CA1339531C - Process for the production and burning of a natural-emulsified liquid fuel - Google Patents
Process for the production and burning of a natural-emulsified liquid fuelInfo
- Publication number
- CA1339531C CA1339531C CA 538911 CA538911A CA1339531C CA 1339531 C CA1339531 C CA 1339531C CA 538911 CA538911 CA 538911 CA 538911 A CA538911 A CA 538911A CA 1339531 C CA1339531 C CA 1339531C
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- Canada
- Prior art keywords
- oil
- process according
- water emulsion
- fuel
- ppm
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L1/00—Liquid carbonaceous fuels
- C10L1/32—Liquid carbonaceous fuels consisting of coal-oil suspensions or aqueous emulsions or oil emulsions
- C10L1/328—Oil emulsions containing water or any other hydrophilic phase
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T137/00—Fluid handling
- Y10T137/0318—Processes
- Y10T137/0391—Affecting flow by the addition of material or energy
Abstract
A process for the preparation of a natural liquid fuel and, more particularly, a process that allows a high sulfur natural fuel to be converted into energy by combustion with a substantial reduction in sulfur oxide emissions.
Description
RACKGROUND OF THE INVENTION
The present invention relates to a process for the preParation of a natural 1iquid fuel and, more partlcularLy, a process that allows a high sulfur natural fuel to be converted ;nto energy by comhustion with a substantial reduction in sulfur oxide emissions.
~ atural bitumens found in Canada, The Soviet Union, United States, China and ~7enezuela are normally liquid with viscosities ranging from 10,000 to 200,000 CP and API gravities of less than 10. These natural bitumens are current]y produced either by mechanical pumping, steam injection or by mining techniques. Wide spxead use of these materials as fuels is precluded for a number of reasons w~ich include ~iff-culty in production, transp~rtation and handling of the material and, more importantly, unfavorable combustion characteristics including high sulfur oxide emissions and unburned sol.i~s. Because of the foregoing, the natural bitumens have not been successfully used on a commercial basis as fuels due to the high costs associated with steam injection, pumping and flue gas desulfurization sy~stems whic~ are necessary in order to overcome the foregoing difficulties.
Naturally it would be highly desirable to be able to use the natural bitumens of the type set forth above as a a natural fuel.
. ~
1~39531 The present invention seeks to provide a process for the production of a natural liquid fuel from natural bitumens.
In particular the present invention seeks to produce a natural liquid fuel from natural bitumens by forming an oil in water emulsion of said natural bitumens.
Still further the present invention seeks to provide an oil in water emulsion for use as a liquid fuel having characteristics for optimizing the combustion process.
Still further the present invention seeks to provide optimum burning conditions for the combustion of an oil in water emulsion of natural bitumens so as to obtain excellent combustion efficiency, low unburned particulate solids and low sulfur oxide emissions.
The present invention relates to a process for the preparation of a natural liquid fuel and, more particularly, a process that allows a high sulfur natural fuel to be converted into energy by combustion with a substantial reduction in sulfur oxide emissions.
", 1339~31 In accordance with this invention a process for the preparation of a natural liquid fuel for burning comprises forming an oil in water emulsion from a bitumen crude oil, and adjusting the alkali metal content of the emulsion such that the alkali metal content is about at least 50 ppm.
In a particular embodiment the emulsion is burnt as a fuel.
Suitably the bitumen crude oil has a viscosity of 1,400 cst to 5,100,000 cst at 50~C.
(1.4 x 10 6 m2/s to 5.1 x 10 3 m2/s).
, ",,~
~ ., .
In accordance with a particular embodiment of the invention a mixture of water plus an emulsi-fying agent is injected into a well so as to form a downhole oil in water emulsion. U.S. Patent 3,467,195 to McAuliffe et al discloses a suitable process for forming a downhole oil in water emulsion suitable for use in the process of the present invention. The amount of water in the emulsifying agent injected into the well is controlled so as to form an oil in water emulsion having specific characteristics with regard to water content, droplet size and alkali metal content. In accordance with a particular feature of the present invention it has been found that in order to optimize combustion characteristics of the oil in water emulsion, the oil in water emulsion formed downhole should be characterized by a water content of 15 to 35 vol. %, a droplet size of about lO to 60 !um and an alkali metal content of greater than 50 ppm and preferably about 50 to 600 ppm. The emulsifying agent is preferably present in the oil in water emulsion in an amount of between 0.1 to 5% by weight based on the total weight of oil in water emulsion.
~, 1339~31 The downhole oil in water emulsion is then pumped by a downhole deep well pump as is known in the art to a flow station where degasification can be accomplis~ed if necessary. The oil in water emulsion is thereafter transported to a combustion station. At the combustion station the oil in water emuL~sion is conditioned so as to optimi~e the water content so as to optimize the water content, droplet size and alkali metal content for hurning. After conditioning, the oil in water emulsion is c~aracterize~ hy a water content of 15 to 35 vo1.~, a droplet size of ahout 10 to 60~ m a,nd an alXali metal content of about 50 to 600 ppm. The emulsion is then burned under the following conditions: fuel temperature (~~ of 20 to 80, preferably 20 to 60, steam/fuel ratio (wt¦wt) of 0.~5 to 0.5, preferabLy 0.05 to 0.4, air!fuel ratio (wt/wt? of 0.05 to 0.4, preferably 0.05 to 0.3, and steam pressure (Bar) of 2 to 6, preferably 2 to 4, or air pressure (Bar~ of 2 to 7, preferably 2 to 4.
In accor~ance w;t~ t~e ~resent invention it has been found that the oll in water emulsion produced in the process of the present invention, w~en conditioned ;n accordance with the present invention an~ burned under controlled operating conditions, results in a combustion e~ficiency of 99.9~, a low particulate solids content and sulfur oxjde emi,ssions consistent with that obtained when burning traditional ~o. 6 fuel oil.
13395~1 B~IEF DESCRIPTION OF THE DRA~INGS
Figure l is a diagram illustrating the flow scheme of the process of t'ne present invention.
Figure 2 is a graph showing typical droplet size of an oil in water emulsion.
~ igure 3 is a grap~ showing comparative sulfur dioxide emissions between the oil in water emulsion of t~e present invent;on and No. ~ fuel oil.
Figure 4 is a graph showing comparative sulfur trioxide emissions between the oil in water emulsion of the present invention and ~o. 6 fuel oil.
Dl~P.ILEn nESCRIPTIO~
The process of the present invention will be descri~ed with re e-ence to Figure 1.
A deep well 10 having a downhole deep well pump is fed with water and an emulsifying additive so as to form an oil in water emulsion which can be pumped from the well 10 by-the deep well pump anA delivered via line 12 to a degasification station 14. The degassed oil in water emulsion may then be stored in storage area 15 for subsequent transportation by means 18 suc~ as tanker, truck, pipeline or the like. Once transported, the oil in water emulsion can be stored in storage area 20 and~or de]ivered to a conditioning zone 22 where it is conditioned prior to burning in combustion area 24.
In accordance with the present invention, the process of the present invention is drawn to the preparation and burning of a natural fuel removed from a deep well. The fuel for which the process is suitable is a bitumen crude oil having a high sulfur content such as those crudes typically found in the Orinoco Belt of Venezuela. The bitumen crude oil has the folLowing chemical an~ physical properties: C wt.~ of 7~.2 to 85.~, H wt.~ of 10.0 to ]0.8, O wt.~ of 0.26 to ~.1, N wt.% of 0.50 to ~.66, S wt.~ of 3.68 to 4.02, Ash wt.
of 0.05 to 0.33, Vanadium, ppm of 420 to 520, ~ickei, ppm of 90 to 1~0, Iron, ppm of 10 to 60, Sodium, ppm of 60 to 200, Gravity, ~API of 1.0 to 12.0, Viscosity (~ST~, 122~F of 1,400 to 5,100,~00, Viscosity (CST~, 210~F of 70 to 16,000, LHV (KCAL/KG) of 8500 to 10,000, and Asphaltenes wt.% of ~.n to 15Ø In accordance with the present invention, a mixture comprising water and an emulsifying additive is in~ected into the well so as to form an oil in water emulsion which is pumped by means o~ a downhole deep wel1 pump from the well. It is a critical feature of the present invention that the characteristics of the oil in water emulsion be such as to optimize transportation and combustion of the oil in water emulsion. The oil in water emulsion from the well should be c~aracterized by a water content of about between 15 to 35 vol.%, ~referably about between 20 to 30 v~1.%; a drop~et size of about between 10 to 60 ~m, preferably about between 40 to ~0 ~m, and an alkali metal content of greater than 50 ppm and preferably about between 50 to 600 ppm. It has been found that the level of alkali metals in the oll in water emulsion has a great effect on the amount of gaseous emissions upon combustion of the emulsion.
During the process for pro~ucing the bitumen cru~e oll by injecting water, a formation water i~ coproduced therewith. An analysis of the formation water found in the Orinoco Belt is set forth in mable l.
