FORM-2
THE PATENTS ACT. 1970 (39 of 1970)
COMPLETE SPECIFICATION
(Section 10, rule 13)
"Water in oil emulsification for improved combustion &
reduced air pollution"


Thermax Limited
with Corporate office at Thermax House, 4 Pune-Mumbai Road, Shivajinagar, Pune
411005, Maharashtra, India.
an Indian Company registered under the provisions of the Companies Act, 1956,
The following specification particularly describes the invention and the manner in
which it is to be performed: -


FIELD OF INVENTION:
This invention relates to emulsion.
Particularly, this invention relates to water in oil emulsion, and the process of preparing water in oil emulsion.
More particularly, this invention relates to water in oil emulsion for improving combustion and thermal efficiency.
Still particularly, this invention relates to water in oil emulsion that reduces emissions and related pollution.
DEFINITIONS
Combustion - involving combinations or resulting from combination
Fuel oil - Fraction obtained from petroleum distillation / contains residual oil left over
from distillation with air.
Furnace oil (FO) - A dark viscous residual fuel obtained by blending mainly heavier
components from crude distillation unit, short residue and clarified oil from fluidized
catalytic cracker unit and is also known as Fuel Oil.
Heavy oil - A type of crude oil which is very viscous and does not flow easily having
high specific gravity, low hydrogen to carbon ratios, high carbon residues, and high
contents of asphaltenes, heavy metal, sulphur and nitrogen
Low sulphur heavy stock (LSHS) - A residual fuel processed from indigenous crude
Surfactant - A chemical that stabilizes mixtures of oil and water by reducing the
surface tension at the interface between the oil and water molecules. Water and oil are
not miscible in each other; addition of surfactant to the mixture keeps it from
separating into layers.
Wetting agent - A substance that reduces the surface tension of a liquid, causing the
liquid to spread across or penetrate more easily the surface of a solid
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BACKGROUND OF INVENTION:
Emulsion is a mixture of two immiscible liquids. Emulsions are of two types: oil in water (o/w) and water in oil (w/o). Emulsion does not form easily and requires energy input like shaking, agitating, stirring, homogenizing or spray processes. In general emulsion is unstable. The instability is because small droplets that tend to recombine forming larger droplets exhibiting the process of coalescence.
Water in oil emulsion is difficult to formulate than oil in water. Oil in water emulsion is one wherein oil is dispersed in water and water in oil when water droplets are dispersed in oil. The fate to form water in oil emulsion or oil in water emulsion depends on the volume fraction of both phases and on the type of emulsifier. Emulsifiers and emulsifying particles tend to promote dispersion of the phase in which they do not dissolve very well.
It is desirable to prepare water in oil emulsion which is stable for a longer period of time.
Additives such as emulsifying agents and surface active substances like surfactants stabilize emulsion by increasing the kinetic stability of emulsion such that the emulsion thus formed remains stable for long.
Water in oil (w/o) emulsion has three components: an aqueous phase; a hydrophobic (oil) phase; and surfactant. In w/o emulsions, water is dispersed as droplets and suspended in the oil phase.
A surfactant is a molecule that has two portions: one portion is water-soluble (hydrophilic, lipophobic) while the other portion is oil-soluble (hydrophobic, lipophilic). This property of dual solubility make surfactants attractive vehicle to stabilize emulsions because they bridge the interface between the oil and the water.
Most emulsifiers are considered surfactants or surface active agents. These materials are able to reduce the surface tension of water. An emulsifier to be surface active agent is related to its HLB, or hydrophile-lipophile balance. HLB is determined by the
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size of the hydrophilic (water loving or polar) portion of a molecule as compared to the size of the lipophilic (oil loving or nonpolar) portion. The HLB system ranks the relative polarity of materials. The most polar, water soluble, materials are at the top of the twenty-point scale with more non-polar, oil soluble, materials closer to zero. HLB value facilitates the choice of surfactant and oil with regard to practical application. In addition to HLB value, surfactant concentration influences on the type and stability of emulsion. Therefore, to achieve optimum performance matching the surfactant HLB value with the HLB requirement is important.
