CROSS REFERENCE TO RELATED APPLICATION

This application claims the priority of the provisional application serial number

62/598,702 and 62/616,072. Applicant hereby incorporates by reference the entire content of provisional application serial numbers 62/598,702 and 62/616,072.

FIELD OF INVENTION

The present invention is related to a process for producing a chemical composition and the composition produced by that process.

BACKGROUND OF THE INVENTION

Acidic compositions are used for various industrial and household purposes. These purposes can vary greatly from additives used to aid in drilling operations to assist with the removal of drill cuttings, with the lubrication of the drill pipes, a well stimulation additive, or even an additive to aid in the release of a jammed pipe in a borehole. Acidic compositions may also be used as a non-toxic additive to assist with the extraction of precious metals from metal- containing ore, soil or rock. Acidic compositions may also be used as a a nutritional supplement, as pH adjustment agent, as a carrier (metal ions), as a chemical modifier and a multitude of other tasks. Hence, there is a need for acidic compositions with a multitude of effective uses and applications.

SUMMARY OF THE INVENTION

An acidic composition produced by the process of providing an acid selected from the group including: phosphoric acid, fumaric acid, nitric acid, sulfurous acid, sulfonic acid, perchloric acid, acetic acid, sulfuric acid or a combination thereof, providing a solubilized sulfate solution comprising water and a sulfate selected from the group including sodium sulfate, Ammonium sulfate, magnesium sulfate, zinc sulfate, manganese sulfate, Barium Sulfate, Calcium Sulfate, Iron Sulfate, Potassium Sulfate, Nickel Sulfate, radium sulfate, Strontium Sulfate, dihydro-sulfate or a combination thereof, combining the acid and the solubilized sulfate within a reaction vessel to form a mixture (I), wherein the mixture generates an exothermic reaction, generating temperatures in the range of 150°F to 950°F to form a mixture (II) and cooling mixture (II) within the reaction vessel using either an air coolant, a liquid coolant, a gas coolant, or a combination thereof to form the composition and wherein the composition has a pH value of less than 6.5.

DETAILED DESCRIPTION

The present invention now will be described more fully hereinafter in the following detailed description of the invention, in which some, but not all embodiments of the invention are described. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

In describing the invention, it will be understood that a number of techniques and steps are disclosed. Each of these has individual benefit and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques. Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination of the individual steps in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combinations are entirely within the scope of the invention and the claims. The instant invention includes a composition comprising a solution comprising an acid selected from the group including: phosphoric acid, fumaric acid, nitric acid, sulfurous acid, sulfonic acid, perchloric acid, acetic acid, sulfuric acid or a combination thereof, mixed with a solubilized sulfate solution comprising water and a sulfate selected from the group including sodium sulfate, Ammonium sulfate, magnesium sulfate, zinc sulfate, manganese sulfate, Barium Sulfate, Calcium Sulfate, Iron Sulfate, Potassium Sulfate, Nickel Sulfate, radium sulfate, Strontium Sulfate, dihydro-sulfate or a combination thereof to form a mixture (I), wherein the mixture generates an exothermic reaction, generating temperatures in the range of 150°F to 950°F to form a mixture (II) and wherein the mixture is cooled using either an air coolant, a liquid coolant, a gas coolant, or a combination thereof to form the composition and wherein the composition has a pH value of less than 6.5.

The first basic ingredient used is a strong, low pH acid such as, phosphoric acid, fumaric acid, nitric acid, sulfurous acid, sulfonic acid, perchloric acid, acetic acid, sulfuric acid or a combination thereof. Preferably, the acid is a food grade acid. The acid is of at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99% or 99.9% purity. The acid may also be between approximately 98% to approximately 99.9% purity.

The next basic ingredient used is water selected from the group comprising: distilled water, deionized water, purified water, filtered water, pharmaceutical grade water, medical grade water, reverse osmosis water, or a combination thereof. The water preferably has a mega Ohm count between 5 -19. The water is combined with a sulfate selected from the group including sodium sulfate, Ammonium sulfate, magnesium sulfate, zinc sulfate, manganese sulfate, Barium Sulfate, Calcium Sulfate, Iron Sulfate, Potassium Sulfate, Nickel Sulfate, radium sulfate, Strontium Sulfate, dihydro-sulfate or a combination thereof to form a solubilized sulfate. The acid and the solubilized sulfate are combined within a reaction vessel to form a mixture (I). The reaction vessel may be any vessel known in the art which can sustain the temperatures generated during the formation of the instant composition. The interior of the reaction vessel is coated with an inert material such as Teflon®, Kynar®, PVC, CPVC, Viton® and stainless steel. The reaction vessel is an inline blending apparatus to which no pressure is added as the acid and the solubilized sulfate (mixture (I)) passes through the reaction vessel. The reaction generated when the acid in the solubilized sulfate passed through the reaction vessel is an exothermic reaction which generates temperatures in the range of 200°F to 800°F, 300° F to 800 °F, 400° F to 700°F, 500°F to 800°F, 600°F to 800°F. A cooling jacket surrounds the reaction vessel in order to control the temperature as the reaction takes place and the acidic composition is formed. The acidic composition then leaves the reaction vessel and is carried to the cooling system where the temperature is further decreased. The coolant used in either the cooling jacket or the cooling system is an air coolant, a liquid coolant, a gas coolant, or a combination thereof. The liquid coolant is selected from the group including: water, ethylene glycol, diethylene glycol, propylene glycol, polyalkylene glycol, poly glycol, betaine, or a combination thereof. The gas coolant is selected from the group including: inert gas, hydrogen, nitrogen, carbon dioxide, or a combination thereof.

