PROCESS HEATER SYSTEM
A process heater system (10) for an industrial envelope (11) comprises a main combustion chamber (20), an afterburner (30), and an exhaust stack (40). Retrofitted heat-recovery piping (50) receives combustion gas downstream of the afterburner (30) and uses it as a heat source for the industrial envelope. When the industrial load in the main combustion chamber (20) is paint, powder coating, varnish, epoxy, grease and/or oil, the secondary materials burned in the afterburner 30 can be considered alternative fuel, not solid wastes.
This application claims priority under 35 U.S.C. 119(e) to U.S. Provisional Patent Application No. 61/370,804 filed on Aug. 4, 2011. The entire disclosure of this provisional application is hereby incorporated by reference.
BACKGROUNDAn industrial process heater can comprise a main combustion chamber, an afterburner, and an exhaust stack. The main combustion chamber volatizes an industrial load (e.g., dry paint, powder coating, varnish, epoxy, oil, and/or grease). A supplemental combustion chamber which is a first zone (or zone one) of the afterburner, completes the combustion of non-hazardous volatized organic material. Combustion gas passes from the supplemental combustion chamber to a second zone (or zone two) of the afterburner. The combustion gas dwells for at least half a second in the afterburner, and then passes to the exhaust stack for exhaust outside the envelope of the industrial facility.
SUMMARYA system is provided wherein stack-exhaust heat is captured and transmitted for use as an energy source for the industrial envelope. For example, the stack-exhaust heat can be used to radiantly heat the envelope of the industrial facility. Alternatively, the recovered heat can be used to heat water or another liquid. In either or any event, material combusted in the afterburner is a recycled alternative fuel, not a solid waste.
Referring now to the drawings, and initially to
The main combustion chamber 20 has a gas burner 21 and volatizes the industrial load. In other words, the industrial purpose of the process heater is performed in the main combustion chamber 20. This purpose can comprise, for example, heat cleaning fixtures, parts, and/or equipment to remove non-hazardous material that is not a solid waste.
The afterburner 30 comprises a supplemental combustion chamber 31 having its own gas burner 32 and in communication with the main combustion chamber 20. Often, as illustrated, the supplemental chamber 31 is within the same package perimeter as the main combustion chamber. The supplemental chamber 31 is considered the first zone of the afterburner 30 and its function is to complete the combustion of non-hazardous volatized organic material transported from the main chamber 20.
The afterburner 30 comprises a second zone 33 located downstream of the supplemental combustion chamber 31. This second zone 33 can be, as illustrated, outside the package perimeter of the chambers 20 and 31, and vertically aligned with the exhaust stack 40. The afterburner 30 can be sized so that combustion gas dwells therein for at least half a second. From the afterburner 30, combustion gas passes to the exhaust stack 40 for exhaust outside the industrial envelope 11.
The heat-recovery piping 50 can comprise a network of pipes which each include an adapter region 51, an inlet region 52, an intermediate region 53, and an outlet region 54. The adapter region 51 is connected to the exhaust stack 40 to receive combustion gas therefrom. An existing exhaust stack 40 can be retrofitted with the adapter region 51.
The heat-recovery piping 50 can project, turn, and extend to effectively cover the industrial envelope 11. For example, as is best seen by referring additionally to
The pipes 50 are preferably positioned close to the ceiling and horizontally oriented. For example, the pipes 50 can be hung about twelve to sixteen feet over the floor of the industrial envelope 11. Lower heights are possible, but may require shielding to prevent overheating of personnel. Higher heights are also possible, but may result in lost heat (e.g., about 1% per foot). The pipes 50 can be supported by beams, girders or joists. The piping 50 may also be gradually sloped downward (e.g., about ¼ inch per each ten feet length) to prevent water accumulation.
As is best seen by referring additionally to
As shown in
In the adapter region 51 and the inlet region 52, the heat-recovery piping 50 includes insulation 57 on its inside surface as shown in
Returning now back to
As is shown in
The exhaust device 70 can be continuously run to provide the system 10 with a “self-sealing” feature insuring that combustion gas does not escape into the industrial envelope 11.
As is shown in
Thus, the system 10 is a process heater unit with an afterburner 30 and a heat recovery system (50, 60, 70, 80, 90). The material combusted in the afterburner 30 is fuel used to provide heat or other energy for the industrial envelope 11. This fuel material is recycled and legitimately used as an alternative fuel or ingredient. It can be produced and used for energy recovery from a non-hazardous valuable commodity secondary material with meaningful heating value and without contaminants significantly higher in concentration than traditional fuel. When the industrial load in the main combustion chamber 20 is paint, powder coating, varnish, epoxy, grease and/or oil, the secondary materials burned in the afterburner 30 are not solid wastes.