Surfactants are in use alone or in combination in pigment dispersion, personal care, metal working fluids, metal cleaning pastes, furniture polishes and for the similar kind. However, selection of surfactants depends on the system used and its use in pigment, personal care products, metal working fluids or cleaning pastes, furniture polishes and similar kind. Low hydrophilic / lipophilic balance (HLB) of 3 to 6 is required for water in oil emulsion for cosmetics. Within this range there is limited number of emulsifiers available for use in cosmetics and toiletries and these are Sorbitan stearate (HLB 4.7), Polyglyceryl oleate (HLB 5.0), Lecithin (HLB approx. 4.0), Sorbiton monooleate (HLB), Glycerol monooleate, Lanolin and Lanolin alcohols.
Emulsion is prepared by emulsification process. Emulsification process is affected by the mixing ratio of the surfactants, the properties of the oil being used, mechanical shearing force, and volume ratio of the phases and the introduction of additives. While emulsifying the water in oil emulsion, suitable surfactants need be chosen to prepare a stable emulsion. Choice of a suitable surfactant is also dependent upon oil properties, thus the optimal HLB value range of selected surfactant may vary from system to system.
Water in oil emulsion is prepared by adding very slowly water to the oil phase containing the emulsifier, such that the water does not pool up excessively on the surface. To achieve this, continuous stirring while adding the water is essential. Dispersion of water droplets in the oil fuel can be effected by repeated and intense mechanical treatments, including ultrasonic homogenizing, mechanical homogenizing, or centrifugal pumping.
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In some chemical and industrial processes it is desirable to create stable water in oil emulsion. Recently, it was thought to be desirable to use water in oil emulsion as fuel in order to limit the pollution resulting from the combustion of oil. It is well known that the combustion of oil causes formation of carbon monoxide, nitrogen oxides, uncombusted parts of the oil, and soot. Addition of a suitable amount of water will reduce this pollution without reducing the combustion yield. The general disadvantage of the existing water in oil fuel is stability that is not satisfactory causing operational disturbances.
The benefits of burning emulsion fuels were first documented by Eric Charles Cottell in the seventies. Since then numerous processes have been developed to try and achieve similar results, mostly using chemical stabilization or surfactants to produce a 'clean' fuel. However, this required dedicated storage and return tanks and stability was not guaranteed.
Positive effects from addition of water to fuels include reduced fuel consumption, cleaner exhausts, cleaner boiler tubes, less luminosity and shorter flame length. Amount of water, ranging from 3 to 40 volume %, is required to obtain significant reductions in carbon emissions and in improved combustion performance whereas Sjogren A. demonstrated that less water is required for significant combustion improvement where the water is more finely dispersed in the oil, preferably as particles having diameters in the range from 2 to 5 urn.
PEP-99™ is a commercially available product controls water droplet size in the range of 5 jam to 20 \im in diameter within the oil and prevents coalescence. PEP-99™ emulsion is water in o il emulsion fuel consisting 5 percent to 10 percent water dispersed as droplets in a continuous oil phase providing maximum combustion. Proper mixing and proportioning of the water, oil and PEP-99™ surfactant creates stable emulsion ready to burn.
Another commercially available product is Aiken Even-Flo® 905 is a combination of surface active materials and organic compounds designed to prevent or neutralize contaminants. Emulsifying agents disperse the water and sludge into particles so small
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that they are carried through the system and burn without creating any deposits. Other surfactants, in the formula, help mix together any incompatible oils and breakup accumulations of water and sludge. The organic compounds reduce the degenerative effect of sulphur and vanadium. The organic surfactants in Aiken Even-Flo® 905 inhibit corrosion, which otherwise would occur at the water-wetted areas in the tank and throughout the fuel oil system.
PRIOR ART:
US patent 3,749,318 describes the ultrasonic formation of water in oil dispersions, without adding emulsifying agent, for use in burners.
