Additive for solid hydrocarbon fueled direct fired burners, furnaces, open flames and related processes

Abstract

The present invention relates to the field of fuel additives for hydrocarbon fuels that acts to enhance efficiency and/or reduce pollution. The fuel additive is a phosphorus-containing composition that can be added to the surface of solid hydrocarbon fuels for combustion with the fuel in a direct fired burner, furnace or open flame.

1 . A process for enhancing fuel performance of a hydrocarbon fuel in a combustion system having a direct fired burner, furnace or open flame comprising the steps of: providing a fuel additive to the hydrocarbon fuel in an amount effective to enhance fuel performance to the direct fired burner, furnace or open flame and combusting the hydrocarbon fuel with the fuel additive, the fuel additive comprising a mixture of salts and a dispersion fluid, the mixture of salts comprising: 
 [Y] x H 2 PO 4 ; and    [Y] x+ HPO 4 , wherein [Y] is a cation, the dispersion fluid being operable to maintain the salts within the dispersion fluid in at least a partially dispersed state to create a solution, the enhanced fuel performance being measurable by increased fuel efficiency or decreased pollutant output in an exhaust gas resulting from the combustion of the fuel and the fuel additive.    
   
   
       2 . The process of  claim 1  for enhancing fuel performance wherein the fuel additive is ammonia-free.  
   
   
       3 . The process of  claim 1  for enhancing fuel performance wherein the fuel additive further comprises [NH 4 ] 2 HPO 4 .  
   
   
       4 . The process of  claim 1  for enhancing fuel performance wherein the fuel additive further comprises NH 4 C 2 H 3 O 2  where C 2 H 3 O 2  is an acetate group.  
   
   
       5 . The process of  claim 1  for enhancing fuel performance wherein the pH of the solution is between about 6.0 and 8.0.  
   
   
       6 . The process of  claim 1  for enhancing fuel performance wherein phosphorus is present in the hydrocarbon fuel in an amount of between about 1 and 150 ppm by weight.  
   
   
       7 . The process of  claim 1  for enhancing fuel performance wherein the hydrocarbon fuel is a solid hydrocarbon fuel, preferentially coal, more preferentially high sulfur coal and most preferentially high sulfur and low BTU coal.  
   
   
       8 . A process for creating an enhanced hydrocarbon fuel for use in a combustion system comprising the step of adding an amount effective to enhance fuel performance to the hydrocarbon fuel of a chemical addition composition, the chemical addition composition comprising reaction products from mixing of a source of phosphoric acid, an alkali metal hydroxide, ammonium hydroxide and water.  
   
   
       9 . The process of  claim 8  for creating an enhanced hydrocarbon fuel wherein the chemical addition composition further comprises acetic acid.  
   
   
       10 . A process for creating a fuel additive for enhancing combustion of a hydrocarbon fuel, the process comprising the step of: mixing the salts [Y] x H 2 PO 4  and [Y] x+ HPO 4 , wherein [Y] is a cation, in a solvent to at least partially disperse the salts in the solvent to create an phosphorus-containing parent solution that is operable to enhance combustion when added to a direct fired burner, furnace or open flame in the presence of a solid hydrocarbon fuel and combusted.  
   
   
       11 . A combustion additive comprising a mixture of salts and a dispersion fluid, the mixture of salts comprising: 
 [Y] x H 2 PO 4 ; and    [Y] x+ HPO 4 , wherein [Y] is a cation, the dispersion fluid being operable to maintain the salts within the dispersion fluid in at least a partially dispersed state to create a solution, the fuel additive being operable to enhance combustion when placed into contact with fuel in a direct fired burner, furnace or open flame and combusted, the enhanced combustion being measurable by increased fuel efficiency or decreased pollutant output in an exhaust gas resulting from the combustion of the fuel and the fuel additive.    
   
   
       12 . The fuel additive of  claim 11  further comprising [NH 4 ] 2 HPO 4 .  
   
   
       13 . The fuel additive of  claim 11  further comprising NH 4 C 2 H 3 O 2  where C 2 H 3 O 2  is an acetate group.  
   
   
       14 . The fuel additive of  claim 11  wherein the pH of the solution is between about 6.0 and 8.0.  
   
   
       15 . An enhanced fuel comprising a substantial amount of solid fuel suitable for combustion and an amount of fuel additive, of  claim 11 , operable to enhance combustion.  
   
   
       16 . The enhanced fuel of  claim 15  wherein phosphorus is present in the hydrocarbon fuel in an amount of between about 1 and 150 ppm by weight.  
   
   
       17 . The enhanced fuel of  claim 15  wherein the amount of fuel additive is the amount operable to reduce emissions upon combustion of the enhanced fuel as compared to the combustion of the hydrocarbon fuel without the fuel additive.