kPa (2 atm.). 9. Sposób według zastrz. 1, w którym wprowadzanie gazu i ciekłego obejmuje podnoszenie ciśnienia ciekłego paliwa, opcjonalnie podnoszenie ciśnienia ciekłego paliwa oznacza uzyskanie ciśnienia co 203kPa (2 atm.). 10. The method according to claim 1 further comprising injecting aerated fuel into the combustion chamber and burning the aerated fuel to obtain mechanical force, optionally injecting the aerated fuel further comprising oxidizing gas in a stoichiometric ratio, and may further include introducing the emulsion into the combustion chamber in a ratio greater than the stoichiometric amount. 10. Sposób według zastrz. 1 ponadto obejmujący wtryskiwanie napowietrzonego paliwa do komory spalania i spalanie napowietrzonego paliwa w celu uzyskania siły mechanicznej, opcjonalnie wtryskiwanie napowietrzonego paliwa ponadto zawierającego gaz utleniający w stosunku stechiometrycznym i może ponadto obejmować wprowadzanie emulsji do komory spalania w stosunku przewyższającym ilość stechiometryczną. 11. A system for the production of aerated fuels, comprising;11. System do produkcji napowietrzonych paliw, zawierający;a pump (5) located above the high shear device (40, 200), wherein the pump (5) is connected to the inlet of the high shear device for liquid transfer;pompę (5) ulokowaną powyżej urządzenia wysokiego ścinania (40, 200), przy czym pompa (5) ma połączenie z wlotem urządzenia wysokiego ścinania do przesyłu cieczy;a high shear device (40, 200) having at least one toothed set of rotor and stator (220, 230, 240) configured to achieve a tip speed of at least 5 m / s, which device produces an emulsion from gas and fuel, the emulsion having vesicles with an average diameter less than about 1.5μ ^ ι;and an engine (10) configured to burn the emulsion. urządzenie wysokiego ścinania (40, 200) mające co najmniej jeden zębaty zestaw rotora i statora (220, 230, 240) skonfigurowany do osiągania prędkości końcówki co najmniej 5 m/s, które to urządzenie wytwarza emulsję z gazu i paliwa, przy czym emulsja ma pęcherzyki o średniej średnicy mniejszej niż około 1,5μ^ι;i silnik (10) skonfigurowany do spalania emulsji. 12. System according to claim The high shear device of claim 11, wherein the high shear device (40, 200) achieves a tip speed greater than 23 m / s, wherein the high shear device (40, 200) is optionally configured to achieve a shear rate greater than about 20,000s-1. 12. System według zastrz. 11, w którym urządzenie wysokiego ścinania (40, 200) osiąga prędkość końcówki większa niż 23 m/s, przy czym urządzenie wysokiego ścinania (40, 200) jest opcjonalnie skonfigurowane do osiągania szybkości ścinania większej niż około 20.000s-1. 13. System according to claim The process of claim 11, wherein the high shear device (40, 200) is configured to create a local pressure of at least about 1000 MPa at the tip. 13. System według zastrz. 11, w którym urządzenie wysokiego ścinania (40, 200) jest skonfigurowane do tworzenia miejscowego ciśnienia co najmniej około 1000 MPa na końcówce. 14. System according to claim The process of claim 11, wherein the emulsion comprises a mixture of liquid fuel and gas above the upper explosion limit (GGW) of the liquid fuel. 14. System według zastrz. 11, w którym emulsja zawiera mieszaninę ciekłego paliwa i gazu powyżej górnej granicy wybuchowości (GGW) ciekłego paliwa. 15. The method according to claim 1 or a system according to claim The process of claim 11 wherein the gas comprises at least one of the group consisting of air, methanol, nitric oxide, propane, nitromethane, oxalate, organic nitrates, acetone, kerosene, toluene and tricarbonyl (methylcyclopentadiene) manganese. 15. Sposób według zastrz. 1 lub system według zastrz. 11, w którym gaz zawiera co najmniej jeden z grupy złożonej z powietrza, metanolu, tlenku azotu, propanu, nitrometanu, szczawianu, azotanów organicznych, acetonu, nafty, toluenu i trikarbonylu (metylocyklopentadieno)manganowego. "AJENTOWA" BELLEPAT "LAW OFFICE KANCELARIA PRAWNO “AJENTOWA "BELLEPAT" Izabela Szychuiska-Hawranek ul Słowackiego 44, 37-700 Przi»'nvśl tel. (016) 732-37-77 fax: (016) .176-02-87 tel kom. (0608) 503-081 e-maS bsltepat@op.pl NIP: 795-207-16-72 REGON: 1803505(6 Izabela Szychuiska-Hawranek ul. Słowackiego 44, 37-700 Przi »'nvśl tel. (016) 732-37-77 fax: (016). 