Multi-fueled multi-use combustion chamber

Abstract

The MULTI-FUELED MULTI-USE COMBUSTION CHAMBER removes pollutants effectively, efficiently and economically from flowing gases. The system will virtually eliminate the majority of compounds such as oxides of nitrogen, hydrocarbons, carbon monoxide, odors and organic and inorganic particulates from the exhaust gases of internal combustion engines or other sources of combustion. The pollution source may be exhaust gases from internal combustion engines, incinerators, restaurant stoves, bakery stoves, dry cleaners, automotive repair, paint, sewage treatment plants, power generating stations or manufacturing facilities. The incinerator directly eliminates the undesirable and harmful pollution of the exhaust.

Description

BACKGROUND

[0001] 1. Field of Invention

[0002] The invention relates generally to the energy efficient and economical elimination of pollutants exhausted from a contained gaseous pollutant source and, more particularly, to an incinerator device for significantly reducing pollutants exhausted from emissions and noxious odors from volatile organic compounds. Because of its uniqueness of being a combustion chamber the same device can be used to power up Brayton Cycle turbine engines.

[0003] 2. Description of Prior Art

[0004] Attention is called to U.S. Pat. Nos. 3,074,469: 4,785,748: 4,915,038: 5,572,866: 5,320,523: 5,381,659: 5,381,660 and 5,417,059

[0005] Reducing air pollution, particularly pollution from a contained gaseous pollutant source such as engine emissions and noxious odors from volatile organic compounds continues to be a pressing need worldwide. Stronger environmental regulations for controlling of pollution, particularly reducing pollutant emissions from internal combustion engines continue to be enacted both in the United States and throughout the world. Existing technology to eliminate emissions includes using particulate filtering devices to trap and subsequently burn the trapped particulates to clean the filter. Other devices include combustion chambers that attempt to directly eliminate pollution as it is exhausted from a pollution source, but fail to adequately reduce pollutants because the devices themselves produce large amounts of pollutants and may be energy inefficient. Other devices that directly eliminate pollution and are energy efficient may be large, difficult to attach to the pollution source, or require significant design changes to adapt to different pollution sources. In addition, many existing systems are expensive to manufacture and assemble due to the number of individual components, particularly related to the fuel supply and ignition components.

[0006] Therefore, for the foregoing reasons there is a need for an incinerator chamber and incinerator system that continuously and significantly reduces compounds such as oxides of nitrogen, hydrocarbons, carbon monoxide, odors and organic and inorganic particulates from pollution exhausted from a contained pollution source, including combustion engines, while maximizing its energy efficiency.

[0007] There is also a need for an easy to assemble and removable fuel, fresh air and ignition system that can be easily assembled, attached and removed and that can be used on incinerators and other types of combustion chambers or similar devices that are capable of using gaseous and liquid fuel.

SUMMARY OF INVENTION

[0008] The present invention is directed to a device, system and method of use that satisfies these needs. The present invention provides for an incinerator chamber and removable fuel injection system for gaseous and liquid fuel that maximizing its energy efficiency. The incinerator device having features of the present invention comprises a incinerator, with N number of cylindrical shaped incinerator chambers connected in series. The first cylindrical shaped incinerator chamber has an inlet duct on one end for receiving a flow of a gaseous mixture and an output duct on the opposite end for expelling the gaseous mixture that has been cleaned while in the incinerator chamber. Next, there are N−1 number of additional cylindrical shaped incinerator chambers, with each chamber having an inlet duct on one end for receiving a flow of gaseous mixture from the output duct of the previous cylindrical incinerator chamber.