US patent 3,826,771 discloses the use of sorbitan monostearate and Sorbiton monooleate as water in oil emulsifying agents.
US patent 4,048,963 describes process of burning liquid fuel, sonically emulsified producing extremely stable fine particles. The water in oil emulsion contained 10% to 30% water without emulsifying agent.
US patent 4,394,131 describes a stable combustion fuel emulsion free of surfactants for furnaces, boilers and engines. The emulsion consisting of water less than about 20% by weight, water droplets of uniform size of less than about 0.5 u,m and stable for three months or more. The method of preparation involved high energy rotary impact milling.
US patent 4,395,266 describes water in mineral oil emulsions and a process for producing such emulsions. The emulsion is produced from water, mineral oil, a surfactant and a stabilizer and useful as fuel in improved combustion. The stabilizer of the invention is a polymeric stabilizer formed in situ by reacting anionic and cationic surfactant.
US patent 4,672,090 describes improved water in oil emulsion polymerization process using a surfactant system. The surfactant system consisting 1.0 to 5.0 percent of an oil soluble alkanolamide, polyoxyethylene derivatives of sorbitan esters and optionally a partially-esterified N,N-alkanol fatty amide and polyoxyethylene (5) Sorbiton
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monooleate and the polyoxyethylene derivatives of sorbitan esters have HLB values in the range of 9.0 to 11.0. The system provided improved settling storage stability; small particle size; low bulk viscosity; improved high temperature tolerance; low oil content; improved solids loadings; and comparable or improved performance.
US patent 4,696,638 relates to process and apparatus, for the improved preparation of
water in oil emulsions for use in the combustion of oil fuels in a combustion zone.
Combustion efficiency improved water in the water in oil emulsion of 1 to about 10
um droplets.
Addition of effective proportion of emulsifying agent may further improve stability.
The water in oil emulsion needs introduction into the body of the oil fuel prior to
combustion.
US patent 4,602,970 describes a method of stabilizing an emulsion explosive comprising an oxidant, a fuel and an emulsifier containing at least one double-boiding, Sorbiton monooleate (SPAN 80).
US patent 5,852,075 describes polyether modified siloxane as surfactant used in ink for ink jet printers to exhibit excellent wetting on hydrophobic surfaces.
US patent 6,077,338 describes use of 0.1% by weight of low molecular weight polyether modified siloxane to provide the surface tension in the same range for all ink colors.
US patent application 20080006326 describes a simple, more effective, economical and reliable means of producing an emulsion at the point of combustion using ordinary tap water and no additives.
RU patent 2349631 describes process of preparing a fine nano size emulsion of the type "water in liquid fuel", and also "water in oil", for use in internal combustion engines, thermal machines, boilers, ovens, and also in pharmaceuticals and food industry. Method involves mixing organic phase and aqueous phase with additives or without adding surfactants under the action of UHF of an electromagnetic field.
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Various improved devices, method of making uniformly fine water in oil emulsion with or without emulsifying agent are available for use as a clean-burning and efficiently-burning fuel. However, to have all criteria such as suitable surfactants to improve stability, combustion and thermal efficiency of emulsion and cost effective method in one is difficult. There are not many water in oil emulsions and / or emulsifiers available that fulfill abovementioned criteria. Therefore, an efficient surfactant / emulsifier system specially designed for water in oil emulsion to satisfy the needs is a must.
The water in oil emulsion described herein is not disclosed or suggested by the above-cited references.
OBJECTS OF THE INVETION
An object of this invention is to provide emulsion
Another object of this invention is to provide emulsion, typically water in oil emulsion.
Another object of this invention is to provide stable water in oil emulsion that controls water droplets size and prevent coalescence.
Still further object of this invention is to provide stable water in oil emulsion.
Yet another object of this invention is to provide efficient, economic water in oil emulsion, typically for use in boilers, furnaces and the like.
Further object of this invention is to provide a simple and effective technique to produce water in oil emulsion small size oil droplet particles to reduce particulate matter, improve combustion efficiency, and reduce unburnt matter.