176-02-87 mobile phone (0608) 503-081 e-maS bsltepat@op.pl NIP: 795-207-16-72 REGON: 1803505 (6 Pełnomocnik: Proxy: ίου ίου FIG. 1 FIG. 1 KANCELARIA PRAWNO-PATENTOWA "BELLEPAT" LAW AND PATENT OFFICE "BELLEPAT" Izabela Szychulska-Hawranek ul. Słowackiego 44, 37-700 Przemyśl tel. (016) 732-37-77 fax: (016) 675 02-87 mobile phone (0608) 503-081 e ~ mail:bellepat@OD.rt NIP: 795-207-16-72 REGON: 180 350 .. 6 Izabela Szychulska-Hawranek ul. Słowackiego 44, 37-700 Przemyśl tel. (016) 732-37-77 fax: (016) 675 02-87 tel. kom. (0608) 503-081 e~mail: bellepat@OD.rt NIP: 795-207-16-72 REGON: 180350.. 6 Pełnomocnik: Proxy: REPRESENTATIVE MA Izaksla Sa ^ ulikc-Hawranek nrvipisu 3192 RZECZNAFATENTOWY mgr Izaksla Sa^ulikc-Hawranek nrvipisu 3192 205 205 FIG.2 FIG.2 Pełnomocnik: Proxy: KANCELARIA PRAWNO-PATENTOWA "BELLEPAT" LAW AND PATENT OFFICE "BELLEPAT" Iza bela Szych niska-Hawranek ul. Słowackiego ą 37-700 Przemyśl tel. (016) 732-37-77 fax: (016) 675 02-87 e~maii:Pellepat@OD.Dl NIP. 735-207-16-72 REGON'18935-· β Iza bela Szych niska-Hawranek ul. Słowackiego ą 37-700 Przemyśl tel. (016) 732-37-77 fax: (016) 675 02-87e~Maii:Pellepat@OD.Dl NIP. 735-207-16-72 REGON'18935- · β RZECZĄ: ΡΑΤΞΝΤΟν/Υ mgr Izabelo 'Syffiuldtff-Hawranek nr M&i3u 3192 THINGS: ΡΑΤΞΝΤΟν / Υ mgr Izabelo 'Syffiuldtff-Hawranek nr M & i3u 3192
60 paragraphs in 4 sections, as filed
Technical field
The present disclosure generally relates to internal combustion engines. More specifically, the disclosure relates to the operation of an internal combustion engine.
Background of the invention
The volatile crude oil and distillate market affects the cost of fuels for consumers. Increased costs can translate into prices for kerosene, gasoline and diesel. Greater demand and higher prices mean that consumers want to achieve better performance of internal combustion engines. Engine performance, which is associated with fuel consumption, is usually defined as the comparison of all chemical fuel energy and usable energy in the form of kinetic energy obtained from fuel. The most basic concept of engine efficiency is the thermodynamic limit for obtaining energy from fuel as part of the thermodynamic cycle. The most general and economically important concept is engine economy, referred to, for example, as the number of miles driven per gallon in automotive applications.
Internal combustion engines, like those used in passenger cars, are engines in which fuel and oxidant are mixed and burned in the combustion chamber. Usually these are four-stroke engines. The four-stroke cycle includes suction, compression, combustion and exhaust stroke. As a result of the combustion reaction, heat and pressurized gases form, which expand. Expansion of the resulting gases affects the mechanical parts of the engine, causing the work to be used. The resulting gases allow obtaining more energy than the energy of the compressed fuel and oxidant mixture. After the available energy is used, the heat that has not been converted to work is removed by the cooling system as waste heat.
Unburned fuel is discharged from the engine during the exhaust stroke. To achieve almost complete combustion, it is necessary that the ratio of fuel to the oxidant during engine operation is close to the stoichiometric ratio. Although this reduces the amount of unburned fuel, it is the reason for the increase in emissions of certain regulated pollutants. These impurities can be the result of a weak mixture of fuel and oxidant formed before it enters the combustion chamber. In addition, the use of fuel in a ratio close to the stoichiometric ratio increases the risk of explosion. The danger of detonation is that the fuel spontaneously ignites in the engine before the end of the combustion stroke. Detonation can lead to irreversible damage to the engine. To avoid this, more fuel is introduced into the engines.
Thus, there is a need in the market for improved methods for mixing fuel and oxidant prior to injection into internal combustion engines.
Mixers are known based on US 6 383 237 B1, DE 297 13519 U1 and US 2002/0089074 A1.
SUMMARY OF THE INVENTION
A high shear system and a process for producing fuel fuel are disclosed. The method of creating the emulsion is: providing a high shear device having at least one set of toothed rotor and stator configured to achieve a tip speed of at least 5 m / s, introducing gas and liquid fuel into the high shear device, and producing an emulsion from gas and liquid fuel, the gas containing bubbles with an average diameter less than about 5 μm.
