Installation of fume removal with gas recovery in charcoal kilns for reuse in agriculture.

Abstract

A smoke removal system with gas recovery for charcoal kilns for reuse in agriculture, characterized in that it includes the following elements: a) A collection module (1) for collecting the smoke generated by one or more kilns (19) by means of extractor hoods (17-17') connected to the flue chimneys (18-18') of said kilns (19), and which includes a suction turbine (27). b) A pre-filtration module (2) connected to the collection module (1) which incorporates a first inertial separation stage (21) with activated carbon for coarse particles. c) A gas scrubbing module (3) at the outlet of the pre-filtration module (2), which includes an internal countercurrent shower system. d) A water recovery module (4) associated with the gas scrubbing module (3) which includes a settling tank, water recirculation means, and a level control system. e) A treated flue gas outlet (26), connected to the gas scrubbing module (3) with an extraction turbine (25) in between. f) A control panel (5) with pressure / flow, level, and temperature sensors, governed by a programmable microcontroller.

Description

Installation of fume extraction systems with gas recovery in charcoal kilns for reuse in agriculture TECHNICAL SECTOR The present invention relates to an installation that has been specially designed to mitigate the emission of solid particles and harmful gases from industrial combustion processes. The object of the invention is to offer a modular and adaptive system, capable of being integrated into existing production lines with the least possible impact. BACKGROUND OF THE INVENTION In the practical application of the invention, the cleaning of industrial fumes is fundamental to reducing polluting emissions derived from combustion or heat treatment processes. There are various systems, classified according to the type of contaminants they remove, such as bag filters, electrostatic precipitators, ceramic or metallic filters, etc. However, the applicant is unaware of the existence of a smoke elimination equipment with the characteristics that will be described below. EXPLANATION OF THE INVENTION The proposed smoke removal equipment with gas recovery in charcoal kilns for reuse in agriculture fully and satisfactorily resolves the aforementioned problem, based on a highly effective solution. To this end, the installation of the invention is constituted from a collection module for the fumes generated by the oven, which are redirected by means of extractor hoods connected to the smoke outlet chimneys of said oven or ovens, a flow that is forced by means of a suction turbine. Next, a pre-filtration module is installed, which incorporates a first stage of inertial separation with activated carbon for coarse particles. This module directs the pre-filtered gases to a gas scrubbing module that includes an internal counter-current shower system. According to another feature of the invention, the equipment additionally includes a water recovery module that includes a decanter, water recirculation means, and a level control system. Once treated, the gases are redirected to a flue outlet by means of an extraction turbine. The device is complemented by a control panel with pressure / flow, level and temperature sensors, governed by a programmable microcontroller. More specifically, the water recovery module includes the following elements: Activated carbon filter. Secondary filter of white gravel and Zeolite. Decantation and storage tank. Means of recirculating treated water to the gas scrubbing module. The water recirculation circuit is complemented by a hydraulic-pneumatic system involving a pneumatic compressor along with a pneumatic diaphragm pump, as well as an FRL (Filter-Regulator-Lubricator) unit. For its part, the pre-filtering module includes a vertical cyclone with tangential inlet. The gas scrubbing module includes stainless steel spray nozzles and the aforementioned recirculating pump. In parallel, the recovery and settling tank consists of a rectangular tank of 1000 liters with an overflow connection, and a flow meter system. Finally, the control panel includes an IP65 watertight enclosure with PID controllers, a flow sensor, two frequency converters (one for each turbine: suction and discharge), electrical protections, a touch screen with integrated PLC, as well as control elements on the front of the panel such as a main power switch, emergency stop button, start button, stop button, correct operation indicator and fault indicator. Based on this structure, a comprehensive solution is offered to the problem of fumes generated in industrial thermal processes, addressing not only the filtration of particles, but also the recovery of wastewater for possible reuse or further treatment. The combination of functional design, appropriate materials, and validation under real-world conditions has allowed us to achieve the stated technical objectives, highlighting: High efficiency in retaining contaminant particles. Compact and modular design. Low maintenance. Compatibility with existing industrial work environments. BRIEF DESCRIPTION OF THE DRAWINGS To complement the description that follows and to aid in a better understanding of the characteristics of the invention, according to a preferred embodiment thereof, a set of drawings is included as an integral part of said description, in which, for illustrative and non-limiting purposes, the following has been represented: Figure 1 shows a schematic view of a smoke removal installation with gas recovery in charcoal kilns for reuse in agriculture carried out in accordance with the object of the present invention. Figure 2 shows a front elevation view of the equipment of the invention properly installed. Figure 3 shows a profile view of the assembly in Figure 2. PREFERRED EMBODIMENT OF THE INVENTION In view of the figures shown, it can be observed that the smoke removal system with gas recovery in charcoal kilns for reuse in agriculture consists of an installation that includes the following modules or functional elements: Collection module (1): collects the fumes generated by the oven (19) by means of extractor hoods (17-17) connected to the chimneys (18-18) of fume outlet of the ovens (19) through a circuit of ducts (20) in which a main duct (28) is defined that feeds the pre-filtering module (2) assisted by a suction turbine (27) .. Pre-filtration module (2): incorporates a first stage of inertial separation (21) with activated carbon for coarse particles. Gas scrubbing module (3): internal countercurrent shower system, optimized by computational fluid dynamics to maximize gas-liquid contact. Water recovery module (4): compact decanter with recirculation and level control system. Control panel (5): Includes pressure / flow, level and temperature sensors, governed by a programmable microcontroller. All modules have been designed with ease of maintenance, minimal energy consumption, and low production costs