Further object of this invention is to provide eco-friendly water in oil emulsion that improves combustion and thermal efficiency and saves fuel.
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SUMMARY OF THE INVENTION
The invention envisages emulsion, typically stable water in oil emulsion which comprises: i) water; ii) oil; and Hi) combinatorial surfactant. The combinatorial surfactant controls water droplet size and prevent coalescence.
According to this invention, there is provided a process for preparing the water in oil emulsion in the range of 5 to 20 urn. The hydrophobic lipophilic balance (HLB) value of the stable emulsion is from 7 to 11.
This invention encompasses stable water in oil emulsion for improving combustion and thermal efficiency.
DETAILED DESCRIPTION
This invention relates to water in oil emulsion comprising combinatorial surfactant.
In the present invention, combinatorial surfactant is hereinafter referred as Thermosol E-Plus.
Further, this invention water in oil emulsion includes water, oil, and combinatorial surfactant for use in improving combustion and thermal efficiency.
Essentially, in water in oil emulsion, water is selected from group of deionized water, soft water, demineralised water, and well water. In the present invention demineralised water is preferred and is present from 4 to 6 percent by weight and more preferably 5% by weight.
Further, water in oil emulsion uses heavy oil includes furnace oil, fuel oil, and low sulphur heavy stock. Present invention uses furnace oil present in the range from 94 to 96 percent by weight. Preferably 95% of furnace oil is used in water in oil emulsion.
Essentially, Thermosol E Plus composition includes one or more surfactants selected from group of alkyl and polyether modified siloxane, oxazoline type, sorbitan
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monooleate, PEG monooleate, PEG dilaurate, PEG 200 monolaurate, sorbitan ester, glycerol monooleate, and cocoamine ethoxylate.
Preferably, Thermosol E Plus is composed of variety of surfactants that are bifunctional in nature. These are alkyl and polyether modified siloxane of molecular weight at least 10000, oxazoline type, and sorbitan monooleate.
Preferably, Thermosol E Plus includes alkyl and polyether modified siloxane, Tegopren 7008 (Tegopren 7008: alkyl- and polyether-modified polymethylsiloxane), oxazoline type, Alkaterge T-IV (Alkaterge T-IV: Ethanol, 2, 2'- (2-heptadecenyl-4(5H)oxazoline), and Sorbiton monooleate (Span 80). The ratio of Tegopren 7008, Alkatergre T-IV, and Sorbiton monooleate (Span 80) ranges from 3:7.5:40 to 9:22.5:120. Thermosol E Plus is composed of Tegopren 7008, Alkatergre T-IV, and Sorbiton monooleate in the ratio of 6:15:80.
Thermsol E-Plus is water in oil emulsifier for reducing fuel consumption, since emulsification helps to quickly oxidize FO that is less residence time is required. It also reduces the flame volume thereby reducing the furnace size or more fuel in same size furnace can be fired. This improves performance and output of the boiler / heater preferably in heavy fuel fired FO units.
The composition of present invention is stable at ambient / room temperature for >365 days and 4 to 6% emulsion in water with 500 - 1000 mg.L"' of Thermosol E Plus gives excellent stability at 30 - 40° C temperature. The emulsion mixture is stable for 12 to 18 hours. In presence of heavy oil with little agitation it reemulsifies and mixes well. Same composition is not available. Conventional combinations are different by composition.
Another aspect of present invention is to provide a process for the preparation of water in oil emulsion.
Preferably, emulsion is water in oil emulsion comprising 5 percent by weight demineralised water, 95 percent by weight furnace oil, and Thermosol E Plus ranging
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from 0.1 to 0.5 percent by weight. The resultant mixture is stable water in oil emulsion.