In the embodiment described in the present disclosure, the process uses a high shear mechanical device to provide better time, temperature and pressure conditions, which improves dispersion of multiphase compounds.
These and other embodiments, features and advantages will become apparent from the detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
To better illustrate the preferred embodiment of the present invention, the corresponding drawings are attached in which:
Figure 1 is a schematic of a high shear fuel system according to an embodiment of the disclosure.
Figure 2 shows a cross-section of a high shear device for obtaining aerated fuels.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
overview
The system and method of producing aerated fuel is disclosed in the disclosure, consisting of mixing liquid fuels and oxidizing gas using a high shear device. The system and method uses a high shear mechanical device to ensure immediate contact and mixing of reactants in a controlled environment in the reactor / mixer equipment before introducing them into the internal combustion engine. The high shear device accurately distributes oxidizing gases in liquid fuel to improve combustion. In some cases, the system is configured for transport.
For chemical reactions and mixtures of liquids, gases and solids, kinetic laws are taken into account, which are dependent on time, temperature and pressure, to determine reaction speed and mixing accuracy. When there is a need to combine into an emulsion two or more raw materials with different phases, for example solid and liquid, liquid and gas, solid, liquid and gas, one of the limiting factors determining the reaction speed and mixing accuracy is the contact time of the reactants . Notwithstanding the limitations associated with any particular theory, it is known that, according to the chemical laws of emulsion, submicroscopic particles, globules or bubbles dispersed in a liquid move primarily due to the action of Brownian motion during diffusion.
Mixing oxidants and fuels prior to combustion involves an additional risk of explosion. The explosion limit in air is measured as a percentage by volume at room temperature. The upper explosion limit parameter, hereinafter referred to as GGW, refers to the maximum gas or vapor concentration above which the substance will not ignite or explode because above this concentration the amount of oxidant is insufficient to ignite the fuel. The lower explosion limit parameter, hereinafter referred to as DGW, refers to the minimum gas or vapor concentration in the air below which the substance will not ignite or explode, because below this threshold the amount of oxidant is insufficient to ignite the fuel. Mixtures of fuel and oxidant between these limits create an increased risk of explosion. In order for combustion or explosion to occur, three components must be present in the correct ratio. In some cases, the ignition source may include a spark, flame, high pressure, or other sources without restrictions. Control of the oxidant / fuel mixture, conditions and containers are possible measures to reduce the risk of explosion.
DGW for gasoline is around 1.4% by volume and GGW around 7.6% by volume. For diesel, the risk of an explosion is lower compared to gasoline. This is because diesel has a higher flash point, which prevents rapid evaporation and the formation of a flammable aerosol. For diesel, DGW is about 3.5% by volume, GGW is about 6.9% by volume. Keeping fuel mixtures, such as gasoline or diesel, below LEL and above GGW is important to reduce the risk of explosion.
High shear fuel system
As shown in Figure 1, the High Shear Fuel System (SWŚP) 100 includes tank 50, pump 5, high shear device 40 and engine 10. SWŚP 100 includes vehicle 30. Vehicle 30 includes a car, truck, tractor, train or other transport vehicle without limiting myself to this. Optionally, the vehicle 30 may comprise a mobile, portable or other transportable engine, e.g. a generator. Vehicle 30 is driven or powered by engine 10. The engine 10 includes an internal combustion engine. In some embodiments, the engine 10 includes a gasoline or diesel engine. Optionally, the engine 10 may, without being limited to this, include any engine that operates by burning any fuels with an oxidizer, e.g. a petroleum or propane engine.
Fuels are stored in tank 50. Tank 50 is configured for storage, transport and consumption of liquid fuels. The tank 50 includes at least two holes, an inlet 51 and an outlet 52. The tank 50 is accessed from outside the vehicle 30 through the filling inlet 51. The tank 50 is connected to a motor 10 for transferring liquid through at least outlet 52. In some cases, the tank 50 comprises a fuel tank or a fuel cell. In some cases, the reservoir 50 may be pressurized. Optionally, the tank 50 may be configured to store gaseous fuels.
The outlet 52 is coupled to the fuel line 20 directed to the pump 5. The pump 5 is configured to transfer fuel from the tank 50 to the engine 10. In the embodiments, the pump 5 is connected to the tank 50 and the motor 10 for fluid transmission. Pump 5 is configured to maintain an elevated pressure in the fuel line, i.e. to create an elevated pressure 12 fuel line. Pump 5 has a fluid transfer connection to the elevated pressure 12 fuel line. In addition, the pump 5 can be configured to maintain elevated pressure in the SWŚP 100 and control the fuel flow through the SWŚP. The pump 5 may be any fuel pump configured to transfer fuel to the internal combustion engine known to those of skill in the art. Optionally, the pump 5 may include any suitable pump, for example a Roper type 1 gear pump from Roper Pump (Commerce, Georgia) or a pressure booster pump, model 2P372E, Dayton Electric Co (Niles, IL). In some cases, pump 5 is resistant to fuel corrosion. Optionally, all contact parts of the pump 5 contain stainless steel.
