Catalyst and method for improving combustion efficiency in engines, boilers, and other equipment operating on fuels

#1. Technical Field

#The present invention relates in general to a fuel additive that is a combustion catalyst, and in particular to an additive containing an over-based magnesium compound combined with a soluble iron compound for which the median particle size in the additive is less than about 0.01 micrometers.

#1. Description of the Prior Art

#FIG. 1 shows a comparison between the median particle size in the present invention and the median particle size in a typical catalyst used in hydrocarbon fuels.

#FIG. 2 shows a comparison of the activation energies for combustion catalyst reactions with and without the catalyst of the present invention.

#FIG. 3 shows the relationship between emission of particulate matter and catalyst concentration for the present invention and for a typical catalyst.

#Field tests have shown that iron with a particle size of less than about 0.01 micrometers behaves as a true catalyst based on kinetic theory. For example, in U.S. patent application Ser. No. 10/192,261, it is discussed that oil-soluble iron combined with oil-soluble magnesium is a very effective combustion catalyst in compression-ignited (Diesel) reciprocating engines. The synergistic mixture of metals results in suppression of hydrocarbons in the exhaust (soot or smoke) and an 8 to 12% increase in fuel efficiency. Also, U.S. patent application Ser. No.60/373,249 shows that oil-soluble iron combined with oil-soluble magnesium is a very effective combustion catalyst in spark-ignited reciprocating engines.

#It has been determined that this novel combination of iron and magnesium in naphtha based fuels (gasoline) yields an unexpected increase in RON of 3 or more units. It has also been found that the iron compound employed in this product does not disassociate or form iron sulfides. This observation is entirely unexpected as iron compounds typically exhibit negative side effects as discussed above. It appears that catalysis occurs from release of energy by electrons decaying from highly energized to degenerate orbitals. This is observed in the emission spectra of the element. An examination of the emission spectra of iron and magnesium demonstrates a reinforcement of the energy by non-duplicated primary spectra lines. It is believed that the mechanism of catalysis is that the reaction of hydrocarbon with oxygen to form carbon dioxide and water is rapidly quenched by dilution with air and reduced temperature. The energy from decaying electrons in the metal catalyst re-energizes the reaction process so that combustion is completed. This results in lower temperatures of operation and reduced NOx formation.

#A combination of an oil-soluble organo-metallic iron combustion catalyst with oil soluble magnesium to reduce vanadium deposits and corrosion has been shown to result in significant reduction of smoke in the exhaust of engines operating at steady state and non-equilibrium start-up conditions. Such a combination has also resulted in increased power, improved fuel economy and radically reduced smoke emissions in steam boilers and compression-ignited reciprocating engines. The iron-magnesium combination acts synergistically to give increased catalytic activity in such combustion processes. U.S. patent application Ser. No. 10/192,261, which is incorporated herein, discusses this combination.