The present invention water in oil emulsion containing demineralised water 5% by weight, furnace oil 95% by weight and combinatorial surfactant comprising Tegopren 7008, Alkatergre T-IV, and Sorbiton monooleate in the ratio of 6:15:80 is stable at a temperature ranging from 30 to 40° C for at least 365 days, and 4 to 6 percent by weight of emulsion in demineralised water at 500 to 1000 mg.L"1 of combinatorial surfactant is stable at a temperature ranging from 30 to 40° C, and by agitating the mixture reemulsifies in presence of furnace oil, said mixture in furnace oil is stable for 12 to 18 hours wherein Sorbiton monooleate acts as emulsifier, Siloxane derivative as stability improver, and Alkaterge T-IV as corrosion inhibitor cum lubricity improver.
Use of such emulsified oil results in saving in soot, CO, unburnt resulted in fuel saving of 2.5%.
Essentially, preparation of water in oil emulsion involves dispersing 4 to 6% by weight water as droplets in a continuous oil phase using Thermosol E-Plus. Thorough mixing using laboratory stirrer results in droplets in the range of 5 \xm to 20 um in diameter within the oil.
Thermosol E Plus control water droplet size and prevents coalescence. With proper mixing and proportioning of water and oil, Thermosol E Plus produces composition that is very stable and ready to burn.
The high-speed homogenizer is the most rapid and convenient method as compared to other techniques for preparing w/o emulsions. The step of homogenization allows formation of small sized droplets.
Essentially, the process of preparing water in oil emulsion comprising 4 to 6 percent by weight demineralised water in pre-emulsifying form, 0.1 to 0.5 percent by weight of Thermosol E-Plus, and adding 95 percent by weight furnace oil. Homogenization using emulsification technique produces oil droplet particle size of at least 10 um at
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burner outlet thereby maintains viscosity even in presence of high level of Conradson carbon residue content. Normally the oil droplet particle size is 80 um to 100 urn by conventional method.
In place of 100% oil fired boilers, use of 5 to 6 % water in preemulsified form and 94 to 95% heavy oil forms a suitable mixture to fire it in boiler. This help to reduce direct fuel consumption, reduction in particulate matter and improvement in combustion efficiency.
Water in oil emulsion system and products as concept is used in boilers and furnaces. The emulsions prepared to provide reduced particulate matter due to lower soot formation, simultaneously increasing thermal efficiency as well as reduction in fireside fouling. The emulsion prepared also improves combustion reducing NOx and unburnt carbon.
A typical burner atomizer produces a spray of fuel oil droplets around 100 urn to 200 urn in diameter. This depends on fuel quality and atomizer design. Typically, larger fuel droplets do not completely burn, leaving unburned carbon to collect on heat transfer surfaces and escape as particulate matter in the exhaust gases. This reduces overall thermal efficiency.
In the combustion of water in oil emulsion, the primary spray fuel droplets are further divided as a result of the spontaneous vaporization caused by rapid heating of the water dispersed with the individual fuel droplets. The internal water droplets undergo spontaneous nucleation of steam bubbles at a temperature well above 93.3° C (200 F), causing a violent conversion of the water droplet to steam. The vaporization, in turn, produces a rapid expansion of the surrounding oil droplets, fragmenting the oil into a vast number of smaller fuel droplets. The name for this process is secondary atomization. Droplets of emulsified fuel, 200 um in size, fragmented into a multitude of 1 to 10 (Am size fuel droplets. Secondary atomizations to be effective in a combustion process, very small droplets with a well controlled size distribution are necessary. If the number of water droplets (1 urn or less) is too small, insufficient energy will be produced to cause secondary atomization. On the other hand, larger droplets (10 urn or larger) reduce the number of droplets for explosion and tend to
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produce less violent explosions within the oil droplets because of nucleation taking place at lower temperature.
Thermosol E Plus is recognized for its ability to produce proper size and uniformly distributed water in oil droplets with unusual stability. This process greatly increases the number and surface area of the fuel droplets in the flame zone. Since the combustion of fuel is a surface reaction, the greater the surface area, the less time it takes to burn out the carbon.
Thermosol E Plus has the ability to produce water in oil emulsion of uniform and proper size of water in oil droplets rendering stability for longer period of time.