Pump 5 increases fuel pressure in fuel line 20 to be higher than atmospheric pressure, 101 kPa (1 atm); it is preferred that the pump 5 increases the pressure to 203 kPA (2 atm), possibly to a level above 304 kPA (3 atm). The pump 5 raises the pressure and feeds the high shear device 40 through the elevated pressure fuel line 12.
Pump 5 is drained through an elevated pressure fuel line 12. The elevated pressure fuel line 12 includes an oxidizer feeder 22. The oxidizer feeder 22 is configured to inject oxidants into an elevated pressure fuel line 12. The oxidizer feeder 22 may include a compressor or a pump to inject oxidants. to a high pressure fuel line 12. The oxidizer feeder 22 contains air. The oxidizer feeder 22 may contain fuel additives or alternative reactants for combustion or emission control. In addition, the oxidizer feeder 22 may contain a means for evaporating fuel additives for introduction into the pressurized fuel line 12. For example, the oxidizer feeder 22 may contain water, methanol, ethanol, oxygen, nitrous oxide, or other compounds as known to those skilled in the art for improving the performance, emissions and other engine performance parameters 10 without exclusivity. The elevated pressure fuel line 12 is further configured to supply fuel and oxidant to UWŚ 40. The elevated pressure fuel line 12 is connected to UWŚ 40 for fluid transfer. The oxidizer feeder 22 has a connection with UWŚ 40 for transferring liquid 40 through the elevated pressure fuel line 12. Alternatively, the oxidizer feeder 22 has a direct connection with UWŚ 40 for transferring liquid.
UWŚ 40 is configured to thoroughly mix oxidants from the feeder 22 and fuel in the high pressure fuel line. As discussed in detail below, the high shear device 40 is a mechanical device that uses, for example, a mixing head with a rotor and stator, between which there is a constant distance. In UWŚ 40, oxidizing gas and fuel are mixed to form an emulsion containing microbubbles and nanobubbles of oxidizing gas. In embodiments, the dispersion results in submicroscopic-sized vesicles. In embodiments, the dispersion produces bubbles with an average size less than about 1.5 μm. In embodiments, the bubble size is from about 0.1 μm to about 1.5 μm. In embodiments, the average bubble size is less than about 400nm, more preferably less than about 100nm.
UWŚ 40 is used to form emulsions with oxidizing gas bubbles in the fuel injection line 19. The emulsion may also contain microfoam. In some cases, the emulsion may contain aerated fuel or liquid fuel with a gas component. Regardless of the assumptions associated with any particular method, it is known that, according to the chemical laws of emulsion, submicroscopic particles, globules or bubbles dispersed in a liquid move primarily due to the action of Brownian motion. In embodiments, high shear mixing creates air bubbles that are able to remain dispersed at atmospheric pressure for about 15 minutes. The bubbles in some cases are able to remain dispersed for a much longer time depending on their size. UWŚ 40 is connected to the engine 10 for transferring fluid through the fuel injection line 19. The fuel injection line 19 is configured to transport combustion fuel to the engine 10.
The fuel injection line is configured to supply the fuel and oxidant emulsion to the engine 10. The fuel injection line 19 is coupled to UWŚ 40 and a liquid engine 10.
The fuel injection line is configured to maintain the emulsion beyond the explosion limits of the fuel, namely below DGW and above GGW. The fuel injection line 19 further includes insulation against flames, sparks, heat, electrical discharges, or other potential sources of ignition. In some cases, the fuel injection line 19 may include, without exclusive, any components associated with the vehicle's fuel injection system, e.g., fuel pressure regulators, fuel rail and fuel injectors.
As discussed above, the SWŚP 100, components and operation of the SWŚP 100 are monitored and controlled by the on-board processor or injection controller (ECU) 75. The ECU 75 includes any processor configured for vehicle monitoring, detecting, modifying and controlling devices. In addition, the ECU 75 can be electrically connected, without exclusivity, to sensors, solenoids, pumps, relays, switches or other components that are means of regulating or modifying the operation of the SWŚP 100 to change the operating parameters of the motor. ECU 75 is configured to control the operation of UWŚ 40, for example to ensure safe oxidant emulsion in fuel.
