PROCESS FOR THE PRODUCTION OF IMPROVED DIESEL FUELS USING RECLAIMED HYDRAULIC OIL
Background of the Invention
The present invention relates to the production of diesel fuels from waste oils and, more particularly, to a process for producing highly efficient diesel fuels employing a high concentration of reclaimed oils including hydraulics as feedstock.
As a direct result of environmental regulations relating to the containment and disposal of waste lubricating oils, methods and apparatus
directed to the reclamation of waste oils have been developed. For example, U.S. Patent No. 3,346,483 discloses a method of re-refining waste lubricating oils by admixing the used oils with sulfuric acid and subsequently distilling, i.e., hydrogenating the admixture at 40 atm pressure and a temperature of
360° C in the presence of a catalyst to obtain certain fractions.
More recently, U.S. Patent No. 5,141 ,628 describes a method of
cleaning and regenerating used oils heating the used oils, after rough filtering, to a temperature of 50° C to 100° C and adding thereto a solution of 0.5 to
2.5 weight percent alkali water glass solution having a water content of 30.0 to 70.0 weight percent and a polyalkylene glycol. The solution is allowed to
settle at which time they are separated. No specific information is provided regarding the end use of the regenerated materials. Until recently, processes employing the reclaimed oils have apparently not received much attention.
Further, of the few known patents which relate to the use of reclaimed oils in forming diesel fuels, the known references are considered to be unduly complicated or require necessary treatment steps, among other perceived
drawbacks. For example, U.S. Patent No. 4,784,751 to McGhee discloses a method and apparatus for recovering contaminated crank case or other heavy oils by pumping the material through a filter and into a divided tank.
Thereafter, the oil is heated to a temperature of 180° F to vaporize water,
antifreeze and other contaminants and is pumped into a blending tank including a supply of clean diesel fuel. Interestingly, the McGhee patent is specifically directed to small scale operations.
A more elaborate method and apparatus for recycling waste lubrication
oil for reuse as fuel oil is disclosed in U.S. Patent No. 5,507,307 to Montegari et al. The method according to Montegari comprises pumping fuel oil via a primary pump at a first flow rate and waste lubrication oil at a second flow rate via a secondary pump through a pair of filters under pressure into a
static mixer at carefully controlled rates. The two oils are then blended together under pressure and fed through a coalescer filter to dehydrate the blend. In contrast to the foregoing, it is an object of the present invention to provide a simplified method of producing diesel fuels using reclaimed oils.
It is another object to provide a system for producing improved diesel fuels wherein the system is fully operational at ambient temperatures and
pressures, i.e., room temperature and standard pressures.
Another object of the present invention relates to the elimination of chemical processing such as acid degradation and distillation to achieve a useful reclaimed oil for use in formulating an improved diesel fuel.
It is yet another object of the present invention to provide a cost effective method and apparatus for the production of diesel fuels from reclaimed oils. In accordance with the foregoing objects, among others, the process for the production of upgraded diesel fuels includes the steps of: a) reclaiming a volume of used oil having a water content of no
more than about 0.5 weight percent and at least 10.0 weight percent of used hydraulic oil by pumping said used oil through a plurality of nominal filters; b) pumping said reclaimed oil through a water removal filter into a mixing tank;
c) pumping a volume of fuel oil having a water content of no more than about 0.5 weight percent into said mixing tank to form a raw used oil blend; and d) pumping said raw blend through a series of filters including at
least one sub-micron filter capable of removing dyes from said raw blend; whereby a diesel fuel capable of use in an internal combustion engine operating on a thermodynamic cycle is obtained.
By "used oil", it is meant an oil composition including less than 0.5 weight percent water, used crankcase oil and at least 10.0 weight percent
used hydraulic oil- By "fuel oil", it is meant an oil selected from the group consisting of diesel fuels (grade 1 and 2), furnace oils (grade 1 and 2), stove oils (grade
1 and 2) and mixtures thereof.
