Diesel emissions filtering system and method

Abstract

The invention is embodied in an emission control system for reducing diesel particulate matter (DPM) from diesel engine exhaust gases comprising an aqueous filter apparatus constructed and arranged to form a water bath for all exhaust gas output from the engine and including in the water bath a preselected significant quantity of a low foaming wetting composition having a high affinity for hydrocarbons. The invention is further embodied in a diesel emissions filtering method including pre-filtering diesel fuel and removing DPM from exhaust gases by filtration through an aqueous solution having a low foaming wetting composition.

1 . An emission control system for reducing diesel particulate matter (DPM) from the exhaust gas output from a diesel engine, comprising an aqueous filter apparatus positioned in the exhaust output passageway from the diesel engine and being constructed and arranged to form a water bath in said passageway through which all DPM laden exhaust gases from said engine must pass before being discharged to ambient, the water bath of said aqueous filter apparatus comprising water as a major constituent and a wetting composition as a minor constituent, said wetting composition comprising a chemical hydrocarbon cleaner including at least one component selected from the group consisting of detergents, soaps, surfactants and mixtures thereof, and a defoaming agent.  
   
   
       2 . The emission control system of  claim 1 , in which said aqueous filter apparatus comprises a gas scrubber tank filled to a predetermined level with said water bath, said exhaust output passageway having a discharge end positioned below the level of said water bath, and gas diffusing means in said tank for dispersing exhaust outflow gases throughout the water bath.  
   
   
       3 . The emission control system of  claim 2 , wherein said gas diffusing means comprises a perforated gas discharge pipe at the discharge end of said passageway whereby to effect percolation of exhaust gases through the water bath.  
   
   
       4 . The emission control system of  claim 2 , in which said gas scrubber tank has an exhaust discharge outlet to ambient, and wherein said gas diffusing means comprises vertical baffle means disposed in said gas scrubber tank between the discharge end of said exhaust output passageway into the water bath and said exhaust discharge outlet to thereby produce circuitous flow paths of exhaust gases through the water bath in said tank.  
   
   
       5 . The emission control system of  claim 4 , wherein said vertical baffle means includes plural horizontal ports extending therethrough to provide limited by-pass flow of exhaust gases across said circuitous gases flow paths.  
   
   
       6 . The emission control system of  claim 2 , in which said gas scrubber tank has an exhaust gas inlet end receiving the exhaust output passageway from the engine, and having an exhaust gas outlet end above the level of the water bath and forming a gas discharge outlet to ambient, said gas diffusing means for dispersing including at least two mixing means for creating circuitous and turbulent flow of exhaust gases through said water bath.  
   
   
       7 . The emission control system of  claim 6 , wherein one of said mixing means comprises a perforated gas discharge pipe on the inlet side of said scrubber tank for discharging of exhaust gases from said exhaust output passageway through the water bath.  
   
   
       8 . The emission control system of  claim 6 , wherein one of said mixing means comprises a plurality of baffles between the inlet and outlet ends of said scrubber tank to circulate exhaust gases intimately throughout the water in serpentine flow paths around and between the baffles.  
   
   
       9 . The emission control system of  claim 8 , including another mixing means in the form of ports through the baffles to accommodate minor limited direct flow of a portion of exhaust gases through the baffles in a direction substantially perpendicular to the serpentine flow direction of exhaust gases around and between the baffles.  
   
   
       10 . The emission control system of  claim 1 , including water level sensing means for assuring safe operating water levels of said water bath.  
   
   
       11 . The emission control system of  claim 1 , in which said aqueous filter apparatus comprises water curtain means for discharging an aqueous water wall formed of a solution of said major body of water and minor amount of super-wetting agent.  
   
   
       12 . The emission control system of  claim 11 , in which said water curtain means comprises closed scrubber tank means having a gas inlet side connecting to the engine and a gas discharge side connecting to ambient, a supply source of blended water and wetting composition, and water spray means for discharging a continuously flowing curtain wall of such solution across the tank means, and said gas inlet side having gas dispersing means for discharging exhaust gases from the engine throughout the upstream inlet side for passage therefrom through the curtain wall to the downstream outlet side.  
   
   
       13 . The emission control system of  claim 12 , in which said supply source hold a relatively large amount of blended water and wetting composition and said scrubber tank means is relatively small, and said scrubber tank means including discharge means for outflowing used solution from the bottom thereof.  
   
   
       14 . The emission control system of  claim 13 , in which said scrubber tank means has a volumetric capacity in the range of 4 to 10 gal. and said supply source of solution comprises a solution blending tank having a volumetric capacity in the range of 25 to 60 gal.  
   
   
       15 . The emission control system of  claim 12 , including means for regulating the flow of solution to said water spray means.  
   