In the example configuration, SWŚP 100 is configured to operate with a diesel engine. SWŚP 100 aerates diesel fuel at a level above GGW. Aeration is the process of adding oxidizing gas to the fuel, for example as very small bubbles, so that when injected into the engine, the fuel burns to a near-complete level.
In SWŚP 100 diesel fuel is stored in tank 50. Diesel fuel is taken from tank 50 by pump 5. When pump 5 supplies diesel oil to high shear device 40, negative pressure in fuel line 20 causes fuel to be taken from tank 50. Pump 5 increases the pressure of liquid diesel fuel.
When the fuel under pressure 12 leaves the pump 5 and an oxidizer is introduced into it from the feeder 22, a mixture of oxidant and fuel is included in the fuel line at elevated pressure 12;
they are two components from three components needed for ignition. In this embodiment, the oxidant contains air. Regardless of the assumptions of any particular theory, it is assumed that a high pressure liquid is more difficult to evaporate. Thus, diesel fuel is above GGW, i.e. the upper explosion limit. The oxidizer and fuel under pressure are mixed at UWŚ 40. Because the system is under pressure and the fuel is above GGW, it does not ignite or explode. In addition, the oxidizing gas breaks down into microbubbles and nanobubbles, and disperses throughout the fuel. The scattered microbubbles and nanobubbles in the fuel are part of the emulsion. The fuel injection line 19 feeds the emulsion to the engine 10 for combustion.
In engine 10, the emulsion is burned with additional air from the atmosphere. Because diesel fuel is an air emulsion, it can be injected into the engine in quantities exceeding the stoichiometric amount. Regardless of theoretical restrictions, it is assumed that diesel fuel can burn to a degree close to the total, which is associated with a reduction in emissions of regulated pollutants, for example oxides and nitrogen. In addition, the diesel emulsion does not detonate in the engine. Detonation is the ignition of fuel in the engine before the correct moment in a four-stroke cycle. Consequently, the diesel emulsion burns more, reducing pollutant emissions, and improving efficiency and efficiency. Obtaining a high shear fuel system 100 to improve these parameters is possible by using a high shear device 40.
High shear device
High-shear devices (apparatus), such as high-shear mixers and high-shear grinders, are generally divided into classes based on their fluid mixing ability. Mixing is a process of reducing the size of heterogeneous particles in a fluid. One measure of the degree or accuracy of mixing is the energy density that the mixing device generates per volume unit to break up the fluid. Classes are distinguished based on the energy density obtained. There are three classes of industrial mixers with sufficient energy density to produce uniform mixtures or emulsions with particle or bubble sizes in the range of 0 to 50 μm.
Homogenizing valve systems are usually classified as high energy devices. The processed fluid is pumped under very high pressure through a narrow gap valve to a lower pressure environment. The pressure gradually decreases in the valve, and the resulting turbulence and cavitation cause the particles to break up in the fluid. Such valve systems are most commonly used in milk homogenization and allow particle sizes ranging from about 0.01 mm to about 1 mm. At the other end of the spectrum are high shear mixing systems, classified as low energy devices. These systems usually have blades or rotors that rotate at a high speed in the fluid processing tank, which in most common applications is a food product. They are used when the average particle, globule or bubble size above 20 microns is acceptable in the fluid being processed.
In terms of fluid mixing energy density, colloid mills are classified between low energy high shear mixers and valve homogenization systems, which are classified as intermediate energy devices. A typical colloid mill configuration includes a conical or disc rotor, which is separated from the complementary, liquid-cooled stator with a precisely controlled gap between the rotor and stator, which can range from 0.025 mm to 10.0 mm. The rotors can preferably be driven by an electric motor directly or by a belt mechanism. After proper adjustment, many colloid mills can allow average particle or globule sizes from 0.01 μm to about 25 μm in the processed fluid. These possibilities make colloid mills suitable for a variety of applications, including for processing colloid and oil / water emulsions, such as the preparation of cosmetics, mayonnaise, silicone and silicon amalgam, and roof tar mixtures.
Figure 2 is a schematic of a high shear device 200. The high shear device comprises a combination of at least one rotor and stator. Rotors and non-exclusive stators may also be known as generators 220, 230, 240 or staged components. The high shear device comprises at least two generators, and most preferably the high shear device comprises at least three generators.