[0009] In an alternative embodiment of the invention, the diameter of the previous chamber can be smaller than the diameter of the present incinerator chamber so that an expansion of the gaseous exhaust occurs when the exhaust exists from the smaller chamber's output duct into the input duct of the larger in diameter chamber causing turbulence in the chamber that allows the gaseous exhaust to remain in the chamber for a longer period of time FIG. 6. In one alternative embodiment, a turbulator disc may be placed in the inlet duct of each of the additional incinerator chambers to enhance the amount of turbulence within the chamber when a gaseous mixture of fuel, fresh air and pollution is input into the chambers. The turbulator discs may be washer shaped and are composed of a material capable of withstanding temperatures in excess of about 2000 degrees F., usually high temperature metal or ceramic. In an alternative embodiment of the invention, the sum of the diameter of the multiple randomly spaced holes is equal to or of greater diameter than the diameter of the input duct into the chamber. The number of incinerator chambers that may be connected in series varies according to the application, with the optimum number for use with internal combustion engines being two or three.

[0010] The first chamber, a mixing and burning chamber, has an inlet duct on one end for receiving a flow of a gaseous mixture and an output area on the opposite end for expelling the gaseous mixture that has been cleaned while in the chamber. Next, there are N number of additional mixing and reaction chambers, with each chamber having an inlet area on one end for receiving a flow of gaseous mixture from the output area of the previous chamber. In an alternative embodiment, the diameter of the previous chamber can be the same size or smaller than the diameter of the present incinerator chamber so that an expansion of the gaseous exhaust occurs when the exhaust exits from the smaller chamber's output area into the input area of the larger in diameter chamber causing turbulence in the chamber that allows the gaseous exhaust to remain in the chamber for a longer period of time. In one alternative embodiment, a turbulator disc may be placed in the inlet area of each of the additional mixing and reaction chambers to enhance the amount of turbulence within the chamber when a gaseous mixture of fuel, fresh air and pollution is input into the chambers.

[0011] In an alternative embodiment, the sum of the diameter of turbulator hole is equal to or greater than the diameter of the input duct into the previous chamber. However, the number of chambers, the diameter of each N chamber, and length of each chamber is determined by the amount of gaseous pollution to be input to the incinerator chamber system and by the amount of pollution to be removed. Because the chambers are connected in series with each other and may be graduated in size, each chamber has a turbulence zone that causes the heated exhaust gas to be retained in that chamber for a longer period of a time. In addition, the placement of the turbulators in the input of the mixing and reaction chambers also enhances the amount of turbulence within the chamber when a gaseous mixture of fuel, fresh air and pollution is input into the chambers. Pollution gases enter through the inlet duct FIGS. 5 and 6 and into the mixing and burning chamber where they are heated to a temperature that is sufficient to destroy the pollutants. As the gases pass through the output area of the mixing and burning chamber and enter the mixing and reaction chamber, they are expanded and slowed and are mixed through the action of the additional turbulence caused by the expansion. The gases are then directed through the output area of the mixing and reaction chamber, through an exhaust tube. A fuel injection mechanism comprising a gaseous or liquid removable fuel injection assembly, is contained on and supported by a baseplate, connected to the outer housing of the incinerator system by retainer bolts. This includes a fuel supply for misting fuel and injecting the misted fuel into the incinerator chamber and an ignition mechanism, which ignites the fuel in the incinerator chambers on initial system startup.

[0012] In the present method of using a chamber incinerator system to remove pollutants from a flow of a gaseous mixture, fresh air and vaporized fuel are forced into the inlet duct of the first incinerator chamber and this fuel and fresh air mixture is ignited within the incinerator chamber. Exhaust from a pollution source is input into the input duct of the first incinerator chamber, the chamber is heated to its optimal operating temperature, usually between about 600 to about 2000 F. The exhaust is passed from a pollution source through the first incinerator chamber and through N number of additional incinerator chambers connected in series with the first incinerator chamber, for a time sufficient to reduce the undesirable and harmful compounds within the exhaust from a pollution source and then expelling the exhaust out of the incinerator.