TABT.E I
ANALYS IS OF FORMAT ION WATER
Cl (mg/L! 23640 CO3 (mg/L) 2.1 HC03 (mg/L) 284 NO3 (mg/L) 10 SO4 (mg/L? --Na (mg/L) 14400 Ca (mg/L) 427 Mg (mg/L) 244 K (mg/L) 462 ~H~ (mg/L) 32 SiO2 (mg/L) 54 P~ 8.0 13~9~i31 As can be seen from ~able 1, the formation water contains significant amounts of alkali metaLs (Na and K ). ~y controlling the amount and alkali metal content of the water injected w;th the emulsifying agent insures that the oil in water emulsion produced has the required alkali metal and water content as set forth above. As noted ahove, the wate~ injected also contains an emulsifier ad~itive. The emulsifier is added so as to obtain an amol~nt of ahout between 0.1 to S.O wt.%, ~referably from about between 0.] to 1.0 wt.~, based on the total weight of the oil in water emulsion produced.
In accordance with tlle present invention the emulsifier additive is selected from the group consisting of anionic surfactant.s, non-ionic surfactants, cationic surfactants, mixtures of anionic and non-ionic surfactants and mi,xtures of cationic and non-ionic surfactants. T~e non-ionic surfactants suitable for use in the process are selected from the group consisting of ethoxyLated alkyl phenols, ethoxylated alcohols, ethoxylated sorbitan esters and mixtures thereof.
Suitable cationic surfactants are selected from the group consisting of the hydrochlorides of fatty d~amines, imidazolines, ethoxylated amines, amido-amines, quaternary ammonium compounds and mixtures thereof while suita~le anonic surfactants are selected _9_ 1~395~1 from the group consisting of long chain carboxylic, sulphonic acids and mixtures thereof. A preferred surfactant is a non-ionic surf~ctant with a h;dro ph;/,~
hidrophilic-lipophilic balance of greater than 13 such o ~ y ~ t e d as nonylphenol o~ialhyl~cd w~th 20 ethyLene oxide units. Preferred anionic surfactants are selected from the group consisting of alkylaryl sulfonate, alkylaryl sulfate and mixtures thereof.
The water additive mixture in~ected into the well sta~ilizes the oil in water emulsion. ~he water injected will depend on the formation water being coproduced with the bitumen. Its salt content will also depend on the bitumen water ratio required for appropriate handling and burning and finally will depend on the type and amount of emulsifier. It is at this stage that the fuel is formulated to give the desired characteristics for handling and burning. Once the emulsion is formed and pumped out of the well, it can be ~egasi ied without much pro'olem due to its low viscosity. ~his is not the case when 'oitumen alone has to be degasified which requires heating prior to separation of the gas.
The emulsion then can be storaged and pumped through the f]ow station and main stations and additives like imidazolines can be added to avoid any corrosion to 13.~9.531 the metal walls because of the presence of water. In any of the sta~es an in-line ~lender may be installed (after degasification, before pumping through a pipeline, before loading a tanker, etc. ! to ensure a good emulsion with the adequate droplet size distribution as required above.
Once the oi'- in water emuLsion is transported to the combustion facility the emulsified fuel is conditloned so as to optimize the water content, droplet size and alXali meta~ content of the oil in water emulsion. The conditioning consists of an on-line mixer and an alkali metal level controller. The purpose of the on-line mixer is to control mean droplet size of the emulsified liquid fuel. Droplet size distribution has a very important effect on combustion c~aracteristics of this natural fuel, particularly in flow controllability and burn-out. Size distribution of the droplets are shown in Figure 2 immediately before and after the on-line mixex. It can be seen that mean droplet size is reduced from 65 down to 51 ~m. It is also seen that droplet size distribution is smoothed, that is, becoming a bell shaped-curve. In a~cordance with the present invention the oil in water emu]sion shoul~ be characterized by a dxoplet size of from about between 10 to 60-~m.
1339~31 It ~as also heen found that tl1e content of alkali metals in the oil in water emulsion has a great effect on its combustion characteristics, particularly on sulfur oxide emiss~ons. Alkalie metals such as sodium and potassium have a positive effect in reducing sulfur dioxide emission. It is believed th~t, due to high interfacial bitumen water sur~ace to volume ratio, alkali metals react with sulfur compounds present in the natural fuel to produce alXali sulfides such as sodium sulfide and potassium sulfide. During combustion, these sulfides are oxidized to sulfates thus fixing sulfate to the comhustion ashes and thus preventing sulfur from going into the atmosphere as part of the flue gases. As noted above, alkali metals are already added to the emulsion during the producing step of the natural fuel emulsion by means of a natural mix of alkali metals contained in the production water. If alkali metal leveLs in the emulsion fuel are not found to be optimal then some additional amount can be added to the emulsion in the alka~i level controller. This is done by adding production water, saline w~ter or synt'netic aqueous solutions of alkali metals. In accordance with the present invention the oil in water emulsion should be characterized by an alkali metal content of greater t'nan 50 ppm and preferably about between S0 to 600 ppm, ideally 50 to 300 ppm.
Once the oil in water emulsion is conditioned it is ready for burning. Any conventional oil gun burner can be empLoyed such as an internal mixing burner or twin hyperbolic atomizers. Atomization uslng steam or air under the following operating conditions is preferred:
fuel temperature (~~-~ of 20 to 80, preferably ~0 to 60, steam/fuel ratio (wt/wt) of 0.05 to 0.5, preferably 0.05 to 0.4, air~fllel ratio ~wt/wt~ of 0.05 to 0.4, preferably 0.05 to 0.3, and steam pressure (Bar) of 1.5 to ~, preferably 2 to 4, or air pressure (Bar) of 2 to 7, preferably 2 to 4. Under these conditions excellent atomization and efficient combustion was obtained coupled with good flame stability.
Advantages of the present invention will be made clear from a consideration of the following examples.
In order to demonstrate the effects of alkali metal levels on the combustion characterlstics of oiL in water emulsions as compared to Orinoco bitumen, two emulsi~ns were prepared having the characteristics set forth beLow in Tahle II ~Orinoco bitumen is also set forth). The alkali metal was sodium.
FUEL C~A~ACTERISTICS
EMULSION EMULSION
ORINOCO #1 #2 ALKALI METAL LEVEL
(PPM IN FUEL~ 0 10 160 LHV (BTU/Lb! 17455 13675 13693 VOL.~ OF BITUMEN 100 77 77 VOL.~ OF WATER 0 23 23 All the fuels were burned un~er the operating conditions set forth in Table III.
TABLE III
OPERATING CONDITIONS
EMULSION EMULSION
~ ORINOCO #1 #2 FEED RATE (Kg/h~ 19.5 23.5 23 TOTAL HEAT INPUT (BTU/H) 750000 750000 750000 FUEL TEMPERATURE (~C) 115 24 60-70 STEAM/FUEL RATIO (~/~) 0.4 0.2 0.43 STEAM PRESSURE BAR 4 4 2.8 MEAN DROPLET SIZE ~m~ -- 50 51 ~he gaseous emisslons an~ combustion efficlency for each of the fuels is set forth below in Table IV.
~L~ IV 1339531 ~OMBUSTIO~ CHARACTERISTICS
EMULSION EMULSION
ORINOCO #1 #2 C~2 (molar ~) 13.5 3.4 13 CO (ppm v) 0 0 0 ~2 (molar ~ 3 3.5 3 SO~ (ppm v) 1500 1450 850 S03 (ppm v) 12 8 6 ~Ox (ppm v) 690 430 417 PAP~TICULAT~ (mg/Nm3) 20 13 11 EFFICIENCY 99.0 99.9 99.9 LENGTH OF RUN (HR) 100 36 100 The results indicate that an increase in combustion efficiency is obtained for emulsified Orinoco over Orinoco virgin bitumen, that is, 99.9% compared to 99.0~. In addition,.a comparison of Emulsion ~1 and Emulsion #2 indicates that sulfur oxide emissions, SO2 and SO3 decrease with an increase in alkali metal (sodium) levels.
EXAMPLE I T
The effects of operating conditions on the combustion c~aracteristics of various fuels were studied. Table V compares Orinoco crude with eight oil in water emulsions.
TABLE V
FUEL CHARACTERISTICS
EMULSION EMULSION EMULSION EMULSION EMULSION EMULSION EMULSION EMULSION
ORINOCO #3 #4 #5 #6 #7 #8 #9 #10 ALKALINE LEVEL
~ (PPM IN FUEL) 0 180 180 180 180 180 180 180 70 LHV (BTU~Lb~ 17455 12900 12900 12900 13600 13600 13600 13600 13712%
VOL.% OF BITUMEN ln0 70 70 70 76 76 76 76 78 VOL.~ OF WATER 0 30 30 30 24 24 24 24 22 ~ r 1339~31 The Orinoco bitumen and emulsions #3, #6, #7 and #10 were atomized with steam. Emulsions #4, #5, #8 an~ #9 were atomized with air. The alkali metal employed in Emulsions #3, ~4, #5 and #6 was sodium while potassium was added in ~mulsions #7, #8, #9 and #10. The operating conditions are set forth in Table VI.