Water in emulsion improves combustion by creating secondary atomization (micro explosion) when the oil drop (with encapsulated water particles) is heated up in the combustion chamber.
The invention is further illustrated in the form of examples. However, these examples should not be construed as limiting the scope of the invention.
EXAMPLES
Experiment 1
In the present experiment, 80% heavy oil, furnace oil was taken in a suitable container. 20% of demineralised water was added to oil using a laboratory grade stirrer at 3000 rpm for 30-60 minutes with 1000 mg.L'1 of Glycerol monooleate in preemulsified form. The mixture was allowed to stabilize.
After 4 hours, stratification was observed.
The mixture was not suitable for combustion purpose and discarded.
Experiment 2
An experiment was designed wherein 90% of furnace oil mixed with 10%
demineralised water preemulsified using 0.1% of Glycerol monooleate while using a
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laboratory model stirrer at 3000 rpm for 30-60 minutes to emulsify water in oil. The emulsion was allowed to stabilize.
Stratification process was initiated after 8 hours.
The mixture was discarded since it not suitable for combustion purpose.
Experiment 3
90% furnace oil with 10% soft water in preemulsified with 500 mg.L'1 of Glycerol monooleate and Cocoamine ethoxylate 15 moles of/ 500 mg.L"1 and mixed at ambient / room temperature (28 to 30° C) by stirring using laboratory model of stirrer at a speed of 3000 rpm.
The mixture was stable for 3 to 4 hours without stratification. Stratification initiated after 3 to 4 hours.
The mixture was discarded as it was not suitable for combustion purpose.
Experiment 4
95% furnace oil with 5% water containing Sorbitan ester (1725 cm"1 to 1750 cm"1 as
IR spectra) at 1000 mg.L"1 concentration
The mixture was stable when stirred at 3000 rpm using laboratory model of stirrer at
ambient/ room temperature (28 to 30°C) for a period of 7 Hrs.
The ratio of oil and water as 95: 5 was found suitable and used in subsequent experiments.
Experiment 5
For water in oil emulsification basic HLB value was decided to maintain in the range
of 7 - 11 using various surface active agents such as:
PEG 200 monolaurate (HLB 9.3), PEG dilaurate (HLB 7.6)
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HLB value range of 7 - 11 and oil to water ratio of 95:5 was fixed. Water was preemuisified before mixing in oil using suitable emulsifier - Glycerol monooleate (HLB - 4); Sorbiton monooleate (HLB - 4.3); PEG monooleate (HLB - 10.4).
Using above selected surface active agent experiment was repeated as ratio of oil 95: water 5 with Sorbiton monooleate as predominant surfactant having correct HLB value to meet water in oil emulsification which has principally functioned as emulsifier.
The mixture was found stable for 12 Hrs and hence this surface active agent selected for further experiments.
Using Sorbiton monooleate (Span 80), an ICI surfactant, with varied molecular weight studied for formulation compatibility in which it was found that alkyl and allyl polyether modified siloxane having >1000 MW found stable. Alkyl and polyether modified siloxane (high molecular weight > 10000) - polymeric and polyfunctional structure, having a typical silicone properties like hydrophobic, non ionic in nature with refractive index 1.43 - 1.44, water insoluble and purchased from Evonik Gold Schmidt Corporation as Tegopren 7008, belongs to silicone tensides with good wetting behaviour.
When formulated which was tested for 95:5 of oil to water with 1000 mg. L"1 dose , emulsion mix was found 12 to 15 hrs stable as there was no stratification / separation of oil and water. From this experiment siloxane derivative was chosen as key ingredient.
Experiment 6:
From experiment no. 5, formulation compatibility of ingredients established with 15 hrs stability in 95:5 ratio emulsion of water in oil, with further experimentation to improve compatibility and formulation stability, various grades of imidazolene and imidazolene ethoxylate tried such as Imidazolene made from Oleic Acid-Aminoethylethanol amine, Oleic-Diethylene triamine, Oleic-Tetraethylene pentaamine and ethoxylate 4-5 mole found poor in compatibility in formulation itself hence discontinued.