[0013] In the heating step when the operating temperature is reached, in-putting fresh air, fuel and exhaust from an input duct that is smaller in diameter than each incinerator chamber, causes a sudden expansion of gases to occur in each incinerator chamber which results in a turbulence zone flowing from one end each incinerator chamber to the opposite end, which causes the heated mixture to be retained for a sufficient time in the series of incinerator chambers to reduce undesirable and harmful compounds within the exhaust before being expelled.

[0014] The present invention continuously and significantly reduces compounds such as oxides of nitrogen, hydrocarbons, carbon monoxide, and volatile organic compound particulates from pollution exhausted from a contained pollution source, including combustion engines. The chamber configuration maximizes energy efficiency while removing pollution by providing turbulence areas in each chamber that allow the pollution from a gaseous source to be retained for a slightly longer period of time in each chamber, and the longer period of time the gas is contained in the chambers, the more the pollution is reduced. The sudden expansion that occurs when the gaseous pollution is input from one chamber to the next aids in the mixing of heated air and gaseous pollution and in producing turbulence within each chamber. The turbulator discs also aid in mixing and creating turbulence. The design of the incinerator chamber and incinerator system is streamlined which makes it easy to manufacture and easy mount to the gaseous pollution source. The removable fuel injection assembly is simple to attach to the incinerator housing and easy to service, replace and maintain over the life of the device. Because the size of the chambers and the number of chambers to be located in series can vary according to the volume of gaseous pollution and the amount of pollution to be removed, the system design can be flexibly tailored to the particular application.

[0015] Many uses can be found for Brayton Cycle turbine engines developed from off the shelf bladed turbochargers or Tesla bladeless turbines and using common fuels as a source of energy. These systems, in turn, can spool up small high-speed alternators to produce the needed electrical power for hybrid/electric systems or auxiliary power units or through the proper mechanical speed reduction systems be made as the power source for numerous applications.

[0016] Another embodiment of the invention is to provide for novel combustion chamber technologies that are capable of serving as the driving force for Brayton Cycle turbine engines which are well known to those of skill in the art.

[0017] Turbine engines can perform the tasks of producing rotating energy if only they have efficient combustion chambers to drive the rotating turbines. This type of an engine is not meant to produce thrust as in the jet engine of an airplane but to produce force to turn a shaft and produce efficient rotating energy.

[0018] Brayton Cycle turbines uses a compressor usually radial out flow to raises the pressure of the combustion chamber inlet air. The air is then moved into the burner chamber, where fuel is injected and combusted to cause expansion of the air. Power is produced when the heated, high-pressure mixture is expanded and cooled through a turbine.

[0019] Reducing air pollution, particularly pollution from a contained gaseous pollutant source such as engine emissions and noxious odors from volatile organic compounds continues to be a pressing need worldwide. Stronger environmental regulations for controlling of pollution, particularly reducing pollutant emissions from internal combustion engines continue to be enacted both in the United States and throughout the world. Existing technology to eliminate emissions includes using particulate filtering devices to trap and subsequently burn the trapped particulates to clean the filter. Other devices include combustion chambers that attempt to directly eliminate pollution as it is exhausted from a pollution source, but fail to significantly reduce pollutants because the devices themselves produce large amounts of pollutants and may be energy inefficient. Other devices that directly eliminate pollution and are energy efficient may be large, difficult to attach to the pollution source, or require significant design changes to adapt to different pollution sources. In addition, many existing systems, standard jet engines, are expensive to manufacture and assemble due to the number of individual components, particularly related to the fuel supply and ignition components.

[0020] For the foregoing reasons, there is a need, therefore for a Brayton Cycle turbine engine combustion chamber, incinerator chamber and incinerator system that continuously and significantly reduces contained pollution source while maximizing its energy efficiency.

[0021] The most common and available fuel to use in a combustion chamber is propane. This fuel is clean burning, easy to handle and readily available anywhere. Gaseous fuels are easy to handle and are the fuel-dispensing systems for most combustion chambers. They are simple to construct and not bothered by the heat generated by the combustion chamber.