TABLE VI
OPERATING CONDITIONS
EMULSION EMULSION EMULSION EMULSION EMULSION EMULSION EMULSION EMULSION
ORINOCO #3 #4 #5 #6 #7 #8 #9 #10 FEED RATE (Kg~h) 20.8 28.9 28.9 28.9 27.4 27.4 27.4 27.4 28.1 TOTAL HEAT INPUT (BTU/H) 820.000 820 .noo 82n.000 820.000 820.000 820.000 820.000 820.000 820.000 ~ FUEL TEMPERATURE (~C) 115 60 - 70 60 - 70 60 - 70 60 - 70 60 - 70 60 - 70 60 - 70 60 - 80 I STEAM/FUEL RATIO (W/W) 0.4 0.34 -- -- 0.4 0.45 -- -- 0.2 AIR/FUEL RATIO (W/W) -- -- 0.20 0.27 -- -- 0.27 0.34 --STEAM/AIR PRESSURE (BAR) 4 1.6 3 3 3.8 3.2 2.8 2.8 2.8 MEAN DROPLET SIZE (~m) -- 43 43 43 60 60 60 60 18 1339~31 The combustion efficiency and gaseous emissions are set forth below in Table VII.
H O
cn ~
t~ #O O a'.
11~) 0 O ~ ~ O ~ ~ O
H --I ~ ~ r--I r--l ~ ~ ~ ~ 1 3 3 9 5 3 1 U~ ~
E~ #U~
~ ~ o . o~ ~ ~ o z H
C~ ~
r- ~ CO
5 t~ O
z O
E # U. ~ o o ~ ~ ~ ~ U~ o ~ o z H
C~t~ # C~', ) ~ ~ t~ O
Z
H E-~ H
r t~ # a:~
E~ ~ ~ O ~ O ~ a~ o t~ ~~ r~ r--Z Z
t~ # ~~ o ~
~ O ~ ~
z H
a~
~ U~ er ~ ~ O
- 5~ ~ O 1~ ~ t~ O
') ~ r~ r--~
H ~ O r-1 1-- ~ C0 ~ ~n o ~D C
Or--lr--I ~ r~ ~1 1~ ~
Z
E Z
~; EJ ~
r ~ r t~
O t~
E O ~ 0~ G ~) H ~
O O ~ C O o ~ Z
O U~ U~ Z P.~
The result.s indicate substantial reductions in sulfur oxides when burning emulsions containin~ alkali metal~s as we]l as an increase in efficiency. In addi.tion, t'ne lower the air/fuel ratio the greater the reduction in sulfur oxides. The same would appear to hold true for lower steam/fuel ratios. Finally, the amount of nitrogen oxides was reduced. As compaxed to Orinoco crudes, the operating conditions in general are less severe when firing emulsified fuels; fuel atomizin~, temperatures and pressures were lower and the use of eit~e.r air or steam added operational flexibility.
Sulfur oxides emission reduction is an important feature of alkaline bearing oil in water emulsions. Sulfur trioxide emissions are responsible for the so-called cold-end corrosion-that is sulfuric acid condensation in cooler parts of boilers (air heaters and economi2ers~.
It is also responsible for ash acidity in electrostatic preclpitators and other solid capture equ;.pment.
The sulfur emissions of oil emulsion $3 of Example II were compared wi.th No. 6 fuel oil and the results a~e set forth in Figures 3 an~ 4. The results indicate that the sulfur oxide emi.ssions of t~e oil in water emulsion are favorable as compared to No. 6 fuel oil and far ~1 .
superior to Orinoco bitumen. 5~2 emission reduction is 33~ as compared to fuel oil No. 6 and 66~ as compared to nrinoco bitumen. Sulfur trioxide emissions are also lower for emulsion #3 as compared to fuel oil No. 6 (2.5% S) and Orinoco bitumen. These reductions account for 17% and 50~ respectively.
This invention may be embodied in other forms or carried out in other ways wit~out departing from the spirit or essential characteristics thereof. The present embodiment is therefore to be considered as in all respects illustrative and not restrictive, the scope of the invention being indicated by the appended claims, and all changes which come within the meaning ~nd range of equiva]ency are intended to be embraced therein.
-~2-
The present invention relates to a process for the preParation of a natural 1iquid fuel and, more partlcularLy, a process that allows a high sulfur natural fuel to be converted ;nto energy by comhustion with a substantial reduction in sulfur oxide emissions.
~ atural bitumens found in Canada, The Soviet Union, United States, China and ~7enezuela are normally liquid with viscosities ranging from 10,000 to 200,000 CP and API gravities of less than 10. These natural bitumens are current]y produced either by mechanical pumping, steam injection or by mining techniques. Wide spxead use of these materials as fuels is precluded for a number of reasons w~ich include ~iff-culty in production, transp~rtation and handling of the material and, more importantly, unfavorable combustion characteristics including high sulfur oxide emissions and unburned sol.i~s. Because of the foregoing, the natural bitumens have not been successfully used on a commercial basis as fuels due to the high costs associated with steam injection, pumping and flue gas desulfurization sy~stems whic~ are necessary in order to overcome the foregoing difficulties.
Naturally it would be highly desirable to be able to use the natural bitumens of the type set forth above as a a natural fuel.
. ~
1~39531 The present invention seeks to provide a process for the production of a natural liquid fuel from natural bitumens.
In particular the present invention seeks to produce a natural liquid fuel from natural bitumens by forming an oil in water emulsion of said natural bitumens.
Still further the present invention seeks to provide an oil in water emulsion for use as a liquid fuel having characteristics for optimizing the combustion process.
Still further the present invention seeks to provide optimum burning conditions for the combustion of an oil in water emulsion of natural bitumens so as to obtain excellent combustion efficiency, low unburned particulate solids and low sulfur oxide emissions.
The present invention relates to a process for the preparation of a natural liquid fuel and, more particularly, a process that allows a high sulfur natural fuel to be converted into energy by combustion with a substantial reduction in sulfur oxide emissions.
", 1339~31 In accordance with this invention a process for the preparation of a natural liquid fuel for burning comprises forming an oil in water emulsion from a bitumen crude oil, and adjusting the alkali metal content of the emulsion such that the alkali metal content is about at least 50 ppm.
In a particular embodiment the emulsion is burnt as a fuel.
Suitably the bitumen crude oil has a viscosity of 1,400 cst to 5,100,000 cst at 50~C.
(1.4 x 10 6 m2/s to 5.1 x 10 3 m2/s).
, ",,~
~ ., .
In accordance with a particular embodiment of the invention a mixture of water plus an emulsi-fying agent is injected into a well so as to form a downhole oil in water emulsion. U.S. Patent 3,467,195 to McAuliffe et al discloses a suitable process for forming a downhole oil in water emulsion suitable for use in the process of the present invention. The amount of water in the emulsifying agent injected into the well is controlled so as to form an oil in water emulsion having specific characteristics with regard to water content, droplet size and alkali metal content. In accordance with a particular feature of the present invention it has been found that in order to optimize combustion characteristics of the oil in water emulsion, the oil in water emulsion formed downhole should be characterized by a water content of 15 to 35 vol. %, a droplet size of about lO to 60 !um and an alkali metal content of greater than 50 ppm and preferably about 50 to 600 ppm. The emulsifying agent is preferably present in the oil in water emulsion in an amount of between 0.1 to 5% by weight based on the total weight of oil in water emulsion.
~, 1339~31 The downhole oil in water emulsion is then pumped by a downhole deep well pump as is known in the art to a flow station where degasification can be accomplis~ed if necessary. The oil in water emulsion is thereafter transported to a combustion station. At the combustion station the oil in water emuL~sion is conditioned so as to optimi~e the water content so as to optimize the water content, droplet size and alkali metal content for hurning. After conditioning, the oil in water emulsion is c~aracterize~ hy a water content of 15 to 35 vo1.~, a droplet size of ahout 10 to 60~ m a,nd an alXali metal content of about 50 to 600 ppm. The emulsion is then burned under the following conditions: fuel temperature (~~ of 20 to 80, preferably 20 to 60, steam/fuel ratio (wt¦wt) of 0.~5 to 0.5, preferabLy 0.05 to 0.4, air!fuel ratio (wt/wt? of 0.05 to 0.4, preferably 0.05 to 0.3, and steam pressure (Bar) of 2 to 6, preferably 2 to 4, or air pressure (Bar~ of 2 to 7, preferably 2 to 4.
In accor~ance w;t~ t~e ~resent invention it has been found that the oll in water emulsion produced in the process of the present invention, w~en conditioned ;n accordance with the present invention an~ burned under controlled operating conditions, results in a combustion e~ficiency of 99.9~, a low particulate solids content and sulfur oxjde emi,ssions consistent with that obtained when burning traditional ~o. 6 fuel oil.
13395~1 B~IEF DESCRIPTION OF THE DRA~INGS
Figure l is a diagram illustrating the flow scheme of the process of t'ne present invention.
Figure 2 is a graph showing typical droplet size of an oil in water emulsion.
~ igure 3 is a grap~ showing comparative sulfur dioxide emissions between the oil in water emulsion of t~e present invent;on and No. ~ fuel oil.
Figure 4 is a graph showing comparative sulfur trioxide emissions between the oil in water emulsion of the present invention and ~o. 6 fuel oil.
Dl~P.ILEn nESCRIPTIO~
The process of the present invention will be descri~ed with re e-ence to Figure 1.
A deep well 10 having a downhole deep well pump is fed with water and an emulsifying additive so as to form an oil in water emulsion which can be pumped from the well 10 by-the deep well pump anA delivered via line 12 to a degasification station 14. The degassed oil in water emulsion may then be stored in storage area 15 for subsequent transportation by means 18 suc~ as tanker, truck, pipeline or the like. Once transported, the oil in water emulsion can be stored in storage area 20 and~or de]ivered to a conditioning zone 22 where it is conditioned prior to burning in combustion area 24.