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ANGUS make Multifunctional oxazoline type surfactant having high dispersibility in water, hydrocarbons and alcohols, useful as corrosion inhibitor, as a dispersant, as oil in water emulsifier and as acid scavenger, liquid at room temperature and best surface active agent, purchased from ANGUS chemical company as Alkaterge T-IV (Ethanol, 2, 2'- (2-heptadecenyl-4(5H)oxazoline); and tried for formulation compatibility. A dark brown liquid with HLB value 8 - 10, having surface tension of 0.1% - 34.2 dyne.cm'1, alkaline viscous liquid, useful as emulsifier, as corrosion inhibitor, pigment dispersion and a lubricity improver. After the comfort of stability and compatibility in formulation, experiment 7 was planned.
Experiment 7
Use of combinatorial surfactant active agents as given in experiment 6 (Thermosol
E-Plus) were used to make water in oil emulsion for combustion improvement for
energy and environmental benefit. Various ratios of surfactants from experiment 6
were tried to achieve complete combustion. Ratio of 6:15:80 of surfactant formed
stable water in oil emulsion when mixed at 0.1% to 0.5% range in preemulsified form
in heavy oil as furnace oil / low sulphur high solids. The combination surfactant
Thermosol E Plus found stable for 18 Hrs when used in concentration at 1000 mg. L"1
in 95:5 of oil in water mixture after suitable homogenization for a period of 60
minutes at 3500 rpm.
The said emulsion was fired in boilers for effectiveness in its combustion
performance.
Boiler Make: THERMAX LIMITED INDIA
Model: RFB 40
Fuel used: Furnace Oil
Fuel consumption: 3000 liters/day (1000 liters /shift)
Emulsifier: 3 batches of 1KL each prepared per day.
Quantity of water taken: 180 kgs/day(60 kg/shift of 8Hrs)
Performance parameters measured during the test are given below -1) C02 % 13.6 increased to 14.2% 2)02%3.1 reduced to 2.7%
3) CO in ppm: 40 ppm reduced to 5 ppm
4) Smoke Index reduced from 2-3 to 1 -0
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5) Consumption reduced by 2.6%
Following was observed during tests which give indication of better combustion:
1) The particulate matter at stack was found to be lower
2) No sparklers were observed in the flame
Derived benefits of the combustion parameters though not measured are:
1) Reduction in NOx due to reduced excess air and lower peak flame temperature,
2) Increase in thermal efficiency due to reduction in fireside deposits.
ADVANTAGES:
Water in oil emulsion creates a "steaming effect" on fuel particles which provide
better surface area. This enables a better atomization and consequent combustion of
the fuel.
Envisage intensive treatment of emulsified fuel for over 3 hours. Thus a uniform and
thorough mixing of the additive components was achieved. A frothy mixture is
created which offers better surface area for combustion.
Issues like fuel quality deterioration are addressed more effectively. A significant
decrease in unburnt and soot emissions can be seen.
Water in oil emulsion offers gross savings which are considerably higher than
conventional additives both on gross and net savings front.
Summary of Potential Benefits using Thermosol E Plus for emulsification of fuel
Improved atomization, improved carbon combustion, reduced fireside deposits, lower particulate in flue gas, lower NOx, shorter flame length and hence reduced flame impingement, improved heat transfer, reduced frequency of soot blowing, reduced acid mist. Each benefit has potential of savings in fuel, maintenance cost and pollution.
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While considerable emphasis has been placed herein on the specific steps of the preferred process and components of the preferred embodiment, it will be appreciated that many alterations can be made and that many modifications can be made in the preferred embodiment without departing from the principles of the invention. These and other changes in the preferred embodiment as well as other embodiments of the inventions will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.
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We claim,
1. Water in oil emulsion comprising combinatorial surfactant.
2. Water i n oil emulsion as claimed in claim 1 wherein, water in oil emulsion
comprising:
i) water,
ii) oil, and
iii) combinatorial surfactant.