The first generator 220 includes rotor 222 and stator 227. The second generator 230 includes rotor 223 and stator 228; and the third generator includes rotor 224 and stator 229. For each generator 220, 230, 240 the rotor is rotatably driven from input 250. Generators 220, 230, 240 are configured to rotate around axis 260 in the direction of rotation 265. Stator 227 is constantly coupled to the wall of the high shear device 255. For example, the rotor 222, 223, 224 may have a cone or disc shape and may be separated from the complementarily shaped stator 227, 228, 229. In embodiments, the rotor and stator comprise a plurality of circumferentially spaced rings having complementary shaped tips. The ring may comprise a single surface or a single tip surrounding the rotor or stator. In embodiments, both the rotor and the stator comprise more than two circumferentially placed rings, more than three rings, or more than four rings. For example, in embodiments, each of the three generators includes a rotor and a stator having three complementary rings, due to which the processed material passes through nine shear gaps or step elements after passing through UWŚ 200. Alternatively, each of the generators 220, 230, 240 can contain four rings, thanks to which the processed material passes through twelve shear gaps or staged elements after passing through UWŚ 200. Each of the generators 220, 230, 240 can be driven by any drive system configured for creating the necessary rotation.
The generators contain gaps between the rotor and stator. In some embodiments, the stators (stator) can be adjusted to achieve the desired shear gap between the rotor and the stator of each generator (rotor and stator assembly). The first generator 220 includes a first slot 225; second generator 230 includes a second slot 235; and the third generator 240 includes a third slot 245. Slots 225, 235, 245 have a width from about 0.025 mm (0.01 inches) to 10.0 mm (0.4 inches). Optionally, the process uses a high shear device 200, where the gaps 225, 235, 245 range from about 0.5 mm (0.02 inches) to about 2.5 mm (0.1 inches). In some cases, a gap of about 1.5 mm (0.06 inch) is maintained. Alternatively, gaps 225, 235, 245 differ between generators 220, 230, 240. In some cases, the gap 225 of the first generator 220 is larger than the gap 235 of the second generator 230, which is larger than the gap 245 of the third generator 240.
In addition, the width of the slots 225, 235, 245 may specify coarse, medium, accurate or precise characteristics. Rotors 222, 223 and 224 and stators 227, 228 and 229 can be toothed. Each generator may contain two sets or more sets of rotor and stator teeth known in the art. Rotors 222, 223 and 224 may include a number of teeth arranged around the periphery of each rotor. Stators 227, 228 and 229 may contain a number of teeth arranged on the perimeter of each stator. In further embodiments, the outer diameter of the rotor may be about 6.0 cm and the stator about 6.4 cm. In embodiments, the outer diameter of the rotor is from 11.8cm to about 35cm. In embodiments, the outer diameter of the stator is from about 15.4cm to about 40cm. Optionally, the rotor and stator may have alternating diameters to vary tip speed and shear pressure. In some embodiments, each of the three stages proceeds using a very accurate generator, having a gap of about 0.025mm to about 3mm.
The high shear device 200 is fed with a reaction mixture containing feed stream 205. Feed stream 205 comprises a dispersible phase and a continuous phase. The term "emulsion" refers to a liquefied mixture that contains distinguishable substances (or phases) that do not mix easily or dissolve in each other. Most emulsions have a continuous phase (or matrix) in which dispersed droplets, bubbles and / or particles of another phase or substance persist. The emulsions may have a high viscosity, for example suspensions or pastes, or may be foams with small gas bubbles suspended in a liquid. As used herein, the term "emulsion" includes continuous phases containing gas bubbles, continuous phases containing particles (e.g., solid catalyst), continuous phases containing droplets or globules of insoluble fluid in the continuous phase, and combinations thereof.
Feed stream 205 may contain a catalyst component in the form of particulate matter. Feed stream 205 is pumped through generators 220, 230, 240 to disperse product 210. In each generator, rotors 222, 223, 224 rotate at high speed relative to solid stator 227, 228, 229. The rotation of the rotors causes a fluid such as in feed stream 205 to be pumped between the outer surface of the rotor 222 and the inner surface of the stator 227, which creates high shear conditions. High-shear forces are generated in slots 225, 235, 245, which the feed stream 205 is subjected to. High-shear forces between the rotor and stator result in the processing of feed stream 205 and dispersions in product 210. Each high shear generator 220, 230, 240 200 has interchangeable combinations of rotor and stator, which allows a narrow distribution of the desired bubble size if feed stream 205 contains gas, or globules if feed stream 205 contains liquid during dispersion in product 210.
The dispersed product 210 as particles, globules or bubbles in a liquid comprises an emulsion. In embodiments, the dispersed product 210 may include a previously immiscible or insoluble gas, liquid or solid in a continuous phase. The dispersed product 210 has an average gas, globule or bubble size smaller than 1 m; preferably the globules have a submicroscopic diameter. In some cases, the average globule size is in the range of about 1 m to about 0.1 m. Optionally, the average globule size is less than 400nm (0.4 μm), and most preferably less than about 100nm (0.1μ ^ ι).