Although the process heater system 10, the main combustion chamber 20, the afterburner 30, the exhaust stack 40, and/or the heat-recovery elements (50, 60, 70, 80, 90) have been shown and described with respect to a certain embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings.
REFERENCE NUMBERS10 process heater system
11 industrial envelope
12 thermostats
13 space-heating unit
20 main combustion chamber
21 main combustion burner
30 afterburner
31 supplemental combustion chamber
32 supplemental combustion burner
33 second zone of afterburner
40 exhaust stack
50 heat-recovery piping
51 adaptor region
52 inlet region
53 intermediate region
54 outlet region
55 housing
56 reflector roof
57 interior insulation sleeve
58 turbulator
60 tail piping
61 separate branches
62 common branch
63 dampers for separate branch
64 damper for common branch
65 moisture drain
70 exhaust device (vacuum pump)
80 controller
90 liquid-heating cycle
91 tank
92 pump
93 inlet tube
94 heat exchanger
95 outlet tube
Claims
1. A process heater system (10) for an industrial envelope (11), comprising:
- a main combustion chamber (20) wherein an industrial load is combusted;
- an afterburner (30) comprising a supplemental combustion chamber (31) in communication with the main combustion chamber (20) and a second zone (33) in communication with the supplemental combustion chamber (31);
- an exhaust stack (40) receiving combustion gas from the second zone (33) of the afterburner (30) and exhausting it outside the industrial envelope (11); and
- heat-recovery piping (50) receiving combustion gas downstream of the second zone (33) the afterburner (30) and transmitting it for use within the industrial envelope (11), whereby material combusted in the afterburner (30) is fuel used to provide energy for the industrial envelope (11).
2. A process heater system (10) as set forth in claim 1, wherein the afterburner (30) is sized so that combustion gas dwells therein for at least half a second.
3. A process heater system (10) as set forth in claim 1, wherein the industrial load in the main combustion chamber (20) is paint, powder coating, varnish, epoxy, grease and/or oil.
4. A process heater system (10) as set forth in claim 1, wherein the material combusted in the afterburner (30) has a meaningful heating value and is without contaminants significantly higher in concentration than traditional fuel.
5. A process heater system (10) as set forth in claim 1, wherein the main combustion chamber (20) volatizes the industrial load.
6. A process heater system (10) as set forth in claim 1, wherein the main combustion chamber (20) has a gas burner (21).
7. A process heater system (10) as set forth in claim 1, wherein the industrial purpose of the main combustion chamber (20) is to heat clean fixtures, parts, and/or equipment to remove non-hazardous material.
8. A process heater system (10) as set forth in claim 1, wherein the afterburner (30) comprises a supplemental combustion chamber (31).
9. A process heater system (10) as set forth in claim 8, wherein the supplemental combustion chamber (31) has its own gas burner (32).
10. A process heater system (10) as set forth in claim 8, wherein the supplemental combustion chamber (31) is in communication with the main combustion chamber (20).
11. A process heater system (10) as set forth in claim 8, wherein the supplemental chamber (31) is in the same package perimeter as the main combustion chamber (20).
12. A process heater system (10) as set forth in claim 8, wherein the supplemental combustion chamber (31) combusts non-hazardous volatized organic material transported from the main combustion chamber (20).
13. A process heater system (10) as set forth in claim 1, wherein the afterburner (30) comprises a second zone (33).
14. A process heater system (10) as set forth in claim 13, wherein the second zone (33) is located downstream of a/the supplemental combustion chamber (31).
15. A process heater system (10) as set forth in claim 13, wherein the second zone (33) is outside of the package perimeter of the main combustion chamber (20).
16. A process heater system (10) as set forth in claim 13, wherein the second zone (33) is vertically aligned with the exhaust stack (40).
17. A process heater system (10) as set forth in claim 1, wherein the heat-recovery piping (50) projects, turns, and extends to effectively cover the industrial envelope (11).
18. A process heater system (10) as set forth in claim 1, wherein four pipes extend tangentially outward from the exhaust stack (40) at settings that are approximately 90° apart and wherein each pipe (50) includes an adapter region (51) connected to the exhaust stack (40) to receive combustion gas therefrom.
19. A process heater system (10) as set forth in claim 18, wherein the exhaust stack (40) is retrofitted with the adapter region(s) (51).
20. A process heater system (10) as set forth in claim 18, wherein the exhaust stack (40) is manufactured to include the adapter region(s) (51).
Type: Application
Filed: Aug 3, 2011
Publication Date: Feb 9, 2012
Inventors: Robert F. Heran (Westlake, OH), Robert A. Koptis (Brook Park, OH)
Application Number: 13/197,205
International Classification: F24D 5/00 (20060101); F23G 5/12 (20060101); F23G 5/027 (20060101); F23B 10/00 (20110101); F23G 7/00 (20060101);