The composition is produced in a continuous process. The composition has a pH value of less than 6, less than 5, less than 4, less than 3, or less than 2.

Looking to the figures wherein like numbers indicate like items, one can see an acidic composition blending system 10 which includes a solubilized sulfate tank 20 connected to reaction vessel 40 by a pipe 24. The flow of solubilized sulfate is controlled by a first valve 25 located at the input end of the pipe 24 and a second valve 27 located at the output end 26 of the pipe 24. The system 10 further includes an acid tank 30 used as a holding tank for the acid utilized in the process. The acid tank 30 is connected to the reaction vessel 40 by a pipe 34.

The flow of acid is controlled by a first valve 35 located at the input end of the pipe 34 and a second valve 37 located at the output end 36 of the pipe 34. Extending upward from the reaction vessel 40 is a vent line 45 which includes a control valve and a check valve 46.

In one embodiment of the instant invention, the acid is added to an injection port that is ¼” to 2” in size at a flowrate which is adjustable. The sulfonated solution (10-80% saturated) is added to another injection port that is ¼” to 2” in size at a flowrate which is adjustable. Both injection ports are secured to the in-line static mixer(s) located within the reaction vessel. The acid and the sulfonated solution will start the blending process inside of the piping system. The piping system will include in-line static mixers and pipping channels (1-2”) approximately 4-25 feet long. The blending portion of the piping will be covered with a cooling jacket/bath. When the acidic composition completes the blending process, it will continue to the cooling system. This will allow the acidic composition to cool down prior to going to a holding tank.

Looking to figures 1 , 2, 3 and 5, several embodiments of reaction vessels 40 are illustrated. Within the reaction vessel lies one or more in-line static mixers 44, 144, 244 through which the acid in the solubilized sulfate pass, are mixed thoroughly and react. Surrounding the static mixers is the fall cooling tower cell 50, 150, 250 which includes a chamber 255 and a plurality of baffles 254. Each reaction vessel 40 further includes an outer casing 41 which encases the cooling tower cell. A plurality of valves 42 are secured to the outer casing which control the flow of coolant both from a coolant reservoir 51 , 151 , 251 through output pipes 52,

152, 252, into the fall tower cooling cell and back to the coolant reservoir through input pipes 53,

153, 253. The coolant from the coolant reservoir 51 , 151 , 251 flows through the chamber 255 over the outer surface of the in-line static mixers 44, 144, 244 while being agitated by a plurality of baffles 254 to ensure optimal heat exchange between the coolant in the in-line static mixer. When the reaction of the acid in the solubilized sulfate is complete with in the reaction vessel resulting in the acidic composition, the composition exits the reaction vessel through a pipe 58, 158, 258 travels to the cooling system 70, 170, 270. Flow through this pipe is controlled by a valve 59, 159, 259. Figures 3 and 4 provide detailed embodiments of a cooling system 70, 170, 270. The cooling system is a series of pipes which make up a product he diffusion pathway 275 which are surrounded by a coolant absorption pathway 282. The acidic composition enters the cooling system 70, 170, 270 through an input 272 and travels through the product heat diffusion pathway 275 where heat is extracted from the acidic composition. He is extracted from the acidic composition by coolant stored in a coolant tank 280 which travels through an output pipe 281 , through the coolant absorption pathway 282 (where heat is extracted), and back to the coolant tank through an output pipe 283. Flow to and from the coolant tank is controlled by a pair of valves 257. The composition then leaves the cooling system through an output 274 to a discharge line 295 and into a holding tank 298. Flow from the output 274 to the discharge line 295 is controlled by one or more valves 297.

Looking back to figures 1 and 2, there is illustrated a control console 65, 165 and a programmable logic controller (PLC) 60, 160 which are used to control the process and the valves associated with the production of the acidic composition.

The instant invention also includes a composition of matter which is prepared by the process of providing an acid selected from the group including phosphoric acid, fumaric acid, nitric acid, sulfurous acid, sulfonic acid, perchloric acid, acetic acid, sulfuric acid or a

combination thereof, providing a solubilized sulfate solution comprising water and a sulfate selected from the group including sodium sulfate, Ammonium sulfate, magnesium sulfate, zinc sulfate, manganese sulfate, Barium Sulfate, Calcium Sulfate, Iron Sulfate, Potassium Sulfate, Nickel Sulfate, radium sulfate, Strontium Sulfate, dihydro-sulfate or a combination thereof, combining the acid and the solubilized sulfate within a reaction vessel to form a mixture (I), wherein the mixture generates an exothermic reaction, generating temperatures in the range of 150°F to 950°F to form a mixture (II) and cooling mixture (II) within the reaction vessel using either an air coolant, a liquid coolant, a gas coolant, or a combination thereof to form the composition; and further cooling the composition within a cooling system until a desired temperature is achieved and wherein the composition has a pH value of less than 6.5.