in mind. The base structure was developed using stainless steel to ensure corrosion resistance and durability. The gas scrubbing module (3) consists of a wet system that scrubs contaminated gases with a liquid, usually water or neutralizing chemical solutions. The interaction between the gas and the liquid causes the transfer of contaminants from the gaseous to the liquid phase. The use of this equipment presents a number of advantages such as the effectiveness of the treatment for both solid particles and polluting gases (SOx, NOx, HCl...). The equipment is capable of neutralizing acidic contaminants using alkaline reagents (e.g., NaOH, lime). It adapts to various flow rates and contaminant loads and can operate in humid or high-temperature environments. Consequently, the inclusion of a gas scrubbing module (3) is optimal for ensuring the efficient retention of particles and acidic compounds generated in the process. Its ability to adapt to different operating conditions and its high cleaning performance make it the most suitable solution compared to other more limited or specific technologies. Regarding the water recovery module (4), it features a closed-loop design for the recovery of enriched water, ensuring optimal reuse of the water used in industrial fume cleaning. This closed loop is specifically designed to maximize efficiency and minimize liquid waste generation through a comprehensive process of filtration, decantation, and water reuse until saturation is reached. The water recovery module (4) consists of the following elements: Activated carbon filter (7) in pellet form: Efficiently absorbs organic and chemical contaminants present in the water from the spray used in the gas scrubbing module (3), substantially improving the quality of the recovered water. Secondary filter (8) of white gravel and ZN Aqua Zeolite; it is composed of white gravel of different granulometries and ZN Aqua Zeolite. Its function is to retain larger suspended solids and capture ammonia, heavy metals, as well as other specific contaminants through ion exchange processes, significantly reducing the remaining contaminant load in the water. Settling tank (9) and storage: With a capacity of approximately 1000 liters, it allows for the natural sedimentation of residual solid particles still present in the water. The tank's design facilitates gravity settling and has specific connections to facilitate the removal and management of sediments accumulated at the base. The water used to spray and scrub the gases in the gas scrubbing module (3) initially flows by gravity to the first activated carbon filter (7), where a large proportion of organic and inorganic contaminants are removed. Subsequently, the flow continues to the second filter (8), composed of white gravel and ZN Aqua Zeolite, where finer particles and specific contaminants are removed by ion exchange. Finally, the treated water passes into the 1000 liter settling tank (9), where it will rest to allow further sedimentation of any remaining solids. The clean water from the top of the tank is recirculated back to the gas scrubbing module spray (3), thus closing the cycle and optimizing the water consumption of the process. When the water reaches a certain saturation level, it is diverted for secondary uses within the industrial facility, such as irrigation or general cleaning, thus contributing to responsible and sustainable environmental management. This system has been designed for high operational efficiency, ease of maintenance, and durability, ensuring consistent performance and significantly reducing the operating and environmental costs associated with the industrial process. The closed circuit for water recovery and reuse is complemented by a hydraulic-pneumatic system that ensures the efficient and controlled delivery of water to the sprayer (10). This integrated system uses a pneumatic compressor (22) along with a pneumatic diaphragm pump (23), thus optimizing the precise distribution of treated water in the smoke scrubbing process. The pneumatic system additionally includes an FRL (Filter-Regulator-Lubricator) unit, which ensures that the air supplied by the compressor is clean, free of impurities, pressure regulated, and properly lubricated to prolong the service life of the pneumatic components involved. Based on this structure, the operation is as follows: The pneumatic compressor (22) continuously feeds the 50-liter compressed air tank (24), maintaining a regulated and constant pressure. From this tank, the compressed air passes through the FRL unit to ensure its optimal quality before reaching the pneumatic diaphragm pump (23). The pneumatic diaphragm pump (23) propels water from the 1000 liter settling tank to the sprayers (10) installed in the gas scrubbing module (3). Compressed air also directly feeds the sprayers, assisting in the fine atomization of the water to maximize the efficiency of gas scrubbing. This integrated hydraulic-pneumatic circuit design ensures smooth, efficient, and controlled operation, optimizing energy consumption and guaranteeing consistent system performance. The collection and pre-filtration chamber will be obtained from a vertical cyclone with tangential inlet, with a separation efficiency of 70% for particles larger than 15 µm. The fume scrubbing unit will be equipped with stainless steel spray nozzles and a recirculating pump. The countercurrent design allows for greater particle retention. The washed fumes will be expelled upwards through an extraction turbine (25) to which the final fume outlet (26) is connected. The recovery and settling tank, as previously stated, consists of a rectangular tank of 1000 liters with an overflow connection, and a flow meter system to maintain a constant level. Regarding the electrical panel and control panel (5), it will include an IP65 watertight enclosure with PID controllers, flow sensor and variable frequency drives to regulate the process, as well as the following main elements: Two frequency converters (one for each turbine: suction and discharge). Electrical protections Touchscreen (11) with integrated PLC Control elements on the front of the panel such as main power switch (12), emergency stop button (13), start button (14), stop button (15), correct operation indicator (16) and fault indicator (17). From this screen you can activate / deactivate the suction turbine, the drive turbine, the water pump, and select the working mode. Similarly, the interface on the screen allows you to adjust the RPM of both turbines (minimum: 200 RPM / maximum: 1500 RPM). The revolutions can be modified in real time, during operation, to adapt to the needs of the process. Regarding the operating mode, you can select between two modes: Fixed speed: - Both turbines operate at the revolutions previously set. Variable speed: - The suction turbine maintains the set RPM while the drive turbine dynamically adjusts its speed to maintain a constant differential filter pressure, according to the set value (between 0 and 500 Pa).