By "nominal filters", it is meant filters having an average porosity of 5.0 microns or more.
By "absolute filters", it is meant filters having an average porosity of less than about 5.0 microns to about 0.1 microns.
By "finite filter", it is meant a filter having an average porosity of less than 0.1 microns.
By "upgraded diesel fuel", it is meant a fuel having a cetane number of at least 35 capable of use in an internal combustion engine operating on a thermodynamic cycle.
The general features, advantages and objects of the present invention
will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a schematic view of the apparatus utilized to carry out a process of the present invention; and
Figure 2 is a schematic view of a second apparatus utilized to carry out a process of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to Figure 1 , the apparatus 10 utilized to produce upgraded diesel fuels in accordance with the process of the present invention is
illustrated.
The apparatus 10 generally comprises a first fluid line 12 including a first pump 18 fluidly coupled to a source 16 of used oil including at least 10.0 weight percent hydraulic oil, a water removal filter 20, a plurality of nominal
filters 22, with the fluid line 12 terminating at mixing tank 34. The used oil composition employed in the process of the invention may be 100.0 weight percent used hydraulic oil but, more preferably, the used oil will be an admixture of used crankcase oil and used hydraulic oil wherein the admixture includes less than 0.5 weight percent water. The used crankcase oil may be obtained from a number of sources including manufacturing plants, airlines, automotive repair centers and instant oil change shops, among others. The hydraulic oil component of the used oil admixture can be obtained from various machinery including, but not limited to, automatic and standard transmissions, heavy equipment transmissions, elevators, hydraulic pumps,
aircraft and marine transmissions, medical equipment and printing press transmissions, by way of non-limiting example. Used hydraulic oils, as used
herein, preferably have a kinemac viscosity of between about 30 cSt to about 120 cSt at 40°C.
The water removal filter 20 which generally has an average porosity of between about 1.0 to about 5.0 microns is available commercially from a
variety of sources including Perfect Filtration, Inc. of Tampa, Florida.
The so-called nominal filters 22 are preferably in the form of bag filters
which are generally encased in wire mesh. Bag filters are commercially available from a variety of sources such as Great Lakes Filters, Inc. of Illinois or GAF Filter Bags, Inc. of Georgia, for example. Bag filters provide numerous advantages over standard pleated filters such as ease in installation, a greater surface area for filtering and ease in disposal as the used filters can be sold for industrial use. Additionally, bag filters allow for easy visual inspection to determine whether replacement is necessary.
The apparatus 10 also includes a second fluid line 14 including a pump
32 fluidly coupled to a source 30 of fuel oil for transmitting the fuel oil into the mixing tank 34. As noted, fuel oil as the term is used herein includes diesel fuel, furnace oil, stove oil and mixtures thereof.
Beyond the plurality of absolute filters 42, is a finite filter 44 capable of
removing sub-micronic impurities including, for example, dyes contained in the used hydraulic oil. These so-called finite filters which preferably are formed from polymeric membranes are commercially available from a variety of sources such as Liumar Technologies Corp. of Ottawa, Canada, by way of non-limiting example.
Optionally, a source of additives may be incorporated into the apparatus by introducing certain additives directly into the mixing tank 34, by introducing the additives downstream beyond the finite filter or by a combination thereof. By way of non-limiting example, the additives may
include viscosity enhancers such a paint thinners, for example, cetane improvers such as esters of azotic acid, detergents, corrosion inhibitors and anti-foaming agents. It should be noted that while such additives may be incorporated, additives are not considered essential since the composition of the final diesel fuel 48 tends to have equal or greater fuel efficiency than diesel fuels which are purchased at the pump.
Referring to Figure 2, a second apparatus 110 utilized to produce upgraded diesel fuels in accordance with the process of the present invention as illustrated.