The speed of the tip is the speed (m / s) of the end of one rotating energy transfer element of the reactants or more. For a rotating element, the speed of the tip is the circumferential distance traveled by the rotor tip per unit of time and is generally expressed by the equation V (m / s) = π-D -n ,, where V is the speed of the tip, D is the diameter of the rotor in meters , an denotes the rotor speed as revolutions per second. Thus, tip speed is a function of rotor diameter and rotational speed.
Tip speeds of colloid mills typically exceed 23 m / s (4500 ft / min) and can exceed 40 m / s (7900 ft / min). In the present disclosure, the term "high shear" refers to rotor-stator mechanical devices, such as mills or agitators, whose tips reach a speed exceeding 5 m / s (1000 ft / min) and require an external, mechanically driven device to transfer energy to the product stream that are supposed to react with each other. In some cases, tip speed exceeding 22.9 m / s (4500 ft / min) is achievable and may exceed 225 m / s (44.200 ft / min). The high shear device combines high tip speeds with a very small shear gap, which results in high friction / shear of the processed material. Thus, during operation, it is possible to locally achieve pressure in the range of about 1000 MPa (about 145,000 psi) to about 1050 MPa (152,300 psi) and elevated temperatures at the tip of the shear mixer (depending on the shear gap, tip speed and other factors). In some embodiments, the local pressure is at least 1034 MPa (about 150,000 psi). Local pressure also depends on tip speed, fluid viscosity and the gap between rotor and stator during operation.
The input energy for fluid (kW / l / min) can be approximately determined by measuring the engine energy (kW) and fluid yield (l / min). In embodiments, the energy consumption of the high shear device is greater than 1000 W / m<sup>3</sup>. In embodiments, the energy consumption is in the range of about 3000 W / m<sup>3</sup> up to about 7500 W / m<sup>3</sup>. The combination of high tip speed and a very small shear gap in the shear apparatus 200 allows for high shear. The shear rate usually depends on the viscosity of the fluid. The shear rate is the tip speed divided by the width of the shear gap (minimum clearance between rotor and stator). The shear rate achieved by the high shear machine 200 may be greater than 20,000 s<sup>-1</sup>. In some embodiments, the shear rate is at least 40,000 s<sup>-1</sup>. In some embodiments, the shear rate is at least 100,000 s<sup>-1</sup>. In some embodiments, the shear rate is at least 500,000 s<sup>-1</sup>. In some embodiments, the shear rate is at least 1,000,000 s<sup>-1</sup>. In some embodiments, the shear rate is at least 1,600,000 s<sup>-1</sup>. In some embodiments, the shear rate achieved by UWŚ 40 ranges from 20,000 s<sup>-1</sup> is 100,000 p<sup>-1</sup>. For example, in one application, the rotor tip speed is about 40 m / s.
(7900 feet / min); the gap width is 0.0254 mm (0.001 inch), which results in a shear rate of 1,600,000 seconds<sup>-1</sup>. In another application, the rotor tip speed is approximately 22.9 m / s (4500 feet / min), and the shear gap width is 0.0254 mm (0.001 inch), which results in a shear rate of 901.600 s<sup>-1</sup>. In embodiments where the rotor has a larger diameter, the shear rate may exceed about 9,000,000 s<sup>-1</sup>.
The high shear device 200 allows the formation of a gas emulsion to remain dispersed at atmospheric pressure for at least about 15 minutes. In the present disclosure, an emulsion of gaseous particles, globules or bubbles in a dispersed phase in the product
210, whose diameter is less than 1.5 μm may contain foam. Regardless of the limitations associated with any particular theory, it is known that, according to the chemical laws of emulsion, submicroscopic particles, spheres or bubbles dispersed in a liquid move primarily due to the action of Brownian motion.
The choice of the high shear device depends on the processing requirements and the desired particle size or bubble size dispersed in the final product 210. In some cases, the high shear device 200 includes the Dispax Reactor® reactor from IKA® Works, Inc. Wilmington, NC and APV North America, Inc. Wilmington, MA. The DR 2000/4 model, for example, includes a belt drive, 4M generator, PTFE sealing ring, inlet flange 2.5 cm (1 "), sanitary clamp, outlet flange (1.9 cm) sanitary clamp, high pressure 2HP supply, it has a rotational speed of 7900 rpm, water throughput from about 300 l / h to about 700 l / h (depending on the generator), tip speed from 9.4 m / s to about 41 m / s (about 1850 ft / min to about 8070 ft / min). Several alternative models are available with different inlet / outlet connections, different horsepower, different tip speeds, different rpm and different throughput. For example, the Super Dispax Reactor DRS 2000 reactor. The RFB unit can be a DR 2000/50 unit having a capacity of 125,000 liters per hour or a DRS 2000/50 unit having a capacity of 40,000 liters / hour.