In accordance with the present invention, the process of the present invention is drawn to the preparation and burning of a natural fuel removed from a deep well. The fuel for which the process is suitable is a bitumen crude oil having a high sulfur content such as those crudes typically found in the Orinoco Belt of Venezuela. The bitumen crude oil has the folLowing chemical an~ physical properties: C wt.~ of 7~.2 to 85.~, H wt.~ of 10.0 to ]0.8, O wt.~ of 0.26 to ~.1, N wt.% of 0.50 to ~.66, S wt.~ of 3.68 to 4.02, Ash wt.
of 0.05 to 0.33, Vanadium, ppm of 420 to 520, ~ickei, ppm of 90 to 1~0, Iron, ppm of 10 to 60, Sodium, ppm of 60 to 200, Gravity, ~API of 1.0 to 12.0, Viscosity (~ST~, 122~F of 1,400 to 5,100,~00, Viscosity (CST~, 210~F of 70 to 16,000, LHV (KCAL/KG) of 8500 to 10,000, and Asphaltenes wt.% of ~.n to 15Ø In accordance with the present invention, a mixture comprising water and an emulsifying additive is in~ected into the well so as to form an oil in water emulsion which is pumped by means o~ a downhole deep wel1 pump from the well. It is a critical feature of the present invention that the characteristics of the oil in water emulsion be such as to optimize transportation and combustion of the oil in water emulsion. The oil in water emulsion from the well should be c~aracterized by a water content of about between 15 to 35 vol.%, ~referably about between 20 to 30 v~1.%; a drop~et size of about between 10 to 60 ~m, preferably about between 40 to ~0 ~m, and an alkali metal content of greater than 50 ppm and preferably about between 50 to 600 ppm. It has been found that the level of alkali metals in the oll in water emulsion has a great effect on the amount of gaseous emissions upon combustion of the emulsion.
During the process for pro~ucing the bitumen cru~e oll by injecting water, a formation water i~ coproduced therewith. An analysis of the formation water found in the Orinoco Belt is set forth in mable l.
TABT.E I
ANALYS IS OF FORMAT ION WATER
Cl (mg/L! 23640 CO3 (mg/L) 2.1 HC03 (mg/L) 284 NO3 (mg/L) 10 SO4 (mg/L? --Na (mg/L) 14400 Ca (mg/L) 427 Mg (mg/L) 244 K (mg/L) 462 ~H~ (mg/L) 32 SiO2 (mg/L) 54 P~ 8.0 13~9~i31 As can be seen from ~able 1, the formation water contains significant amounts of alkali metaLs (Na and K ). ~y controlling the amount and alkali metal content of the water injected w;th the emulsifying agent insures that the oil in water emulsion produced has the required alkali metal and water content as set forth above. As noted ahove, the wate~ injected also contains an emulsifier ad~itive. The emulsifier is added so as to obtain an amol~nt of ahout between 0.1 to S.O wt.%, ~referably from about between 0.] to 1.0 wt.~, based on the total weight of the oil in water emulsion produced.
In accordance with tlle present invention the emulsifier additive is selected from the group consisting of anionic surfactant.s, non-ionic surfactants, cationic surfactants, mixtures of anionic and non-ionic surfactants and mi,xtures of cationic and non-ionic surfactants. T~e non-ionic surfactants suitable for use in the process are selected from the group consisting of ethoxyLated alkyl phenols, ethoxylated alcohols, ethoxylated sorbitan esters and mixtures thereof.
Suitable cationic surfactants are selected from the group consisting of the hydrochlorides of fatty d~amines, imidazolines, ethoxylated amines, amido-amines, quaternary ammonium compounds and mixtures thereof while suita~le anonic surfactants are selected _9_ 1~395~1 from the group consisting of long chain carboxylic, sulphonic acids and mixtures thereof. A preferred surfactant is a non-ionic surf~ctant with a h;dro ph;/,~
hidrophilic-lipophilic balance of greater than 13 such o ~ y ~ t e d as nonylphenol o~ialhyl~cd w~th 20 ethyLene oxide units. Preferred anionic surfactants are selected from the group consisting of alkylaryl sulfonate, alkylaryl sulfate and mixtures thereof.
The water additive mixture in~ected into the well sta~ilizes the oil in water emulsion. ~he water injected will depend on the formation water being coproduced with the bitumen. Its salt content will also depend on the bitumen water ratio required for appropriate handling and burning and finally will depend on the type and amount of emulsifier. It is at this stage that the fuel is formulated to give the desired characteristics for handling and burning. Once the emulsion is formed and pumped out of the well, it can be ~egasi ied without much pro'olem due to its low viscosity. ~his is not the case when 'oitumen alone has to be degasified which requires heating prior to separation of the gas.
The emulsion then can be storaged and pumped through the f]ow station and main stations and additives like imidazolines can be added to avoid any corrosion to 13.~9.531 the metal walls because of the presence of water. In any of the sta~es an in-line ~lender may be installed (after degasification, before pumping through a pipeline, before loading a tanker, etc. ! to ensure a good emulsion with the adequate droplet size distribution as required above.
Once the oi'- in water emuLsion is transported to the combustion facility the emulsified fuel is conditloned so as to optimize the water content, droplet size and alXali meta~ content of the oil in water emulsion. The conditioning consists of an on-line mixer and an alkali metal level controller. The purpose of the on-line mixer is to control mean droplet size of the emulsified liquid fuel. Droplet size distribution has a very important effect on combustion c~aracteristics of this natural fuel, particularly in flow controllability and burn-out. Size distribution of the droplets are shown in Figure 2 immediately before and after the on-line mixex. It can be seen that mean droplet size is reduced from 65 down to 51 ~m. It is also seen that droplet size distribution is smoothed, that is, becoming a bell shaped-curve. In a~cordance with the present invention the oil in water emu]sion shoul~ be characterized by a dxoplet size of from about between 10 to 60-~m.
1339~31 It ~as also heen found that tl1e content of alkali metals in the oil in water emulsion has a great effect on its combustion characteristics, particularly on sulfur oxide emiss~ons. Alkalie metals such as sodium and potassium have a positive effect in reducing sulfur dioxide emission. It is believed th~t, due to high interfacial bitumen water sur~ace to volume ratio, alkali metals react with sulfur compounds present in the natural fuel to produce alXali sulfides such as sodium sulfide and potassium sulfide. During combustion, these sulfides are oxidized to sulfates thus fixing sulfate to the comhustion ashes and thus preventing sulfur from going into the atmosphere as part of the flue gases. As noted above, alkali metals are already added to the emulsion during the producing step of the natural fuel emulsion by means of a natural mix of alkali metals contained in the production water. If alkali metal leveLs in the emulsion fuel are not found to be optimal then some additional amount can be added to the emulsion in the alka~i level controller. This is done by adding production water, saline w~ter or synt'netic aqueous solutions of alkali metals. In accordance with the present invention the oil in water emulsion should be characterized by an alkali metal content of greater t'nan 50 ppm and preferably about between S0 to 600 ppm, ideally 50 to 300 ppm.
Once the oil in water emulsion is conditioned it is ready for burning. Any conventional oil gun burner can be empLoyed such as an internal mixing burner or twin hyperbolic atomizers. Atomization uslng steam or air under the following operating conditions is preferred:
fuel temperature (~~-~ of 20 to 80, preferably ~0 to 60, steam/fuel ratio (wt/wt) of 0.05 to 0.5, preferably 0.05 to 0.4, air~fllel ratio ~wt/wt~ of 0.05 to 0.4, preferably 0.05 to 0.3, and steam pressure (Bar) of 1.5 to ~, preferably 2 to 4, or air pressure (Bar) of 2 to 7, preferably 2 to 4. Under these conditions excellent atomization and efficient combustion was obtained coupled with good flame stability.
Advantages of the present invention will be made clear from a consideration of the following examples.
In order to demonstrate the effects of alkali metal levels on the combustion characterlstics of oiL in water emulsions as compared to Orinoco bitumen, two emulsi~ns were prepared having the characteristics set forth beLow in Tahle II ~Orinoco bitumen is also set forth). The alkali metal was sodium.
FUEL C~A~ACTERISTICS
EMULSION EMULSION
ORINOCO #1 #2 ALKALI METAL LEVEL
(PPM IN FUEL~ 0 10 160 LHV (BTU/Lb! 17455 13675 13693 VOL.~ OF BITUMEN 100 77 77 VOL.~ OF WATER 0 23 23 All the fuels were burned un~er the operating conditions set forth in Table III.
TABLE III
OPERATING CONDITIONS
EMULSION EMULSION
~ ORINOCO #1 #2 FEED RATE (Kg/h~ 19.5 23.5 23 TOTAL HEAT INPUT (BTU/H) 750000 750000 750000 FUEL TEMPERATURE (~C) 115 24 60-70 STEAM/FUEL RATIO (~/~) 0.4 0.2 0.43 STEAM PRESSURE BAR 4 4 2.8 MEAN DROPLET SIZE ~m~ -- 50 51 ~he gaseous emisslons an~ combustion efficlency for each of the fuels is set forth below in Table IV.