   
       16 . The emission control system of  claim 2 , in which said aqueous filter apparatus comprises a gas scrubber tank of relatively large size holding a water bath in the volumetric range of 25 to 55 gal.  
   
   
       17 . The emission control system of  claim 2 , in which said gas scrubber tank has a relatively small size holding a water bath in the volumetric range of 3 to 10 gal., and a supply source of blended water and wetting composition solution constructed and arranged for maintaining the water bath level in said scrubber tank.  
   
   
       18 . The emission control system of  claim 1 , in combination with a diesel fuel pre-filter constructed and arranged upstream of the diesel engine for removing non-fuel contaminates from the diesel fuel to thereby improve engine performance.  
   
   
       19 . The emission control system of  claim 18 , in which said fuel pre-filter is interposed in the fuel supply line to the diesel engine, and is constructed for filtering non-combustible contaminates of the diesel fuel whereby to provide a substantially totally-combustible diesel fuel supply to the engine.  
   
   
       20 . The emission control system of  claim 19 , in which said fuel pre-filter includes a first filter for filtering water out of the diesel fuel, and a second filter for filtering air out of the diesel fuel.  
   
   
       21 . The emission control system of  claim 1 , in which the wetting composition is phosphate-free.  
   
   
       22 . The emission control system of  claim 21 , in which the wetting composition is nitrate-free.  
   
   
       23 . The emission control system of  claim 1 , in which the chemical hydrocarbon cleaner is low-foaming.  
   
   
       24 . The emission control system of  claim 23 , wherein the chemical hydrocarbon cleaner comprises at least one surfactant selected from the group consisting of anionic surfactants, cationic surfactants, nonionic surfactants, amphoteric surfactants and mixtures thereof.  
   
   
       25 . The emission control system of  claim 23 , wherein the wetting composition further comprises an organic solvent.  
   
   
       26 . The emission control system of  claim 25  wherein the chemical hydrocarbon cleaner comprises an anionic surfactant.  
   
   
       27 . The emission control system of  claim 26  wherein the anionic surfactant is selected from alkylether sulfates, alkyl sulfates and mixtures thereof.  
   
   
       28 . The emission control system of  claim 25  wherein the chemical hydrocarbon cleaner comprises an amphoteric surfactant.  
   
   
       29 . The emission control system of  claim 25  wherein the chemical hydrocarbon cleaner comprises a nonionic surfactant.  
   
   
       30 . The emission control system of  claim 29  wherein the nonionic surfactant is selected from the group consisting of ethoxylated alcohol, alkanolamines and mixtures thereof.  
   
   
       31 . The emission control system of  claim 30  wherein the nonionic surfactant comprises an ethoxylated nonylphenol.  
   
   
       32 . The emission control system of  claim 31  wherein the nonionic surfactant comprises a mixture of an ethoxylated nonylphenol and an alkanolamine.  
   
   
       33 . The emission control system of  claim 32  wherein the nonionic surfactant comprises a mixture of an nonoxynol 10 and monoethanolamine.  
   
   
       34 . The emission control system of  claim 31  wherein the organic solvent comprises an alkylene glycol ether.  
   
   
       35 . The emission control system of  claim 34  wherein the organic solvent comprises dipropylene glycol methyl ether.  
   
   
       36 . The emission control system of  claim 31  wherein the defoaming agent is selected from petroleum-based antifoams, silicone-based antifoams and mixtures thereof.  
   
   
       37 . The emission control system of  claim 36  wherein the defoaming agent comprises a silicon-based antifoam.  
   
   
       38 . The emission control system of  claim 37  wherein the silicon-based anti-foam comprises an organosiloxane.  
   
   
       39 . The emission control system of  claim 38  wherein the silicon-based anti-foam comprises polydimethylsiloxane.  
   
   
       40 . The emission control system of  claim 31  wherein the wetting composition further comprises a coupling agent.  
   
   
       41 . The emission control system of  claim 40  wherein the coupling agent comprises tetrasodium EDTA.  
   
   
       42 . The emission control system as set forth  41  wherein the chemical hydrocarbon cleaner comprises a soap formed by saponifying a tall oil fatty acid with a caustic comprising an alkanolamine.  
   
   
       43 . The emission control system as set forth in  claim 1  wherein the wetting composition comprises: 
 water;    a chemical hydrocarbon cleaner comprising ethoxylated nonylphenol nonionic surfactant and a soap formed by saponifying a tall oil fatty acid with monoethanolamine;    an organic solvent comprising dipropylene glycol methyl ether;    a coupling agent comprising tetrasodium EDTA; and    a defoaming agent comprising a silicone-based antifoam.    
   
   
       44 . The emission control system of  claim 43  wherein the ethoxylated nonylphenol nonionic surfactant comprises nonoxynol 10.  
   