Regardless of the limitations associated with a particular theory, it is assumed that the level or degree of mixing due to high shear is sufficient to increase the mass transfer rate and may be the cause of local, ideal conditions that will allow a reaction that would not otherwise have been assumed as assumed Gibbs regarding free energy. It is assumed that local, ideal conditions may appear in the high shear device and lead to an increase in temperature and pressure, with the largest increase in local pressure values. The increase in temperature and pressure in the high shear device is immediate and local, moreover, the system returns to general or medium system conditions quickly after the fuel leaves the high shear device. In some cases, the high shear device causes cavitation of sufficient intensity to separate one or more reactants as free radicals that can intensify the chemical reaction or allow it to occur under less stringent conditions than would be needed. Cavitation can also cause an increase in transfer rate, causing local turbulence and microcirculation of liquids (acoustic flow).
Although preferred embodiments of the invention have been shown and described, one of ordinary skill in the art can make modifications thereof without departing from the spirit of the invention. The embodiments described herein are illustrative only and are not limiting. There are many possible variants and modifications of the invention disclosed herein which fall within its scope. If explicit, numerical intervals or restrictions are given, they are to be understood as being indicative of the iteration of ranges or restrictions subject to such explicit intervals and restrictions. (e.g., "from about 1 to about 10" includes, 2, 3, 4, etc.; "greater than" includes 0.10, 0.11, 0.12, 0.13, and so on). The term "optional" for any item in the claim means that the item is required or not required. Both alternatives are within the scope of the invention. The use of broader terms such as "includes", "includes", "having" should be understood as supporting words for narrower terms such as "consists of" "essentially consists", "is essentially composed of" and the like.
Therefore, the scope of protection is not limited by the above description but by the following reservations.
Proxy:
"ATENTOWA" BELLEPAT "LAW OFFICE
Izabela Szych nluka-Hawranek ul Słowackiego 44, 37-700 Pnrenłuśl tel. (016) 7jk-37-77 fax: (016) 675-02-87 mobile phone (0608) 503-081 e-mati <a href="mailto:bellepat@op.pl">bellepat@op.pl</a> NIP: 795-207-16-72 REGON: 1803505 (6
<img file="PL2294296T3_D0001.tif" />
mgr Izabelh Sf chulika-Ha ^ n / ifk nr dpi su 3192
Contents4
27 members in 12 offices
Priority claims6
| Document | Office | Kind | Date |
|---|---|---|---|
| 7815408 | United States of America | P | |
| 09773987 | European Patent Office (EPO) | A | |
| 2009045988 | United States of America | W | |
| EP20090773987 | – | – | – |
| US20080078154P | – | – | – |
| WO2009US45988 | – | – | – |
Members27
| Document | Office | Kind | |
|---|---|---|---|
| CA2728531A1 | Canada | A1 | |
| US2010000502A1 | United States of America | A1 | |
| WO2010002535A2 | World Intellectual Property Organization (WIPO) | A2 | |
| WO2010002535A3 | World Intellectual Property Organization (WIPO) | A3 | |
| EP2294296A2 | European Patent Office (EPO) | A2 | |
| KR20110028645A | Republic of Korea | A | |
| CN102084102A | China | A | |
| HK1148801A1 | Hong Kong, China | A1 | |
| JP2011526997A | Japan | A | |
| EA201071322A1 | Eurasian Patent Organization (EAPO) | A1 | |
| US8261726B2 | United States of America | B2 | |
| EP2294296A4 | European Patent Office (EPO) | A4 | |
| US2012291763A1 | United States of America | A1 | |
| KR101237891B1 | Republic of Korea | B1 | |
| CA2728531C | Canada | C | |
| US8522759B2 | United States of America | B2 | |
| US2013276737A1 | United States of America | A1 | |
| EA019107B1 | Eurasian Patent Organization (EAPO) | B1 | |
| CN102084102B | China | B | |
| US8807123B2 | United States of America | B2 | |
| CN104100420A | China | A | |
| EP2294296B1 | European Patent Office (EPO) | B1 | |
| JP5713894B2 | Japan | B2 | |
| ES2535460T3 | Spain | T3 | |
| PL2294296T3This record | Poland | T3 | |
| BRPI0914104A2 | Brazil | A2 | |
| BRPI0914104B1 | Brazil | B1 |
Numbers
- Publication, DOCDB
- 2294296
- Publication, EPODOC
- PL2294296T
- Application
- 773987
- Application, DOCDB
- 09773987
- Application, EPODOC
- PL20090773987T
Titles2
- English
- HIGH SHEAR PROCESS FOR AIR/FUEL MIXING
- Polish
- Proces wysokiego ścinania w celu mieszania powietrza i paliwa
Classification
- CPC, 3
- F02B43/00
- C10L1/32
- F02M29/02
- IPC, 4
- F02B45 10
- B01F3 00
- B01F7 16
- C10L1 32