~L~ IV 1339531 ~OMBUSTIO~ CHARACTERISTICS
EMULSION EMULSION
ORINOCO #1 #2 C~2 (molar ~) 13.5 3.4 13 CO (ppm v) 0 0 0 ~2 (molar ~ 3 3.5 3 SO~ (ppm v) 1500 1450 850 S03 (ppm v) 12 8 6 ~Ox (ppm v) 690 430 417 PAP~TICULAT~ (mg/Nm3) 20 13 11 EFFICIENCY 99.0 99.9 99.9 LENGTH OF RUN (HR) 100 36 100 The results indicate that an increase in combustion efficiency is obtained for emulsified Orinoco over Orinoco virgin bitumen, that is, 99.9% compared to 99.0~. In addition,.a comparison of Emulsion ~1 and Emulsion #2 indicates that sulfur oxide emissions, SO2 and SO3 decrease with an increase in alkali metal (sodium) levels.
EXAMPLE I T
The effects of operating conditions on the combustion c~aracteristics of various fuels were studied. Table V compares Orinoco crude with eight oil in water emulsions.
TABLE V
FUEL CHARACTERISTICS
EMULSION EMULSION EMULSION EMULSION EMULSION EMULSION EMULSION EMULSION
ORINOCO #3 #4 #5 #6 #7 #8 #9 #10 ALKALINE LEVEL
~ (PPM IN FUEL) 0 180 180 180 180 180 180 180 70 LHV (BTU~Lb~ 17455 12900 12900 12900 13600 13600 13600 13600 13712%
VOL.% OF BITUMEN ln0 70 70 70 76 76 76 76 78 VOL.~ OF WATER 0 30 30 30 24 24 24 24 22 ~ r 1339~31 The Orinoco bitumen and emulsions #3, #6, #7 and #10 were atomized with steam. Emulsions #4, #5, #8 an~ #9 were atomized with air. The alkali metal employed in Emulsions #3, ~4, #5 and #6 was sodium while potassium was added in ~mulsions #7, #8, #9 and #10. The operating conditions are set forth in Table VI.
TABLE VI
OPERATING CONDITIONS
EMULSION EMULSION EMULSION EMULSION EMULSION EMULSION EMULSION EMULSION
ORINOCO #3 #4 #5 #6 #7 #8 #9 #10 FEED RATE (Kg~h) 20.8 28.9 28.9 28.9 27.4 27.4 27.4 27.4 28.1 TOTAL HEAT INPUT (BTU/H) 820.000 820 .noo 82n.000 820.000 820.000 820.000 820.000 820.000 820.000 ~ FUEL TEMPERATURE (~C) 115 60 - 70 60 - 70 60 - 70 60 - 70 60 - 70 60 - 70 60 - 70 60 - 80 I STEAM/FUEL RATIO (W/W) 0.4 0.34 -- -- 0.4 0.45 -- -- 0.2 AIR/FUEL RATIO (W/W) -- -- 0.20 0.27 -- -- 0.27 0.34 --STEAM/AIR PRESSURE (BAR) 4 1.6 3 3 3.8 3.2 2.8 2.8 2.8 MEAN DROPLET SIZE (~m) -- 43 43 43 60 60 60 60 18 1339~31 The combustion efficiency and gaseous emissions are set forth below in Table VII.
H O
cn ~
t~ #O O a'.
11~) 0 O ~ ~ O ~ ~ O
H --I ~ ~ r--I r--l ~ ~ ~ ~ 1 3 3 9 5 3 1 U~ ~
E~ #U~
~ ~ o . o~ ~ ~ o z H
C~ ~
r- ~ CO
5 t~ O
z O
E # U. ~ o o ~ ~ ~ ~ U~ o ~ o z H
C~t~ # C~', ) ~ ~ t~ O
Z
H E-~ H
r t~ # a:~
E~ ~ ~ O ~ O ~ a~ o t~ ~~ r~ r--Z Z
t~ # ~~ o ~
~ O ~ ~
z H
a~
~ U~ er ~ ~ O
- 5~ ~ O 1~ ~ t~ O
') ~ r~ r--~
H ~ O r-1 1-- ~ C0 ~ ~n o ~D C
Or--lr--I ~ r~ ~1 1~ ~
Z
E Z
~; EJ ~
r ~ r t~
O t~
E O ~ 0~ G ~) H ~
O O ~ C O o ~ Z
O U~ U~ Z P.~
The result.s indicate substantial reductions in sulfur oxides when burning emulsions containin~ alkali metal~s as we]l as an increase in efficiency. In addi.tion, t'ne lower the air/fuel ratio the greater the reduction in sulfur oxides. The same would appear to hold true for lower steam/fuel ratios. Finally, the amount of nitrogen oxides was reduced. As compaxed to Orinoco crudes, the operating conditions in general are less severe when firing emulsified fuels; fuel atomizin~, temperatures and pressures were lower and the use of eit~e.r air or steam added operational flexibility.
Sulfur oxides emission reduction is an important feature of alkaline bearing oil in water emulsions. Sulfur trioxide emissions are responsible for the so-called cold-end corrosion-that is sulfuric acid condensation in cooler parts of boilers (air heaters and economi2ers~.
It is also responsible for ash acidity in electrostatic preclpitators and other solid capture equ;.pment.
The sulfur emissions of oil emulsion $3 of Example II were compared wi.th No. 6 fuel oil and the results a~e set forth in Figures 3 an~ 4. The results indicate that the sulfur oxide emi.ssions of t~e oil in water emulsion are favorable as compared to No. 6 fuel oil and far ~1 .
superior to Orinoco bitumen. 5~2 emission reduction is 33~ as compared to fuel oil No. 6 and 66~ as compared to nrinoco bitumen. Sulfur trioxide emissions are also lower for emulsion #3 as compared to fuel oil No. 6 (2.5% S) and Orinoco bitumen. These reductions account for 17% and 50~ respectively.
This invention may be embodied in other forms or carried out in other ways wit~out departing from the spirit or essential characteristics thereof. The present embodiment is therefore to be considered as in all respects illustrative and not restrictive, the scope of the invention being indicated by the appended claims, and all changes which come within the meaning ~nd range of equiva]ency are intended to be embraced therein.
-~2-
Claims (62)
1. A process for the preparation and burning of a natural liquid fuel from bitumen crude oil having a high sulfur content without further refining comprising the steps of:
forming an oil in water emulsion downhole in a well from a bitumen crude oil and pumping the oil in water emulsion from said well, said emulsion having a water content of 15 to 35 vol.%, an emulsifier additive in an amount of between 0.1 to 5%
by weight based on the total of the oil in water emulsion and an oil droplet size of 10 to 60 µm, said bitumen crude oil having the following chemical and physical properties;
C wt.% of 78.2 to 85.5;
H wt.% of 10.0 to 10.8;
O wt.% of 0.26 to 1.1;
N wt.% of 0.05 to 0.66;
S wt.% of 3.68 to 4.02;
Ash wt.% of 0.05 to 0.33;
Vanadium, ppm of 420 to 520;
Nickel, ppm of 90 to 120;
Iron, ppm of 10 to 60;
Sodium, ppm of 60 to 200;
Gravity, ° API of 1.0 to 12.0;
Viscosity (CST) 122°F of 1,400 to 5,100,000;
210°F of 70 to 16,000;
LHV (KCAL/KG) of 8,500 to 10,000; and Asphaltenes wt.% of 9.0 to 15.0;
adjusting the alkali metal content of said emulsion such that said alkali metal content is about at least 50 ppm, said alkali metal being selected from the group consisting of Na+, Ca++, Mg++, K+ and mixtures thereof; and burning said oil in water emulsion as a fuel.
forming an oil in water emulsion downhole in a well from a bitumen crude oil and pumping the oil in water emulsion from said well, said emulsion having a water content of 15 to 35 vol.%, an emulsifier additive in an amount of between 0.1 to 5%
by weight based on the total of the oil in water emulsion and an oil droplet size of 10 to 60 µm, said bitumen crude oil having the following chemical and physical properties;
C wt.% of 78.2 to 85.5;
H wt.% of 10.0 to 10.8;
O wt.% of 0.26 to 1.1;
N wt.% of 0.05 to 0.66;
S wt.% of 3.68 to 4.02;
Ash wt.% of 0.05 to 0.33;
Vanadium, ppm of 420 to 520;
Nickel, ppm of 90 to 120;
Iron, ppm of 10 to 60;
Sodium, ppm of 60 to 200;
Gravity, ° API of 1.0 to 12.0;
Viscosity (CST) 122°F of 1,400 to 5,100,000;
210°F of 70 to 16,000;
LHV (KCAL/KG) of 8,500 to 10,000; and Asphaltenes wt.% of 9.0 to 15.0;
adjusting the alkali metal content of said emulsion such that said alkali metal content is about at least 50 ppm, said alkali metal being selected from the group consisting of Na+, Ca++, Mg++, K+ and mixtures thereof; and burning said oil in water emulsion as a fuel.
2. A process according to claim 1, wherein said emulsion is formed downhole in the well by injecting a mixture of water plus the emulsifier additive into said well so as to form said oil in water emulsion.