   
       45 . The emission control system of  claim 44  wherein the silicone-based antifoam comprises a polydimethylsiloxane.  
   
   
       46 . The emission control system of  claim 1  wherein the wetting composition comprises: 
 at least about 35% by weight water;    a chemical hydrocarbon cleaner comprising an ethoxylated nonylphenol nonionic surfactant and a soap formed by saponifying a tall oil fatty acid with monoethanolamine, wherein the composition comprises from about 10% to about 30% by weight ethoxylated nonylphenol nonionic surfactant, from about 2% to about 8% by weight tall oil fatty acid and from about 1% to about 5% by weight monoethanolamine;    an organic solvent comprising dipropylene glycol methyl ether, wherein the composition comprises from about 5% to about 15% by weight dipropylene glycol methyl ether;    a coupling agent comprising tetrasodium EDTA, wherein the composition comprises at least about 0.5% by weight tetrasodium EDTA; and    a defoaming agent comprising a silicon-based antifoam, wherein the composition comprises at least about 1% by weight silicon-based antifoam.    
   
   
       47 . The emission control system of  claim 46  wherein the ethoxylated nonylphenol nonionic surfactant comprises nonoxynol 10.  
   
   
       48 . The emission control system of  claim 46  wherein the silicone-based antifoam comprises a polydimethylsiloxane.  
   
   
       49 . The emission control system of  claim 2 , in which said gas scrubber tank has an exhaust discharge outlet leading to ambient and, in combination therewith, a final gas filter constructed and arranged to filter substantially all residual DPM material from the cooled and cleaned exhaust gases passing from the gas scrubber tank.  
   
   
       50 . A diesel cleaning system for achieving optimum diesel engine performance and maximum removal of DPM and CO from diesel exhaust emission gases, comprising the steps of: 
 pre-filtering diesel fuel upstream of a diesel engine to remove non-combustibles and enhance more complete fuel burning to minimize residual hydrocarbon content in exhaust gases;    dispersing diesel exhaust emission gases through a water bath having water as a major constituent and as a minor constituent a wetting composition comprising a chemical hydrocarbon cleaner comprising at least one component selected from the group consisting of detergents, soaps, surfactants and mixtures thereof, and a defoaming agent, to thereby remove the majority of DPM matter from such gases.    
   
   
       51 . A method of improving diesel engine performance and removing deleterious materials from diesel fuel and diesel exhaust gases, comprising the steps of: 
 pre-filtering diesel fuel upstream of the engine to remove non-combustible contaminates therefrom;    filtering diesel exhaust gases downstream of the engine to remove DPM and carbon monoxide therefrom including the step of passing such exhaust gases through an aqueous water bath having water as a major constituent and as a minor constituent a wetting composition comprising a chemical hydrocarbon cleaner comprising at least one component selected from the group consisting of detergents, soaps, surfactants and mixtures thereof, and a defoaming agent.    
   
   
       52 . A DPM removal method for removing diesel particulate matter (DPM) from the exhaust gas emission of diesel engines used in class  32  gaseous environment applications, including the steps of: 
 providing water scrubber means downstream of the diesel engine to receive exhaust gas outflow therefrom,    providing an aqueous solution for the water scrubber means comprising a water bath having water as a major constituent and as a minor constituent a wetting composition comprising a chemical hydrocarbon cleaner comprising at least one component selected from the group consisting of detergents, soaps, surfactants and mixtures thereof, and a defoaming agent, and    creating an intimate dispersion of the exhaust gas emission through the aqueous solution of the water scrubber means.    
   
   
       53 . The method of cleaning carbonaceous matter from a first medium, comprising the steps of: 
 selecting a chemical hydrocarbon cleaner including at least one component selected from the group consisting of detergents, soaps, surfactants and mixtures thereof;    selecting a defoaming agent as a secondary constituent;    formulating a wetting composition by combining the primary and secondary constituents in pre-determined proportion;    admixing a major portion of water with a minor portion of the wetting composition to constitute an aqueous solution as a second medium; and    dispersing one of said first and second mediums intimately with the other of said mediums to effectively remove carbonaceous matter from the first medium to the second medium.    
   
   
       54 . A wetting composition useful in treating diesel exhaust emission gases to reduce the concentration of particulate matter and/or carbon monoxide, the composition comprising: 
 water;    a chemical hydrocarbon cleaner comprising at least one component selected from the group consisting of detergents, soaps, surfactants and mixtures thereof; and    a defoaming agent.    
   
   
       55 . The wetting composition of  claim 54  wherein the composition is phosphate-free.  
   
   
       56 . The wetting composition of  claim 54  wherein the composition is nitrate-free.  
   
   
       57 . The wetting composition of  claim 54  wherein the chemical hydrocarbon cleaner is low-foaming.  
   