[0022] The challenge is in the constructing of chambers that will function while using the high-energy liquid fuels such as diesel or JP Jet fuels. If diesel or JP fuels are subjected to heating of the fuels while in fuel lines or the nozzle that dispenses the fuel into the chamber, the fuel will cause a build up of carbon cokeing and a “varnish” like substance in the fuel lines and nozzles of the fuel system. In a short time, the fuel lines and nozzles will become fully plugged with carbon and varnish to a point where the fuel system ceases to function and shuts down. Diesel and JP fuel lines must be kept as cool as possible in order to prevent carbonizing cokeing of the fuels and clogging of the fuel lines and fuel dispensing nozzles.

[0023] The chamber system has a streamlined design that is easy to manufacture, easy to attach to the gaseous pollution source and easy to service and maintain over the life of the device. It allows the system design to be of a flexibly sized according to the volume of gaseous pollution and the amount of pollution to be removed, and provides for an easily removable fuel injection system that can be used on the incinerator or on other types of combustion chambers.

DESCRIPTION OF THE DRAWINGS

[0024] The inventor of this unique combustion chamber has studied and built chambers for numerous years while searching for a solution to the problem of varnish and carbon build cokeing in the fuel lines. As well as the unique sudden expansion combustion chamber system chamber, the basis for this patent application is the overlooked and the unique system for keeping the liquid fuels cool prior to combustion and the reduction of pollution.

[0025] Looking into how to construct a combustion chamber for turbine engines and thermal oxidizer systems continually brings only variations of combustion chambers that are used on aircraft type jet engines complete with what is called the “can” flame holders and most builders revert to using propane or other gaseous fuels. The chambers are not efficient and they are not clean burners and are polluters to one degree or another.

[0026] FIG. 1a. The chamber being proposed is based on “Ram Rocket” technology. In the Ram Rocket motor, there are no moving parts FIG. 1a, only an igniter 1 and fuel dispensing 2 systems. Combustion is sustained and held in place by the physical design of the chamber.

[0027] FIG. 1b. The sudden expansion combustion chamber FIG. 1b works on the same principal as the Ram Rocket technology, only an igniter 1 and fuel dispensing systems 2. As fuel 2 and air 3 are dispensed into the chamber, the igniter ignites the air/fuel mixture 4. Combustion of the air/fuel mixture is sustained in place by the physical design of the chamber (5) and the sudden expansion of the gases.

[0028] FIG. 2. As air and fuel are supplied to the first combustion area, 2 of FIG. 2 and just in front of the spark igniter 1, high voltage is supplied to the igniter to produce a spark across the igniter's gap. This action will cause the air/fuel mixture to produce a flame in the area in front of the fuel injectors 2. As the fuel from the injector ignites, the flame will pass through the restrictive opening 3 and on into the combustion chamber 4.

[0029] FIG. 3. As air from the compressor is fed through the air passage tube 5, it will cool the metal surfaces in the area of the fuel lines 6 and 7 and pass through the holes in the air passage tube 8 and on into the air-fuel mixing area 2. The air flowing around the fuel dispensing assembly 11 will help to disperse the fuel into smaller particles for mixing and burning in the combustion chamber area 4. In this illustration, it is suggested that a spark plug be used to ignite the gaseous or liquid fuel although glow plugs have been successfully used to ignite fuel.

[0030] Air passing the liquid fuel dispensing assembly 11 and fuel nozzle 12 will help to cooling these two items. Air will also flow through passages between the air passage tube 5 and the fuel dispensing assembly 9a, 9b, and 9c etc. Item 7 is the gaseous fuel input tube and is connected to the fuel dispensing ring item 10. Item 6 is the liquid fuel input and is connected to the liquid fuel dispensing assembly 11 and to the liquid fuel nozzle for dispersing of the fuel.