Claims

1. A smoke removal system with gas recovery for charcoal kilns for reuse in agriculture, characterized in that it includes the following elements: a) A collection module (1) for collecting the smoke generated by one or more kilns (19) by means of extractor hoods (17-17') connected to the flue chimneys (18-18') of said kilns (19), and which includes a suction turbine (27). b) A pre-filtration module (2) connected to the collection module (1) which incorporates a first inertial separation stage (21) with activated carbon for coarse particles. c) A gas scrubbing module (3) at the outlet of the pre-filtration module (2), which includes an internal countercurrent shower system. d) A water recovery module (4) associated with the gas scrubbing module (3) which includes a settling tank, water recirculation means, and a level control system.e) A treated flue gas outlet (26), connected to the gas scrubbing module (3) with an extraction turbine (25) in between. f) A control panel (5) with pressure / flow, level, and temperature sensors, governed by a programmable microcontroller.

2. A flue gas removal system with gas recovery in charcoal kilns for reuse in agriculture, according to claim 1, characterized in that the water recovery module (4) includes the following elements: - Activated carbon filter (7). - Secondary filter (8) of white gravel and zeolite. - Settling and storage tank (9).

3. A flue gas removal system with gas recovery in charcoal kilns for reuse in agriculture, according to claim 1, characterized in that the water recovery module (4) includes means for recirculating the treated water to the gas scrubbing module (3). 4.A smoke removal system with gas recovery in charcoal kilns for reuse in agriculture, according to claim 3, characterized in that the water recirculation circuit is complemented by a hydraulic-pneumatic system comprising a pneumatic compressor (22) along with a pneumatic diaphragm pump (23), as well as an FRL (Filter-Regulator-Lubricator) unit.

5. A smoke removal system with gas recovery in charcoal kilns for reuse in agriculture, according to claim 1, characterized in that the pre-filtration module (2) includes a vertical cyclone with tangential inlet.

6. A smoke removal system with gas recovery in charcoal kilns for reuse in agriculture, according to claim 1, characterized in that the gas scrubbing module (3) includes stainless steel spray nozzles and a recirculating pump. 7.A smoke removal system with gas recovery in charcoal kilns for reuse in agriculture, according to claim 2, characterized in that the recovery and settling tank consists of a 1000-liter rectangular tank with an overflow connection and a flow meter system.

8. A smoke removal system with gas recovery in charcoal kilns for reuse in agriculture, according to claim 1, characterized in that the control panel (5) includes: - An IP65-rated watertight enclosure with PID controllers. - A flow sensor. - A frequency inverter for each turbine. - Electrical protections. - A touchscreen (11) with integrated PLC. - Control elements on the front of the panel such as a main power switch (12), emergency stop button (13), start button (14), stop button (15), operating indicator (16), and fault indicator (17).