In contrast to the apparatus of Figure 1 , the used crankcase oil 124 and the used hydraulic oil 116 are supplied to the mixing tank 134 in separate streams under the apparatus 110. Often the used oils, i.e., crankcase and
hydraulic, are obtained from different sources wherein it is more practical to add them separately in a predetermined volume to the mixing tank, rather
than having to analyze and reformulate the admixture each time a slightly different batch is desired.
As such, the apparatus 110 as illustrated in Figure 2 includes a first fluid line 112 including a first pump 118 fluidly coupled to a source 116 of
used hydraulic oil and a plurality of nominal filters 120. Again, the nominal
filters are preferably in the form of bag filters arranged in order of successively decreasing average porosity.
The apparatus 110 also includes a second fluid line 122 including a
pump 126 fluidly coupled to a source of used crankcase oil 124 and a plurality of nominal filters 128 positioned between the pump 126 and the junction 152 of fluid lines 112 and 122, respectively. Preferably a water removal filter 150 is provided in line between the junction 152 and the mixing tank 134 to reduce the water content well below the 0.5 weight percent which may be present in the used crankcase and hydraulic oil streams. A third fluid line 114 which is fluidly coupled to a source 130 of fuel oil and transported via pump 132 to the mixing tank 134 is also provided.
Extending from the mixing tank, preferably above the holding tank drain
136, is a lead away line 138. Positioned along the lead away line 138 is pump 140 for transporting the raw blend of reclaimed crankcase, hydraulic and fuel oils through a plurality of absolute filters 142 designed to remove impurities in a systematic manner. Preferably, the plurality of absolute filters
will be arranged such that the average porosity of each filter becomes successively smaller.
Upon mixing and filtering the raw blend wherein the components range from about 10.0 weight percent to about 100.0 weight percent of used hydraulic oil, more preferably 10.0 weight percent to about 30.0 weight percent used hydraulic oil; 0.0 weight percent to about 75.0 weight percent
used crankcase oil, more preferably 40.0 weight percent to about 75.0 weight
percent used crankcase oil; 15.0 weight percent to about 30.0 weight percent fuel oil; and up to about 5.0 weight percent additives an upgraded diesel fuel capable of use in an internal combustion engine operating on a thermodynamic cycle is obtained. As should be understood by those skilled in the art, regardless of whether a certain quantity of used crankcase oil or additives are employed, the sum weight percent of all components will always equal 100.0 weight percent.
In view of the detailed explanation of the apparatuses utilized to carry out the processes for producing upgraded diesel fuel in accordance with the present invention, a summary of various preferred formulations will now be presented in Table I.
Upon mixing various formulations as set forth in Table I, a single piston internal combustion engine operating on a thermodynamic cycle was employed to test the fuel efficiency of the various compositions as compared to fresh diesel fuel purchased at the pump. Since each test was conducted at room temperature and standard atmospheric pressures, the amount of time
the engine ran for a particular sample of fuel was used as the standard for determining fuel efficiency. The engine employed which was supplied by
Kubota Ltd. of Osaka, Japan had a displacement of 12.9 cubic inches, a gross output of 4.4 horsepower at 2600 rpm, 3.3 k.w. 43.3/rs, and an initial
output of 4.0 horsepower at 2600 rpm, 3.3 k.w. 43.3/rs.
TABLE
* additive employed is a high concentrate paint thinner
As demonstrated by the formulations presented in Table I, it appears that the formulation numbers 3 - 7 offered the best results in terms of fuel efficiency.
In addition to affording enhanced fuel efficiency over diesel fuel purchased at the pump, the engine seemed to run more quietly than the upgraded diesel fuels of the present invention. Further, the exhaust temperature was cooler for the upgraded diesel fuels versus the diesel fuel purchased at the pump, thus indicating less wear and tear occurring internally with the engine.
While the above detailed description describes the preferred embodiment of the present invention, it should be understood that the present invention is susceptible to modification, variation and alteration without deviating from the scope and fair meaning of the following claims.