Fuel processor apparatus for diesel powered vehicles

Abstract

A new fuel processor apparatus for diesel engines, particularly diesel engine powered vehicles, with the apparatus having no moving parts and no internal gaskets or connections to leak or deteriorate, and said apparatus being capable of removing water from the diesel fuel while promoting filterability and combustion efficiency of the fuel.

The questions raised in reexamination request No. 90/001,643, filed Nov. 22, 1988, have been considered and the results thereof are reflected in this reissue patent which constitutes the reexamination certificate required by 35 U.S.C. 307 as provided in 37 CFR 1.570(3).

Description

BACKGROUND OF THE INVENTION

This invention broadly relates to a new fuel processing apparatus for diesel engine powered trucks and automotive vehicles, as well as other diesel engine power installations.

The state of the art is indicated by the following cited references (U.S. Pat. Nos.): Dunman #4,091,782; Quinn #4,146,002; Gratzmuller #3,354,872; McMinn #3,396,512; McCabe #3,762,548; Campbell #3,768,730; Richard #3,913,543; Cheysson #3,925,204; Virgil #3,935,901; McQuerry #3,209,816; Rehm #3,962,999; Zabenski #4,015,567; Amano #4,027,639; Linder #4,044,742; Hawkins #4,072,138; and Richards #4,091,265.

In the past when diesel fuel was plentiful and relatively inexpensive there were significantly fewer problems with the quality of the diesel fuel because of the substantial competition between sellers of the fuel. Refineries, distributors, and retailers of the fuel were careful to keep water out of the fuel, and they usually did not pump out the heavy settlings from the bottom of the fuel storage tanks. In more recent times, with shortages of oil, the fuel suppliers can sell essentially all of their available oil with little difficulty. Additionally, fuel suppliers in the past have blended kerosene and other fuels with lower cloud and pour points to Diesel Fuel to facilitate cold weather flow and use. Fuel allocations due to government regulations and oil shortages have now made it almost impossible to continue this practice. The result has been a distinct tendency toward lesser quality fuel containing substantially more impurities such as water and particulate materials which are very disruptive to proper operation of a diesel engine.

, connected to the return line of the passenger compartment heaterAs shown in the drawings, both embodiments disclosed have the fuel inlet (30 FIG. 1; 112, 113 see FIG. 5) located to introduce fuel into the apparatus approximately at the midpoint of the height of the vessel, a location relatively remote from the bottom region of the vessel, where separated water collects, and from the fuel outlet (36 or 115) located near the top of the vessel. This midpoint fuel entry avoids remixing incoming fuel with previously separated water while providing sufficient residence time to enable water to settle out before the fuel passes into the outlet.

Both embodiments likewise find the internal heating liquid conduit (22, 109) extending through the chamber from its top to bottom (conduit 22, FIG. 1) or at least into the bottom region (conduit 109, FIG. 3) where settled out water collects. In extreme cold weather conditions, the amount of heat supplied to the fuel by the heating liquid may be sufficient to melt or prevent the formation of individual ice crystals in the fuel, but insufficient to melt a body of ice which might be created by freezing of settled out water collected at the bottom of the vessel where it contacts the vessel housing which is essentially at outside ambient temperature. By routing the heating conduit through the bottom region of the vessel where the separated water is collected freezing of this collected water is prevented. By locating the filter (FIGS. 2-5) at the top of the unit, rising heat from the lower portions of the unit assists the heating fuel in keeping the filter from freezing up.

The fuel processor apparatus of the invention functions in a manner related more closely to a chemical or petro-chemical device rather than a mechanical device. Certain highly advantageous considerations in accordance with the invention are as follows:

(1) The specific heat of fuel oil is approximately one third that of water (2) The specific gravity of fuel oil is approximately 80% of the specific gravity of water. (3) The coefficient of expansion differential between diesel fuel and water is so significantly different that when the fuel is heated, the twin phenomena of specific heat and coefficient of expansion causes water entrapped or suspended in the fuel to quickly separate and fall out--where it can be collected and drained away. (4) The surface tension of free water--once it is separated in the device of the invention--prevents water in the fuel processor from becoming resuspended in the fuel. (5) Bacterial growth occurs in fuels but essentially only when water is present. Bacteria are a major threat to fuel filters due to their clogging action. Bacteria have demonstrated their ability to "wick" themselves up around fuel filters to permit their propagation on filter elements--thus rapidly clogging filters and causing engines and vehicle downtime and repair costs. Water in the fuel can also result in the formation of sulfuric acid which is harmful to engine accessories and operation. The device of the present invention through its action of removing water from the fuel acts to alleviate the problems of bacteria formation and sulfuric acid formation. (6) The fuel processor device of this invention effectively dewaters fuel, removing over 99.7% of all suspended water--including that formed through the deterioration of the hydrocarbon molecule, and oxidation by the free oxygen in the atmosphere. (7) Ice crystals form in fuel during cold weather [-32° or lower] when molecules of water are present in fuels. The specific gravity of ice is very near that of fuel and permits ice to flow with the fuel to the filters. When this occurs, ice crystals can completely clog or seriously reduce fuel flow to the engine. The specific heat value for ice is 0.505 [or approximately 1/2 that of water]; ice crystals melt quickly in the fuel processor apparatus of this invention. The newly formed liquid water, being much colder than the fuel and consequently much heavier, immediately falls to the bottom of the fuel processor where it can be drained away. (8) Prevention of paraffin formations when ambient temperatures may drop below the cloud point of the fuel is accomplished by the fuel processor of the invention. In particular the greater weight of the molecules of parrafins and naphthenes are maintained in their liquid state. By enabling these heavy fuel elements to be used during cold weather, fuel economy is realized and the costs of adding chemicals or lighter grade fuels to dissolve the paraffin is eliminated. (9) Fuel oil, especially diesel fuel, shrinks when cooled. Fuel injectors operate by displacing a specific volume, therefore the heat potential of diesel fuel on a volume basis changes according to temperature. The fuel processor of this invention aids in improving fuel economy in diesel powered equipment in cold weather by restoring the diesel fuel molecule to a temperature consistent with factory engine calibrations and settings.

While it will be apparent that the preferred embodiments of the invention disclosed are well calculated to fulfill the objects above stated, it will be apparent that the invention will be susceptible to modification, variation and change without departing from the proper scope or fair meaning of the subjoined claims.

Claims

1. A fuel processor means for use with diesel engines on diesel trucks, automobiles, and the like, and whereby said fuel processor means is operative to preheat heat the diesel fuel and to separate out water-impurities from the diesel fuel, and for melting wax crystals which form in cold ambient conditions before the fuel is transmitted to a particulate filter and enabling the diesel fuel to be used in cold ambient conditions without the use of fuel additives such as chemicals or lighter grade fuels to improve fuel flowability, comprising;

a vertically oriented elongated tubular vessel means which provides for a substantially unconstrained flow path of the diesel fuel therethrough for separating the water-impurities out of the fuel, and collecting the water-impurities at the bottom of said vessel means,

inlet conduit means near the top of said vessel means to introduce hot engine coolant liquid to the said vessel, means,

another conduit means passing through a central portion of said vessel means and into said bottom of said vessel means for transmitting the hot coolant liquid therethrough,

outlet conduit means for recirculating the hot coolant liquid back through the engine cooling system,

a second inlet conduit means for introducing the fuel into to the interior of the said vessel means near the vertical midpoint thereof for flow therethrough whereby said separation of the water-impurities provided by said fuel processor means begins to occur after the fuel enters from said second inlet conduit means into said vessel means, and such that this inlet is above the level of water-impurities being collected in the vessel,

a second outlet conduit means for the fuel located near the top of the said vessel means for transmitting the water-free fuel to the particulate filter and the engine whereby said second inlet conduit means and said second outlet conduit means cause the fuel to flow through said vessel means in a manner which facilitates the separation of the water-impurities and minimizes remixing of the water-impurities being collected,

drain means at the said bottom of the said vessel means for draining out the water-impurities which collect therein to prevent the level of water impurities collected at the bottom of said vessel means from rising to the level of said second inlet conduit means,

and means near the top of the said vessel means for venting the said vessel means when desired.

2. The invention of claim 1 wherein,

said apparatus vessel means includes a top plate and an integral said particulate filter means built-in with the vessel and having a cup shaped canister enclosing a filter media element with an opened end defining inlet and outlet flow ports mounted to said top plate such that said filter is disposed above said top plate with said opened end directed downwardly, said filter operative to perform a filtering operation on the fuel during its passage through the apparatus vessel means.

3. A fuel processor means for use with diesel engines on diesel trucks, automobiles, and the like, and whereby said fuel processor means is operative to preheat heat the diesel fuel and to separate out water-impurities from the diesel fuel and for melting wax crystals which form in cold ambient conditions before the fuel is transmitted to a particulate filter and enabling the diesel fuel to be used in cold ambient conditions without the use of fuel additives such as chemicals or lighter grade fuels to improve fuel flowability, comprising;

a vertically oriented tubular vessel of generally seamless construction means which provides for a substantially unconstrained flow path of the diesel fuel therethrough operative for separating the water-impurities out of the fuel and collecting the water-impurities at the bottom of said vessel,

inlet conduit means near the top of said vessel to introduce hot engine coolant liquid,

another conduit means passing through a central portion of said vessel and into said bottom of said vessel for transmitting the hot coolant liquid therethrough,

outlet conduit means near the bottom of said vessel for recirculating the coolant liquid back through the engine cooling system,

a second inlet conduit means for introducing the fuel intoto the interior of the said vessel near the vertical midpoint thereof for flow therethrough whereby said separation of the water-impurities provided by said fuel processor means begins to occur after the fuel enters from said second inlet conduit means into said vessel,and such that this inlet is above the level of water-impurities being collected in the vessel,

a second outlet conduit means for the fuel near the top of the said vessel for transmitting the water-free fuel to the particulate filter and the engine whereby said second inlet conduit means and said second outlet conduit means cause the fuel to flow through said vessel in a manner which facilitates the separation of the water-impurities and minimizes remixing of the water-impurities being collected, and

drain means at the said bottom of the said vessel for draining out the water-impurities which collect therein.therein to prevent the level of water impurities collected at the bottom of said vessel from rising to the level of said second inlet conduit means.