3. A process according to claim 2, including pumping said oil in water emulsion from said well to a flow station; transporting said oil in water emulsion from said flow station to a combustion station; conditioning said oil in water emulsion so as to optimize the water content, droplet size and alkali metal content of said oil in water emulsion for burning; and burning said optimized oil in water emulsion with reduced sulfur dioxide and sulfur trioxide emissions, said sulfur dioxide and sulfur trioxide emissions being less than that of No. 6 fuel oil.
4. A process according to claim 3, wherein said alkali metal content is about between 50 to 600 ppm.
5. A process according to claim 1, 2, 3 or 4, wherein said emulsifier additive is selected from the group consisting of anionic surfactants, non-ionic surfactants, cationic surfactants and mixtures of cationic and non-ionic surfactants.
6. A process according to claim 5, wherein said non-ionic surfactants are selected from the group consisting of ethoxylated alkyl phenols, ethoxylated alcohols, ethoxylated sorbitan esters and mixtures thereof.
7. A process according to claim 5, wherein said cationic surfactants are selected from the group consisting of the hydrochlorides of fatty diamines, imidazolines, ethoxylated amines, amido-amines, quaternary ammonium compounds and mixtures thereof.
8. A process according to claim 5, wherein said anionic surfactants are selected from the group consisting of long chain carboxylic, sulfonic acids and mixtures thereof.
9. A process according to claim 1 or 2, wherein said emulsifier additive is a non-ionic surfactant with a hydrophilic-lipophilic balance of greater than 13.
10. A process according to claim 9, wherein said non-ionic surfactant is nonylphenol oxyalkylated with 20 ethylene oxide units.
11. A process according to claim 8, wherein said anionic surfactant is selected from the group consisting of alkylaryl sulfonate, alkylaryl sulfate and mixtures thereof.
12. A process according to claim 1, wherein said emulsifier additive is nonylphenol oxyalkylated with 20 ethylene oxide units.
13. A process according to claim 1, 2, 3, 4, 6, 7, 8, 9, 10 or 11, wherein said oil in water emulsion is characterized by 20-30 vol.% of water, 40-60 µm of mean droplet size and 50-600 ppm of alkali metal.
14. A process according to claim 3, including degassing said oil in water emulsion prior to conditioning same for burning.
15. A process according to claim 3, including adding an anti-corrosion additive to said oil in water emulsion prior to transporting same.
16. A process according to claim 3, including conditioning said oil in water emulsion so as to obtain an oil in water emulsion characterized by a water content of from about 20-30 vol.%, a droplet size of from about 10-60 µm and an alkali metal content of about 50-300 ppm.
17. A process according to claim 3, including burning said optimized oil and water emulsion under the following operating conditions:
fuel temperature (°C) of 20 to 80;
steam/fuel ratio (wt/wt) of 0.05 to 0.5;
air/fuel ratio (wt/wt) of 0.05 to 0.4; and steam pressure (Bar) of 2 to 6; or air pressure (Bar) of 2 to 7.
fuel temperature (°C) of 20 to 80;
steam/fuel ratio (wt/wt) of 0.05 to 0.5;
air/fuel ratio (wt/wt) of 0.05 to 0.4; and steam pressure (Bar) of 2 to 6; or air pressure (Bar) of 2 to 7.
18. A process according to claim 3, including burning said optimized oil and water emulsion under the following operating conditions:
fuel temperature (°C) of 20 to 60;
steam/fuel ratio (wt/wt) of 0.05 to 0.4;
air/fuel ratio (wt/wt) of 0.05 to 0.3; and steam pressure (Bar) of 2 to 4; or air pressure (Bar) of 2 to 4.
fuel temperature (°C) of 20 to 60;
steam/fuel ratio (wt/wt) of 0.05 to 0.4;
air/fuel ratio (wt/wt) of 0.05 to 0.3; and steam pressure (Bar) of 2 to 4; or air pressure (Bar) of 2 to 4.
19. A process for the preparation of a natural liquid fuel for burning comprising the steps of forming an oil in water emulsion from a bitumen crude oil, said oil in water emulsion being formed down hole in a well by injecting a mixture comprising water and emulsifier additive into said well to form said emulsion, said emulsion having a water content of 15 to 35 vol. %, a content of the emulsifier additive of between 0.1 to 5% by weight based on the total weight of the oil in water emulsion, and a droplet size of 10 to 60 µm, pumping the oil in water emulsion from the well, adjusting the alkali metal content of the emulsion so that the emulsion has an alkali metal content of at least 50 ppm, said alkali metal being selected from the group consistin of Na+, Ca++, Mg++, K+ and mixtures thereof; said bitumen crude oil having the following chemical and physical properties:
C wt.% of 78.2 to 85.5;
H wt.% of 10.0 to 10.8;
O wt.% of 0.26 to 1.1;
N wt.% of 0.05 to 0.66;
S wt.% of 3.68 to 4.02;
Ash wt.% of 0.05 to 0.33;
Vanadium, ppm of 420 to 520;
Nickel, ppm of 90 to 120;
Iron, ppm of 10 to 60;
Sodium, ppm of 60 to 200;
Gravity, ° API of 1.0 to 12.0;
Viscosity (CST) 122°F of 1,400 to 5,100,000;
210°F of 70 to 16,000;
LHV (KCAL/KG) of 8,500 to 10,000; and Asphaltenes wt.% of 9.0 to 15Ø
C wt.% of 78.2 to 85.5;
H wt.% of 10.0 to 10.8;
O wt.% of 0.26 to 1.1;
N wt.% of 0.05 to 0.66;
S wt.% of 3.68 to 4.02;
Ash wt.% of 0.05 to 0.33;
Vanadium, ppm of 420 to 520;
Nickel, ppm of 90 to 120;
Iron, ppm of 10 to 60;
Sodium, ppm of 60 to 200;
Gravity, ° API of 1.0 to 12.0;
Viscosity (CST) 122°F of 1,400 to 5,100,000;
210°F of 70 to 16,000;
LHV (KCAL/KG) of 8,500 to 10,000; and Asphaltenes wt.% of 9.0 to 15Ø
20. A process according to claim 19, wherein the alkali metal content of said emulsion is 50 to 600 ppm.
21. A process according to claim 19 or 20, wherein the oil in water emulsion is pumped from the well to a combustion station without further refining, the oil in water emulsion is degassed prior to combustion and conditioned such that it has a water content of 20 to 30 wt. % and a droplet size of 40 to 60 µm, and an alkali metal is added so as to reduce the sulfur dioxide and sulfur trioxide emissions, the optimized oil in water emulsion is thereafter heated to a temperature of 10 to 80°C. and the fuel is atomized with a diluent selected from the group consisting of steam and air, at a diluent/fuel ratio of 0.05 to 0.4, the atomized fuel is burnt whereby the sulfur dioxide and sulfur trioxide emissions of the optimized oil in water emulsion are less than that of No. 6 fuel oil.
22. A process according to claim 19 or 20, wherein said emulsifier additive comprises anionic surfactants, non-ionic surfactants, cationic surfactants or mixtures of cationic and non-ionic surfactants.
23. A process according to claim 21, wherein said emulsifier additive comprises anionic surfactants, non-ionic surfactants, cationic surfactants or mixtures of cationic and non-ionic surfactants.
24. A process according to claim 22, wherein said non-ionic surfactants comprise ethoxylated alkyl phenols, ethoxylated alcohols, ethoxylated sorbitan esters or mixtures thereof.
25. A process according to claim 21, wherein said emulsifier additive comprises anionic surfactants, non-ionic surfactants, cationic surfactants or mixtures of cationic and non-ionic surfactants.
26. A process according to claim 22, wherein said cationic surfactants comprise the hydrochlorides of fatty diamines, imidazolines, ethoxylated amines, amido-amines, quaternary ammonium compounds or mixtures thereof.
27. A process according to claim 23, wherein said cationic surfactants comprise the hydrochlorides of fatty diamines, imidazolines, ethoxylated amines, amido-amines, quaternary ammonium compounds or mixtures thereof.
28. A process according to claim 22, wherein said anionic surfactants comprise long chain carboxylic sulfonic acids or mixtures thereof.
29. A process according to claim 21, wherein said anionic surfactants comprise long chain carboxylic sulfonic acids or mixtures thereof.
30. A process according to claim 22, wherein said anionic surfactant comprises alkylaryl sulfonate, alkylaryl sulfate or mixtures thereof.
31. A process according to claim 21, wherein said anionic surfactant comprises alkylaryl sulfonate, alkylaryl sulfate or mixtures thereof.
32. A process according to claim 19 or 20, wherein said emulsifier additive is a non-ionic surfactant with a hydrophilic-lipophilic balance of greater than 13.
33. A process according to claim 21, wherein said emulsifier additive is a non-ionic surfactant with a hydrophilic-lipophilic balance of greater than 13.
34. A process according to claim 19 or 20, wherein said non-ionic surfactant is nonylphenol oxyalkylated with 20 ethylene oxide units.
35. A process according to claim 19, 20, 23, 24, 25, 26, 27, 28, 29, 30, 31 or 33, wherein said oil in water emulsion is characterized by 20-30 vol.
% of water, 40-60 µm of mean droplet size and 50-600 ppm of alkali metal.
% of water, 40-60 µm of mean droplet size and 50-600 ppm of alkali metal.