The basic ingredients are identical to those described above. The reaction vessel may be any vessel known in the art which can sustain the temperatures generated during the formation of the instant composition. The interior of the reaction vessel is coated with an inert material such as Teflon®, Kynar®, PVC, CPVC, Viton® and stainless steel. The reaction vessel is an inline blending apparatus to which no pressure is added as the acid and the solubilized sulfate (mixture (I)) passes through the reaction vessel. The reaction generated when the acid in the solubilized sulfate passed through the reaction vessel is an exothermic reaction which generates temperatures in the range of 200°F to 800°F, 300°F to 800 °F, 400°F to 700°F, 500°F to 800°F, 600°F to 800°F. A cooling jacket surrounds the reaction vessel in order to control the temperature as the reaction takes place and the acidic composition is formed. The acidic composition then leaves the reaction vessel and is carried to the cooling system where the temperature is further decreased. The coolant used in either the cooling jacket or the cooling system is an air coolant, a liquid coolant, a gas coolant, or a combination thereof. The liquid coolant is selected from the group including: water, ethylene glycol, diethylene glycol, propylene glycol, polyalkylene glycol, poly glycol, betaine, or a combination thereof. The gas coolant is selected from the group including: inert gas, hydrogen, nitrogen, carbon dioxide, or a combination thereof. The composition is produced in a continuous process. The composition has a pH value of less than 6, less than 5, less than 4, less than 3, or less than 2.

The instant invention also includes a method of producing an acidic composition comprising the steps of:

(a) providing an acid selected from the group including: phosphoric acid, fumaric acid, nitric acid, sulfurous acid, sulfonic acid, perchloric acid, acetic acid, sulfuric acid or a combination thereof;

(b) providing a solubilized sulfate solution comprising water and a sulfate selected from the group including sodium sulfate, Ammonium sulfate, magnesium sulfate, zinc sulfate, manganese sulfate, Barium Sulfate, Calcium Sulfate, Iron Sulfate, Potassium Sulfate, Nickel Sulfate, radium sulfate, Strontium Sulfate, dihydro-sulfate or a combination thereof;

(c) combining the acid and the solubilized sulfate within a reaction vessel to form a mixture (I);

wherein the mixture generates an exothermic reaction, generating temperatures in the range of 150°F to 950°F to form a mixture (II); and

(d) cooling mixture (II) within the reaction vessel using either an air coolant, a liquid coolant, a gas coolant, or a combination thereof to form the composition; and

wherein the composition has a pH value of less than 6.5.

The above method wherein the reaction vessel is an inline blending apparatus to which no pressure is added as the acid and the solubilized sulfate (mixture (I)) passes through the reaction vessel. In a preferred embodiment, the inline blending apparatus is a static inline mixer which continuously blends the acid and the solubilized sulfate (mixture (I)) as it passes through the reaction vessel. The basic ingredients are identical to those described above. The reaction vessel may be any vessel known in the art which can sustain the temperatures generated during the formation of the instant composition. The interior of the reaction vessel is coated with an inert material such as Teflon®, Kynar®, PVC, CPVC, Viton® and stainless steel. The reaction vessel is an inline blending apparatus to which no pressure is added as the acid and the solubilized sulfate (mixture (I)) passes through the reaction vessel. The reaction generated when the acid in the solubilized sulfate passed through the reaction vessel is an exothermic reaction which generates temperatures in the range of 200°F to 800°F, 300°F to 800 °F, 400°F to 700°F, 500°F to 800°F, 600°F to 800°F. A cooling jacket surrounds the reaction vessel in order to control the temperature as the reaction takes place and the acidic composition is formed. The acidic composition then leaves the reaction vessel and is carried to the cooling system where the temperature is further decreased. The coolant used in either the cooling jacket or the cooling system is an air coolant, a liquid coolant, a gas coolant, or a combination thereof. The liquid coolant is selected from the group including: water, ethylene glycol, diethylene glycol, propylene glycol, polyalkylene glycol, poly glycol, betaine, or a combination thereof. The gas coolant is selected from the group including: inert gas, hydrogen, nitrogen, carbon dioxide, or a combination thereof.

The exact chemical formula for the resultant composition is not clearly known.

Any method described herein may incorporate any design element contained within this application and any other document/application incorporated by reference herein.

In describing the invention, it will be understood that a number of techniques and steps are disclosed. Each of these has individual benefit and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques. Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination of the individual steps in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combinations are entirely within the scope of the invention and the claims.

The present invention may be embodied in other forms without departing from the spirit and the essential attributes thereof, and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. The invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.