[0031] FIG. 4a In another embodiment of the Air/Fuel Dispensing Assembly, liquid fuel will flow through the input feed tube 6 and on to the liquid fuel dispensing assembly injectors at the end of the assembly 10 where it will be dispensed into the fuel and air mixing area 2. Liquid fuel will flow through the input feed tube 6 and on to the injector area where it will be forced out through the dispensing nozzles 12 at the end of the assembly 10 where it will be dispensed into the fuel and air mixing area item 2.

[0032] FIG. 4b The Fuel Dispensing Assembly is built in such a manner as to have air passages 9 between the wall of the Air Passage Tube, item 5, and the Fuel dispensing nozzle 12. Pressurized air passing through the passages 9 will act to disperse the fuel being ejected thought the fuel nozzle 12. The dispersing action is especially critical when using liquid fuels such as diesel or JP fuel. The more atomization of the fuel into a fine mist the easier to ignite and the burning is more complete. Once the fuel is being dispensed an electrical pulse will be sent through wire 13 to the igniter 14 to produce the spark to ignite the fuel. Pressurized air flowing through the small passageways 9 between the body of the Fuel Dispensing Assembly 10 and the Air Passage Tube 5 will serve two purposes, one to help cool the assembly and the other will be to aid in atomization of the fuel coming through the Fuel Nozzles 12. FIGS. 4a and b show a variation of the fuel injector system and igniter system 14 all contained in one injector tube assembly 5.

[0033] FIG. 5 shows the fuel injection system and a single chamber system configured as an incinerator device used for the destruction of Volatile Organic Compounds, VOC. Liquid or gaseous fuels can be injected into the air stream by using round circular injector rings 1b or 1c or any other fuel injector device to mix the fuel with the air stream. 1a being a different perspective of the ring injector. The fuel air mixture will be ignited by the igniter 2. As the air pressure is increased due to the burning fuel and fresh air input to the air/fuel mixing area 3 the combustion process will migrate on into the mixing and burning chamber 4. Fresh air is input through the compressed air tube 5 for the combustion process and combustion of the VOC's being input through tube 6 and into the mixing and burning chamber 4.

[0034] FIG. 6 is the same fuel 1b and 1c, fresh air 5 and VOC input 6 as described in FIG. 5. It shows the fuel injection system and a single chamber system configured as an incinerator device used for the destruction of Volatile Organic Compounds VOC. Liquid or gaseous fuels can be injected into the air stream by using round circular injector rings 1a or any other fuel injector device to mix the fuel with the air stream. The fuel air mixture will be ignited by the igniter 2. As the air pressure is increased due to the burning fuel and fresh air input to the air/fuel mixing area 3 the combustion process will migrate on into the mixing and burning chamber 4.

[0035] Fresh air is input through the compressed air tube 5 for the combustion process and combustion of the VOC's input through tube 6 in the mixing and burning chamber 4.

[0036] Unlike FIG. 5, FIG. 6 is shown with two additional VOC mixing and reaction chambers 7 and 8. Any number of reaction and mixing chambers may be added as required to reduce the levels of pollution from VOC's that are difficult to reduce their molecular constituents.

Claims

1. An incinerator/combustion chamber device, to remove pollutants from a flow of gaseous VOC mixture, comprising:

a. N number of cylindrical shaped incinerator chambers, capable of being heated to a broad temperature range, connected in series and comprising

b. a mixing and burning incinerator chamber having an input duct on one end for receiving a flow of a gaseous mixture and an output area on the opposite end for expelling a gaseous mixture; and

b. N−1 number of additional mixing and reaction incinerator chambers, each chamber having an input area on one end for receiving a flow of a gaseous mixture connected in series to the output area of a previous chamber and an output area on the opposite end for expelling a gaseous mixture.

c. the sudden expansion chamber and air/fuel injecting system is used to provide for unique combustion chamber applications that are capable of serving as the driving force combustors for both bladed and disk “tesla” type brayton cycle turbine engines:

d. the sudden expansion combustor will function on any combustible fuels, gaseous, liquid, or solid that can be injected into the input air stream of the combustor and ignited.

e. a unique sudden expansion combustion chamber geometry, being squared at both input and exhaust ends

f. a combustion chamber system whereby, the unique application of a sudden expansion combustion chamber where the sudden expansion chamber is used as a flame holder as well as the fuel combustion area.

g. an outer housing.

h. an interior insulating layer disposed within the outer housing.