36. A process according to claim 19, 20, 23, 24, 25, 26, 27, 28, 29, 30, 31 or 33, including burning said oil in water emulsion as a fuel.
37. A process according to claim 36, including pumping said oil in water emulsion from said well to a flow station; transporting said oil in water emulsion from said flow station to a combustion station; conditioning said oil in water emulsion so as to optimize the water content, droplet size and alkali metal content of said oil in water emulsion for burning; and burning the optimized oil in water emulsion with reduced sulfur dioxide and sulfur trioxide emissions, said sulfur dioxide and sulfur trioxide emissions being less than that of No. 6 fuel oil.
38. A process according to claim 37, including degassing said oil in water emulsion prior to conditioning same for burning.
39. A process according to claim 37 or 38, including adding an anti-corrosion additive to said oil in water emulsion prior to transporting same.
40. A process according to claim 37 or 38, including conditioning said oil in water emulsion so as to obtain an oil in water emulsion characterized by a water content of from 20-30% vol. % and an alkali metal content of 50-300 ppm.
41. A process according to claim 39, including conditioning said oil in water emulsion so as to obtain an oil in water emulsion characterized by a water content of from 20-30% vol. % and an alkali metal content of 50-300 ppm.
42. A process according to claim 36, including burning said oil and water emulsion under the following operating conditions:
fuel temperature (°C) of 20 to 80;
steam/fuel ratio (wt/wt) of 0.05 to 0.5;
air/fuel ratio (wt/wt) of 0.05 to 0.4; and steam pressure (Bar) of 2 to 6; or air pressure (Bar) of 2 to 7.
fuel temperature (°C) of 20 to 80;
steam/fuel ratio (wt/wt) of 0.05 to 0.5;
air/fuel ratio (wt/wt) of 0.05 to 0.4; and steam pressure (Bar) of 2 to 6; or air pressure (Bar) of 2 to 7.
43. A process according to claim 37, 38 or 41, including burning said oil and water emulsion under the following operating conditions:
fuel temperature (°C) of 20 to 80;
steam/fuel ratio (wt/wt) of 0.05 to 0.5;
air/fuel ratio (wt/wt) of 0.05 to 0.4; and steam pressure (Bar) of 2 to 6; or air pressure (Bar) of 2 to 7.
fuel temperature (°C) of 20 to 80;
steam/fuel ratio (wt/wt) of 0.05 to 0.5;
air/fuel ratio (wt/wt) of 0.05 to 0.4; and steam pressure (Bar) of 2 to 6; or air pressure (Bar) of 2 to 7.
44. A process according to claim 39, including burning said oil and water emulsion under the following operating conditions:
fuel temperature (°C) of 20 to 80;
steam/fuel ratio (wt/wt) of 0.05 to 0.5;
air/fuel ratio (wt/wt) of 0.05 to 0.4; and steam pressure (Bar) of 2 to 6; or air pressure (Bar) of 2 to 7.
fuel temperature (°C) of 20 to 80;
steam/fuel ratio (wt/wt) of 0.05 to 0.5;
air/fuel ratio (wt/wt) of 0.05 to 0.4; and steam pressure (Bar) of 2 to 6; or air pressure (Bar) of 2 to 7.
45. A process according to claim 40, including burning said oil and water emulsion under the following operating conditions:
fuel temperature (°C) of 20 to 80;
steam/fuel ratio (wt/wt) of 0.05 to 0.5;
air/fuel ratio (wt/wt) of 0.05 to 0.4; and steam pressure (Bar) of 2 to 6; or air pressure (Bar) of 2 to 7.
fuel temperature (°C) of 20 to 80;
steam/fuel ratio (wt/wt) of 0.05 to 0.5;
air/fuel ratio (wt/wt) of 0.05 to 0.4; and steam pressure (Bar) of 2 to 6; or air pressure (Bar) of 2 to 7.
46. A process according to claim 36, including burning said oil and water emulsion under the following operating conditions:
fuel temperature (°C) of 20 to 60;
steam/fuel ratio (wt/wt) of 0.05 to 0.4;
air/fuel ratio (wt/wt) of 0.05 to 0.3; and steam pressure (Bar) of 2 to 4; or air pressure (Bar) of 2 to 4.
fuel temperature (°C) of 20 to 60;
steam/fuel ratio (wt/wt) of 0.05 to 0.4;
air/fuel ratio (wt/wt) of 0.05 to 0.3; and steam pressure (Bar) of 2 to 4; or air pressure (Bar) of 2 to 4.
47. A process according to claim 37, 38 or 41, including burning said oil and water emulsion under the following operating conditions:
fuel temperature (°C) of 20 to 60;
steam/fuel ratio (wt/wt) of 0.05 to 0.4;
air/fuel ratio (wt/wt) of 0.05 to 0.3; and steam pressure (Bar) of 2 to 4; or air pressure (Bar) of 2 to 4.
fuel temperature (°C) of 20 to 60;
steam/fuel ratio (wt/wt) of 0.05 to 0.4;
air/fuel ratio (wt/wt) of 0.05 to 0.3; and steam pressure (Bar) of 2 to 4; or air pressure (Bar) of 2 to 4.
48. A process according to claim 39, including burning said oil and water emulsion under the following operating conditions:
fuel temperature (°C) of 20 to 60;
steam/fuel ratio (wt/wt) of 0.05 to 0.4;
air/fuel ratio (wt/wt) of 0.05 to 0.3; and steam pressure (Bar) of 2 to 4; or air pressure (Bar) of 2 to 4.
fuel temperature (°C) of 20 to 60;
steam/fuel ratio (wt/wt) of 0.05 to 0.4;
air/fuel ratio (wt/wt) of 0.05 to 0.3; and steam pressure (Bar) of 2 to 4; or air pressure (Bar) of 2 to 4.
49. A process according to claim 40, including burning said oil and water emulsion under the following operating conditions:
fuel temperature (°C) of 20 to 60;
steam/fuel ratio (wt/wt) of 0.05 to 0.4;
air/fuel ratio (wt/wt) of 0.05 to 0.3; and steam pressure (Bar) of 2 to 4; or air pressure (Bar) of 2 to 4.
fuel temperature (°C) of 20 to 60;
steam/fuel ratio (wt/wt) of 0.05 to 0.4;
air/fuel ratio (wt/wt) of 0.05 to 0.3; and steam pressure (Bar) of 2 to 4; or air pressure (Bar) of 2 to 4.
50. A process for the preparation and burning of a natural liquid fuel from bitumen crude oil having a high sulfur content without further refining comprising the steps of:
(a) providing a downhole deep well pump for pumping said bitumen crude oil from a well, said bitumen crude oil has the following chemical and physical properties:
C wt.% of 78.2 to 85.5;
H wt.% of 10.0 to 10.8;
O wt.% of 0.26 to 1.1;
N wt.% of 0.50 to 0.66;
Vanadium, ppm of 420 to 520;
Nickel, ppm of 90 to 120;
Iron, ppm of 10 to 60;
Sodium, ppm of 60 to 200;
Gravity, °API of 1.0 to 12.0;
Viscosity (CST) 122°F of 1,400 to 5,100,000;
210°F of 70 to 16,000;
LHV (KCAL/KG) of 8,500 to 10,000; and Asphaltenes wt.% of 9.0 to 15.0;
(b) injecting a mixture of water plus an emulsifier additive into said well wherein said emulsifier additive is present in an amount of about between 0.1 to 5% by weight based on the total weight of the oil in water emulsion so as to form an oil in water emulsion having a water content of about between 15 to 35 wt.% and an oil droplet size of about between 10 to 60 µm;
(c) pumping said oil in water emulsion from said well to a flow station;
(d) degassing said oil in water emulsion;
(e) transporting said oil in water emulsion from said flow station to a combustion station without further refining;
(f) conditioning said oil in water emulsion so as to optimize the water content and droplet size and adding an alkali metal so as to obtain an oil in water emulsion wherein said oil in water emulsion has 15-35 vol. of water, 10-60 µm of mean droplet size and at least 50 ppm of alkaline content selected from the group consisting of Na+, Ca++, Mg++
and K+ and mixtures thereof in order to reduce the amount of sulfur emissions produced during subsequent burning as a natural liquid fuel;
(g) heating said optimized oil in water emulsion natural liquid fuel to a temperature of 20°
to 80°C. and atomizing said fuel with a diluent selected from the group consisting of steam and air wherein said steam is at a pressure of 2 to 6 Bar in a steam to fuel ratio of 0.05 to 0.5 and said air is at a pressure of 2 to 7 Bar in an air to fuel ratio of 0.05 to 0.4; and (h) burning said atomized fuel whereby said sulfur dioxide and sulfur trioxide emissions are less than that of No. 6 fuel oil.