4. The invention of claim 3, wherein,

said apparatus vessel is free of moving parts and has no internal gaskets to leak or deteriorate.

5. The invention of claim 3 further characterized as including:

means near the top of the said vessel for venting the said vessel when desired.

6. A fuel processor means for use with diesel engines on diesel trucks, automobiles, and the like, and whereby said fuel processor means is operative to preheat heat the diesel fuel and to separate out water-impurities from the diesel fuel and for melting wax crystals which form in cold ambient conditions before the fuel is transmitted to a particulate filter and enabling the diesel fuel to be used in cold ambient conditions without the use of fuel additives such as chemicals or lighter grade fuels to improve fuel flowability, comprising,

a vertically oriented tubular vessel of generally seamless construction means which provides for a substantially unconstrained flow path of the diesel fuel therethrough operative for separating the water-impurities out of the fuel and collecting the water-impurities at the bottom of said vessel

inlet conduit means to introduce hot liquid from the engine,

another conduit means passing through a central portion of said vessel and into said bottom of said vessel for transmitting the hot liquid therethrough,

outlet conduit means for recirculating the hot liquid back through the engine system,

a second inlet conduit means for introducing the fuel into to the interior of the said vessel near the vertical midpoint thereof for flow therethrough whereby said separation of the water-impurities provided by said fuel processor means begins to occur after the fuel enters from said second inlet conduit means into said vessel, and such that this inlet is above the level of water-impurities being collected in the vessel,

a second outlet conduit means for the fuel near the top of the said vessel for transmitting the water-free fuel to the particulate filter and the engine whereby said second inlet conduit means and said second outlet conduit means cause the fuel to flow through said vessel in a manner which facilitates the separation of the water-impurities and minimizes remixing of the water-impurities being collected,

drain means at the said bottom of the said vessel for draining out the water-impurities which collect therein to prevent the level of water impurities collected at the bottom of said vessel from rising to the level of said second inlet conduit means, and

vent means near the top of the said vessel for venting the said vessel when desired.

7. The apparatus of claim 1 wherein,

said apparatus is free of moving parts and has no internal gaskets to leak or deteriorate.

8. A fuel processor means with an integral filter element for use with diesel engines on diesel trucks, automobiles, and the like, and whereby said fuel processor means is operative to preheat heat the diesel fuel and to separate out water-impurities from the diesel fuel, and melting wax crystals and then filter the diesel fuel, enabling the diesel fuel to be used in cold ambient conditions without the use of fuel additives such as chemicals or lighter grade fuel to improve fuel flowability comprising,

a vertically oriented elongated tubular vessel means for separating the water-impurities out of the fuel and collecting the water-impurities at the bottom of said vessel means, said vessel means defining a top plate,

a filter element having a cup shaped canister enclosing a filter media element with an opened end defining fuel flow ports engaged to the said top plate of said vessel means such that said filter is disposed above said top plate with said opened end directed downwardly and being of integral construction therewith,

inlet conduit means to introduce hot engine coolant liquid to the said vessel means,

another conduit means passing through a central portion of said vessel means and into the bottom of said vessel means for transmitting the hot coolant liquid therethrough,

outlet conduit means for recirculating the coolant liquid back through the engine cooling system,

a second inlet conduit means for introducing fuel to the interior of the said vessel means near the vertical midpoint thereof for flow therethrough,

another interior conduit means passing through said top plate for transmitting the water-free fuel upwardly for passage through the said filter element for filtration,

a second outlet conduit means passing through said top platemeans for removing the fuel from the said filter element and transmitting the fuel to the engine whereby said second inlet conduit means and said second outlet conduit means cause the fuel to flow through said vessel means in a manner which facilitates the separation of the water-impurities and minimizes remixing of the water-impurities being collected, and

drain means at the said bottom of the said vessel means for draining out the water-impurities which collect therein to prevent the level of water impurities collected at the bottom of said vessel means from rising to the level of said second inlet conduit means. 9. The invention defined in claim 1 or claim 8 wherein said engine cooling system includes a compartment heater operable to heat the drivers compartment of the truck or automobile by the passage of the hot engine coolant liquid therethrough at temperatures regulated by the driver, said inlet conduit means being connected in said cooling system in series with said compartment heater to receive liquid coolant from said compartment heater.