Catalytic metal additive concentrate and method of making and using

Abstract

Delivery of metallic combustion catalysts to internal combustion engines and other combustion devices is improved by dosing units that have the ability to effect the slow and positive supply of metallic additives, including platinum and/or cerium containing catalyst compositions, to fuel. The invention provides additive dosing materials and methods for simply and effectively supplying catalytic metal fuel additives to fuel in suitable low concentrations as are effective. The dosing units can be used with devices made to contact diesel fuel. In one approach, a catalytic metal additive concentrate (CMAC) is prepared in normally solid, semisolid or viscous form. The CMAC will preferably be encapsulated with a solid polymer. The encapsulation can be accomplished by embedding or dispersing the CMAC in a suitable polymer. If desired, the CMAC can be dispersed in one polymer and then the resulting composite can be embedded in the same or a different polymer. In an alternative form, a dosing unit can comprise a semisolid CMAC, which could be similarly held in contact with flowing fuel.

1 . A high temperature stable platinum and/or cerium fuel additive dosing unit, comprising: 
 (a) catalytic metal additive concentrate comprising fuel soluble platinum and/or cerium composition stable at temperatures above 100° C., uniformly dispersed in an organic carrier in relative quantities to be normally solid;    (b) encapsulated with a solid polymer as an infusion control composition.    
     
     
         2 . A high temperature stable platinum and/or cerium fuel additive dosing unit according to  claim 1 , wherein the catalytic metal additive concentrate is embedded in the polymer.  
     
     
         3 . A high temperature stable platinum and/or cerium fuel additive dosing unit according to either of claims  1  or  2 , wherein the catalytic metal additive concentrate is uniformly dispersed within the polymer.  
     
     
         4 . A high temperature stable platinum and/or cerium fuel additive dosing unit according to any of claims  1 ,  2  or  3 , wherein the catalytic metal additive concentrate comprises platinum acetylacetoneate.  
     
     
         5 . A high temperature stable platinum and/or cerium fuel additive dosing unit according to any of claims  1 ,  2 ,  3  or  4 , wherein the catalytic metal additive concentrate comprises a cerium soap.  
     
     
         6 . A method of preparing a solid dosing form of fuel additive, by: 
 preparing a stable dispersion of platinum composition in a predetermined Pt/Ce ratio in a solution of cerium soap;    encapsulating the viscous catalytic metal additive concentrate comprising fuel soluble platinum and/or cerium composition stable at temperatures above 100° C. with a infusion controlling polymer.    
     
     
         7 . A method according to  claim 6 , wherein the viscous catalytic metal additive concentrate is encapsulated by embedding it in an infusion control polymer.  
     
     
         8 . A method according to  claim 6 , including the further steps of: 
 mixing the dispersion of platinum composition and cerium soap with an infusion control polymer under conditions effective to uniformly distribute the dispersion within the polymer; and    forming the resulting mixture of polymer into a dosing unit of predetermined shape.    
     
     
         9 . A method according to  claim 7 , including the further step of: embedding the dosing unit in an infusion control polymer.  
     
     
         10 . A method of preparing a solid dosing form of fuel additive, by: 
 preparing a solution of a platinum and/or cerium composition including a low-boiling solvent including a sufficient amount of high-boiling solvent to retain fluidity of the composition in the absence of the low-boiling solvent;    evaporating the low-boiling solvent to prepare a viscous catalytic metal additive concentrate comprising fuel soluble platinum and/or cerium composition stable at temperatures above 100° C.;    encapsulating the viscous catalytic metal additive concentrate comprising fuel soluble platinum and/or cerium composition stable at temperatures above 100° C. with a infusion controlling polymer.    
     
     
         11 . A method of using a solid dosing form of fuel additive, comprising: 
 obtaining a solid dosing form of catalyst according to any of the preceding claims; and    contacting the solid dosing form of catalyst with fuel to partially dissolve the polymer and introduce the catalyst into the fuel prior to combustion.    
     
     
         12 . A method of forming a catalytic metal additive concentrate, comprising: 
 forming a mixture of a catalytic metal soap and a solvent;    removing low-boiling solvent.    
     
     
         13 . A method according to  claim 12 , wherein high boiling solvent is added prior to removing low boiling solvent.  
     
     
         14 . A method according to  claim 12 , wherein the catalytic metal soap comprises a cerium soap.  
     
     
         15 . A method according to  claim 14 , wherein the catalytic metal further comprises platinum acetylacetonate.  
     
     
         16 . A method according to  claim 14 , wherein the catalytic metal further comprises COD-Pt-diphenyl.