   
       58 . The wetting composition of  claim 54  wherein the chemical hydrocarbon cleaner comprises at least one surfactant selected from the group consisting of anionic surfactants, cationic surfactants, nonionic surfactants, amphoteric surfactants and mixtures thereof.  
   
   
       59 . The wetting composition of  claim 58  further comprising an organic solvent.  
   
   
       60 . The wetting composition of  claim 59  wherein the chemical hydrocarbon cleaner comprises an anionic surfactant.  
   
   
       61 . The wetting composition of  claim 60  wherein the anionic surfactant is selected from alkylether sulfates, alkyl sulfates and mixtures thereof.  
   
   
       62 . The wetting composition of  claim 59  wherein the chemical hydrocarbon cleaner comprises an amphoteric surfactant.  
   
   
       63 . The wetting composition of  claim 59  wherein the chemical hydrocarbon cleaner comprises a nonionic surfactant.  
   
   
       64 . The wetting composition of  claim 63  wherein the nonionic surfactant is selected from the group consisting of ethoxylated alcohol, alkanolamines and mixtures thereof.  
   
   
       65 . The wetting composition of  claim 64  wherein the nonionic surfactant comprises an ethoxylated nonylphenol.  
   
   
       66 . The wetting composition of  claim 65  wherein the nonionic surfactant comprises a mixture of an ethoxylated nonylphenol and an alkanolamine.  
   
   
       67 . The wetting composition of  claim 66  wherein the nonionic surfactant comprises a mixture of an nonoxynol 10 and monoethanolamine.  
   
   
       68 . The wetting composition of  claim 65  wherein the organic solvent comprises an alkylene glycol ether.  
   
   
       69 . The wetting composition of  claim 68  wherein the organic solvent comprises dipropylene glycol methyl ether.  
   
   
       70 . The wetting composition of  claim 65  wherein the defoaming agent is selected from petroleum-based antifoams, silicone-based antifoams and mixtures thereof.  
   
   
       71 . The wetting composition of  claim 70  wherein the defoaming agent comprises a silicon-based antifoam.  
   
   
       72 . The wetting composition of  claim 71  wherein the silicon-based anti-foam comprises an organosiloxane.  
   
   
       73 . The wetting composition of  claim 72  wherein the silicon-based anti-foam comprises polydimethylsiloxane.  
   
   
       74 . The wetting composition of  claim 65  further comprises a coupling agent.  
   
   
       75 . The wetting composition of  claim 74  wherein the coupling agent comprises tetrasodium EDTA.  
   
   
       76 . The wetting composition of  65  wherein the chemical hydrocarbon cleaner comprises a soap formed by saponifying a tall oil fatty acid with a caustic comprising an alkanolamine.  
   
   
       77 . A wetting composition useful in treating diesel exhaust emission gases to reduce the concentration of particulate matter and/or carbon monoxide, the composition comprising: 
 water;    a chemical hydrocarbon cleaner comprising ethoxylated nonylphenol nonionic surfactant and a soap formed by saponifying a tall oil fatty acid with monoethanolamine;    an organic solvent comprising dipropylene glycol methyl ether;    a coupling agent comprising tetrasodium EDTA; and    a defoaming agent comprising a silicone-based antifoam.    
   
   
       78 . The wetting composition of  claim 77  wherein the ethoxylated nonylphenol nonionic surfactant comprises nonoxynol 10.  
   
   
       79 . The wetting composition of  claim 78  wherein the silicone-based antifoam comprises a polydimethylsiloxane.  
   
   
       80 . A wetting composition useful in treating diesel exhaust emission gases to reduce the concentration of particulate matter and/or carbon monoxide, the composition comprising: 
 at least about 35% by weight water;    a chemical hydrocarbon cleaner comprising an ethoxylated nonylphenol nonionic surfactant and a soap formed by saponifying a tall oil fatty acid with monoethanolamine, wherein the composition comprises from about 10% to about 30% by weight ethoxylated nonylphenol nonionic surfactant, from about 2% to about 8% by weight tall oil fatty acid and from about 1% to about 5% by weight monoethanolamine;    an organic solvent comprising dipropylene glycol methyl ether, wherein the composition comprises from about 5% to about 15% by weight dipropylene glycol methyl ether;    a coupling agent comprising tetrasodium EDTA, wherein the composition comprises at least about 0.5% by weight tetrasodium EDTA; and    a defoaming agent comprising a silicon-based antifoam, wherein the composition comprises at least about 1% by weight silicon-based antifoam.    
   
   
       81 . The wetting composition of  claim 80  wherein the ethoxylated nonylphenol nonionic surfactant comprises nonoxynol 10.  
   
   
       82 . The wetting composition of  claim 80  wherein the silicone-based antifoam comprises a polydimethylsiloxane.