(a) providing a downhole deep well pump for pumping said bitumen crude oil from a well, said bitumen crude oil has the following chemical and physical properties:
C wt.% of 78.2 to 85.5;
H wt.% of 10.0 to 10.8;
O wt.% of 0.26 to 1.1;
N wt.% of 0.50 to 0.66;
Vanadium, ppm of 420 to 520;
Nickel, ppm of 90 to 120;
Iron, ppm of 10 to 60;
Sodium, ppm of 60 to 200;
Gravity, °API of 1.0 to 12.0;
Viscosity (CST) 122°F of 1,400 to 5,100,000;
210°F of 70 to 16,000;
LHV (KCAL/KG) of 8,500 to 10,000; and Asphaltenes wt.% of 9.0 to 15.0;
(b) injecting a mixture of water plus an emulsifier additive into said well wherein said emulsifier additive is present in an amount of about between 0.1 to 5% by weight based on the total weight of the oil in water emulsion so as to form an oil in water emulsion having a water content of about between 15 to 35 wt.% and an oil droplet size of about between 10 to 60 µm;
(c) pumping said oil in water emulsion from said well to a flow station;
(d) degassing said oil in water emulsion;
(e) transporting said oil in water emulsion from said flow station to a combustion station without further refining;
(f) conditioning said oil in water emulsion so as to optimize the water content and droplet size and adding an alkali metal so as to obtain an oil in water emulsion wherein said oil in water emulsion has 15-35 vol. of water, 10-60 µm of mean droplet size and at least 50 ppm of alkaline content selected from the group consisting of Na+, Ca++, Mg++
and K+ and mixtures thereof in order to reduce the amount of sulfur emissions produced during subsequent burning as a natural liquid fuel;
(g) heating said optimized oil in water emulsion natural liquid fuel to a temperature of 20°
to 80°C. and atomizing said fuel with a diluent selected from the group consisting of steam and air wherein said steam is at a pressure of 2 to 6 Bar in a steam to fuel ratio of 0.05 to 0.5 and said air is at a pressure of 2 to 7 Bar in an air to fuel ratio of 0.05 to 0.4; and (h) burning said atomized fuel whereby said sulfur dioxide and sulfur trioxide emissions are less than that of No. 6 fuel oil.
51. A process according to claim 50, wherein said fuel temperature is 20° to 60° C., said steam pressure is 2 to 4 Bar, said steam to fuel ratio is 0.05 to 0.4, said air pressure is 2 to 4 Bar and said air to fuel ratio is 0.05 to 0.3.
52. A process according to claim 50 or 51, wherein said emulsifier additive is selected from the group consisting of anionic surfactants, non-ionic surfactants, cationic surfactants and mixtures of cationic and non-ionic surfactants.
53. A process according to claim 52, wherein said non-ionic surfactants are selected from the group consisting of ethoxylated alkyl phenols, ethoxylated alcohols, ethoxylated sorbitan esters and mixtures thereof.
54. A process according to claim 52, wherein said cationic surfactants are selected from the group consisting of the hydrochlorides of fatty diamines, imidazolines, ethoxylated amines, amido-amines, quaternary ammonium compounds and mixtures thereof.
55. A process according to claim 52, wherein said anionic surfactants are selected from the group consisting of long chain carboxylic, sulfonic acids and mixtures thereof.
56. A process according to claim 50 or 51, wherein said emulsifier additive is a non-ionic surfactant with a hydrophilic-lipophilic balance of greater than 13.
57. A process according to claim 56, wherein said non-ionic surfactant is nonylphenol oxylated with 20 ethylene oxide units.
58. A process according to claim 55, wherein said anionic surfactant is selected from the group consisting of alkylaryl sulfonate, alkylaryl sulfate and mixtures thereof.
59. A process according to claim 50, 51, 53, 54, 55 or 58, including adding an anti-corrosion additive to said oil in water emulsion prior to transporting same.
60. A process according to claim 50, 51, 53, 54, 55, 57 or 58, wherein said oil in water emulsion has a water content of 20-30% vol. and a mean droplet size of 40-60 µm.
61. A natural liquid fuel having a high sulfur content for burning without further refining in the form of an oil in water emulsion formed downhole in a well from bitumen crude oil comprising a water content of about between 15 to 35 vol.%, an emulsifier additive in an amount of between 0.1 to 5%
by weight based on the total weight of the oil in water emulsion, an oil droplet size of 10 to 60 µm and an alkali metal content of about at least 50 ppm, said alkali metal being selected from the group consisting of Na+, Ca++, Mg++, K+ and mixtures thereof, said bitumen crude oil having the following chemical and physical properties:
C wt.% of 78.2 to 85.5;
H wt.% of 10.0 to 10.8;
O wt.% of 0.26 to 1.1;
N wt.% of 0.50 to 0.66;
S wt.% of 3.68 to 4.02;
Ash wt.% of 0.05 to 0.33;
Vanadium, ppm of 420 to 520;
Nickel, ppm of 90 to 120;
Iron, ppm of 10 to 60;
Sodium, ppm of 60 to 200;
Gravity, °API of 1.0 to 12.0;
Viscosity (CST) 122°F of 1,400 to 5,100,000;
210°F of 70 to 16,000;
LHV (KCAL/KG) of 8,500 to 10,000; and Asphaltenes wt.% of 9.0 to 15Ø
by weight based on the total weight of the oil in water emulsion, an oil droplet size of 10 to 60 µm and an alkali metal content of about at least 50 ppm, said alkali metal being selected from the group consisting of Na+, Ca++, Mg++, K+ and mixtures thereof, said bitumen crude oil having the following chemical and physical properties:
C wt.% of 78.2 to 85.5;
H wt.% of 10.0 to 10.8;
O wt.% of 0.26 to 1.1;
N wt.% of 0.50 to 0.66;
S wt.% of 3.68 to 4.02;
Ash wt.% of 0.05 to 0.33;
Vanadium, ppm of 420 to 520;
Nickel, ppm of 90 to 120;
Iron, ppm of 10 to 60;
Sodium, ppm of 60 to 200;
Gravity, °API of 1.0 to 12.0;
Viscosity (CST) 122°F of 1,400 to 5,100,000;
210°F of 70 to 16,000;
LHV (KCAL/KG) of 8,500 to 10,000; and Asphaltenes wt.% of 9.0 to 15Ø
62. A fuel according to claim 61, wherein said water content is 20-30 vol.%, said droplet size is 40 to 60 µm and said alkali metal content is 50-600 ppm.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| VE875,450 | 1986-06-17 | ||
| US06/875,450 US4801304A (en) | 1986-06-17 | 1986-06-17 | Process for the production and burning of a natural-emulsified liquid fuel |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1339531C true CA1339531C (en) | 1997-11-11 |
Family
ID=25365830
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 538911 Expired - Fee Related CA1339531C (en) | 1986-06-17 | 1987-06-05 | Process for the production and burning of a natural-emulsified liquid fuel |
Country Status (12)
| Country | Link |
|---|---|
| US (1) | US4801304A (en) |
| JP (2) | JPS6354498A (en) |
| BE (1) | BE1001169A5 (en) |
| BR (1) | BR8703535A (en) |
| CA (1) | CA1339531C (en) |
| DE (1) | DE3720216A1 (en) |
| DK (1) | DK169746B1 (en) |
| ES (1) | ES2006507A6 (en) |
| FR (1) | FR2600074B1 (en) |
| GB (1) | GB2191783B (en) |
| IT (1) | IT1211464B (en) |
| NL (1) | NL8701412A (en) |
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-
1986
- 1986-06-17 US US06/875,450 patent/US4801304A/en not_active Expired - Lifetime
-
1987
- 1987-06-05 CA CA 538911 patent/CA1339531C/en not_active Expired - Fee Related
- 1987-06-16 ES ES8701773A patent/ES2006507A6/en not_active Expired
- 1987-06-16 GB GB8713969A patent/GB2191783B/en not_active Expired
- 1987-06-16 DK DK305187A patent/DK169746B1/en not_active IP Right Cessation
- 1987-06-16 BE BE8700658A patent/BE1001169A5/en not_active IP Right Cessation
- 1987-06-17 DE DE19873720216 patent/DE3720216A1/en active Granted
- 1987-06-17 BR BR8703535A patent/BR8703535A/en not_active IP Right Cessation
- 1987-06-17 IT IT6752387A patent/IT1211464B/en active
- 1987-06-17 JP JP62151032A patent/JPS6354498A/en active Granted
- 1987-06-17 FR FR8708437A patent/FR2600074B1/en not_active Expired - Fee Related
- 1987-06-17 NL NL8701412A patent/NL8701412A/en active Search and Examination
- 1987-10-27 JP JP62271596A patent/JPH01115996A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| DE3720216A1 (en) | 1987-12-23 |
| FR2600074A1 (en) | 1987-12-18 |
| NL8701412A (en) | 1988-01-18 |
| GB2191783A (en) | 1987-12-23 |
| ES2006507A6 (en) | 1989-05-01 |
| IT8767523A0 (en) | 1987-06-17 |
| JPH0441712B2 (en) | 1992-07-09 |
| FR2600074B1 (en) | 1991-03-29 |
| DK305187A (en) | 1987-12-18 |
| DE3720216C2 (en) | 1991-04-04 |
| BE1001169A5 (en) | 1989-08-08 |
| GB2191783B (en) | 1989-12-06 |
| BR8703535A (en) | 1987-10-06 |
| JPH01115996A (en) | 1989-05-09 |
| DK169746B1 (en) | 1995-02-13 |
| US4801304A (en) | 1989-01-31 |
| JPS6354498A (en) | 1988-03-08 |
| DK305187D0 (en) | 1987-06-16 |
| IT1211464B (en) | 1989-11-03 |
| GB8713969D0 (en) | 1987-07-22 |
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