3. Water in oil emulsion as claimed in claim 1 wherein, water is one selected from group of deionized water, soft water, demineralised water, and well water.
4. Water in oil emulsion as claimed in claim 1 wherein, oil is heavy oil, one selected from group of furnace oil, fuel oil, and low sulphur heavy stock.
5. Water in oil emulsion as claimed in claim 1 wherein, combinatorial surfactant is one or more selected from group of alkyl and polyether modified siloxane, oxazoline type, sorbitan monooleate, PEG monooleate, PEG dilaurate, PEG 200 monolaurate, sorbitan ester, glycerol monooleate, and cocoamine ethoxylate,
6. Water in oil emulsion as claimed in claim 1 wherein, water is demineralised water and present ranging from 4 to 6 (3 to 15%) percent by weight.
7. Water in oil emulsion as claimed in claim 1 wherein, oil is furnace oil and present ranging from 94 to 96(85 to 97%) percent by weight.
8. Water in oil emulsion as claimed in claim 1 wherein, combinatorial surfactant comprising alkyl and polyether modified siloxane of molecular weight at least 10000, oxazoline type, and sorbitan monooleate.
9. Water in oil emulsion as claimed in claim 6 wherein, demineralised water is 5 percent by weight.
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10. Water in oil emulsion as claimed in claim 7 wherein, furnace oil is 95 percent by weight.
11. Water in oil emulsion as claimed in claim 8 wherein, combinatorial surfactant comprising alkyl and polyether modified siloxane is Tegopren 7008 (Tegopren 7008: alkyl- and polyether-modified polymethylsiloxane), oxazoline type is Alkaterge T-IV (Alkaterge T-IV: Ethanol, 2, 2'- (2-heptadecenyl-4(5H)oxazoline), and Sorbiton monooleate (Span 80), and Tegopren 7008, Alkatergre T-IV, and Sorbiton monooleate is present in the ratio of ranging from 3:7.5:40 to 9:22.5:120.
12. Water in oil emulsion as claimed in claim 11 wherein, combinatorial surfactant comprising Tegopren 7008, Alkatergre T-IV, and Sorbiton monooleate is present in the ratio of 6:15:80.
13. A process for preparing water in oil emulsion comprising 5 percent by weight demineralised water, 95 percent by weight furnace oil comprising combinatorial surfactant ranging from 0.1 to 0.5 percent by weight.
14. A process as claimed in claim 12 and 13 wherein, water in oil emulsion comprising 5 percent by weight demineralised water in pre-emulsifying form, 0.1 to 0.5 percent by weight of combinatorial surfactant, and adding 95 percent by weight furnace oil, said water in oil emulsion formed by homogenization using emulsification technique producing oil droplet particle size of at least 10 urn.

15. A process as claimed in claim 14 wherein, water in oil emulsion produced is stable for at least 365 days at a temperature ranging from 30 to 40° C.
16. Water in oil emulsion as claimed in preceding claims wherein, water in oil emulsion comprising demineralised water 5% by weight, furnace oil 95% by weight and combinatorial surfactant comprising Tegopren 7008, Alkatergre T-IV, and Sorbiton monooleate in the ratio of 6:15:80 is stable at a temperature ranging from 30 to 40° C for at least 365 days, and 4 to 6 percent by weight of emulsion in demineralised water at 500 to 1000 mg.L'1 of combinatorial surfactant is stable at a temperature ranging from 30 to 40° C, and by agitating the mixture reemulsifies in
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presence of furnace oil, said mixture in furnace oil is stable for 12 to 18 hours in which Sorbiton monooleate as emulsifier, Siloxane derivative as stability improver, and Alkaterge T-IV as corrosion inhibitor cum lubricity improver.
17. Use of such emulsified oil results in saving in soot, CO, unbumt resulted in fuel saving of 2.5% when experimented.
Dated this 1st July, 2009
For Thermax Limited
(Mr. Kiran Deshpande) R&D: Chemical Dept.
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1 4 JUL 2009