2. A system whereby the combustion takes place in an area separate from the fuel injection and initial ignition area and:

a. after the initial ignition sequence, the air source pressure is increased until the flame is moved into the sudden expansion combustion chamber and away from the fuel lines, fuel injectors and igniters.

a. the use of an air source in the system to keep the igniter and fuel dispensing system cool enough to allow for continuous operation with little or no degradation to the fuel input system due to heat.

b. the air/fuel air source is used to cause fine misting of the liquid fuels as they are injected into the initial fuel/air mixing area and even dispersion throughout the air/fuel.

d. A system whereby, a unique removable air/fuel injecting mechanism is comprised of a cylindrical tube to convey fresh air, one fuel injecting system for gaseous fuel, one fuel dispensing system for liquid fuel and/or a solid fuel.

e. a long tube assembly, where the air source is injected, next is the fuel injector where the fuel is injected into the air stream and just after the fuel injector is the igniter that ignites the air fuel mixture.

3. according to claim 1, a mixing and burning incinerator chamber having an input duct on one end for receiving a flow of a gaseous mixture and an output area on the opposite end for expelling a hot gaseous mixture.

4. An incinerator device, according to claim 1, wherein the output area of each N number of cylindrical shaped incinerator chambers has a diameter smaller than the input diameter of the chamber it is connected in series with.

5. An incinerator device, according to claim 1, further comprising a turbulator disc placed in the input area of each N−1 mixing and reaction incinerator chambers to enhance the amount of turbulence within the chamber when a gaseous mixture of fuel, fresh air and pollution exhaust are input into the incinerator chambers.

6. A system whereby, according to claim 2, one elongated tube assembly is used to hold the fuel injectors, dispense the air source, contain all fuel lines and electrical connections.

7. An incinerator device, according to claim 1, further comprising a turbulator disc placed in the input area of each N−1 mixing and reaction incinerator chambers to enhance the amount of turbulence within the chamber when a gaseous mixture of fuel, fresh air and pollution exhaust are input into the incinerator chambers.

8. An incinerator device, according to claim 7, wherein the N number of turbulator discs are washer shaped and are composed of metal or ceramic material capable of withstanding temperatures to a broad range.

9. A sudden expansion combustion chamber/incinerator device, according to claim 1, wherein N=2.

10. A sudden expansion combustion chamber/incinerator device, according to claim 1, wherein N=3.

11. A sudden expansion combustion chamber/incinerator device, according to claim 1, wherein N= can be any number above 3 necessary to the systems functioning.

12. A system whereby, when using the chamber system as an incinerator to destroy airborne volatile organic compounds VOC or airborne particulates, an input tube, separate from the fresh air tube is used to conveying said VOC's and particulates into the mixing and burning chamber.

13. A system, according to claim 12 whereby, when using the chamber system as an incinerator to destroy airborne volatile organic compounds a separate air tube is used to injected the fresh air into the air/fuel mixing area of the system and is separate from the VOC input tube.

14. A system, according to claim 12 whereby when using the chamber system as an incinerator device solid, liquid or gaseous fuels are injected into the fresh air stream for mixing and combustion.

15. A system, according to claim 12 whereby, when using the chamber system as an incinerator device liquid or gaseous fuels can be injected into the air stream by using round circular “Ring Injector” rings as shown in FIG. 6.

16. A system, according to claim 12 whereby, when using the chamber system as an incinerator device solid, liquid or gaseous fuels are injected into the air stream by using a fuel injecting spray nozzle device that is part of the air/fuel injector head and fuel igniter system.