Thermally regenerative fluid processing apparatus

Abstract

A regenerative thermal oxidizer assembly includes a first housing member and a second housing member. The first housing member defines a regeneration portion and a combustion chamber. The second housing member defines an inlet chamber and an outlet chamber. A regenerator is disposed within the regeneration portion of the first housing member. A thermal element extends through the first housing member into the combustion chamber for providing heat to the combustion chamber to initiate combustion inside the combustion chamber. The first housing member is rotatable relative to the second housing member about a central axis to rotate the regenerator relative to the inlet and outlet chambers.

Description

Technical Field

[0001] The present invention generally relates to a thermal regenerative fluid treatment apparatus, and more particularly to a compact, low-cost thermal regenerative fluid treatment apparatus. Background Art

[0002] Thermal oxidizers have been used for many years to clean contaminated fluids. More specifically, they are used to remove impurities, such as greenhouse gases, from gaseous waste streams from industrial processes. These gaseous waste streams are known to include volatile organic compounds (VOCs), methane, carbon monoxide, and others. Thermal oxidizers are primarily used in large industrial facilities. Therefore, they are typically built on a large industrial scale to handle large quantities of contaminated fluids.

[0003] However, evolving environmental standards require thermal oxidizers to have flexibility that was not previously envisioned. For example, many small facilities, such as dry cleaners, bakeries, and large-scale farms, are under increasing scrutiny to eliminate even small amounts of VOCs and other greenhouse gases. Available large industrial thermal oxidizers are not suitable for handling small-scale operations. In addition, not every VOC emitting facility requires the same size oxidizer. Therefore, customized oxidizers are sought, but the cost of customized oxidizers is high. Therefore, there is a need for a low-cost, adaptable thermal oxidizer that can be used in a variety of facilities. Summary of the Invention

[0004] A regenerative thermal oxidizer assembly includes a first housing member and a second housing member. The first housing member defines a regeneration portion and a combustion chamber. The second housing member defines an inlet chamber and an outlet chamber. A regenerator is disposed within the regeneration portion of the first housing member. A thermal element extends through the first housing member into the combustion chamber, thereby providing heat to the combustion chamber to induce combustion within the combustion chamber. The first housing member is rotatable relative to the second housing member about a central axis, thereby allowing the first housing member to rotate the regenerator relative to the inlet chamber and the outlet chamber defined by the second housing member.

[0005] The unique and compact design of the thermal oxidizer of the present invention allows for the implementation of a low-cost thermal oxidizer that can be applied to virtually any facility that produces a contaminated fluid that can be oxidized to reduce greenhouse gases. The use of an axial opening simplifies the overall design and eliminates the complex features of existing oxidizers. The simplicity of providing oxidation energy to the combustion chamber through the axial opening significantly reduces the cost of manufacturing the thermal oxidizer of the present invention. In addition, the compact design of the thermal oxidizer of the present invention provides the opportunity for modular implementation in any facility, eliminating the need for custom designs. Thus, two, three or more oxidizers can be interconnected in parallel to accommodate larger scale facilities. For the first time, oxidation technology can be applied to a wide range of uses, achieving significant reductions in greenhouse gases that were previously unattainable. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Other advantages of the present invention will be readily appreciated as they will be better understood with reference to the following detailed description when considered in conjunction with the accompanying drawings, in which:

[0007] Figure 1 shows a cross-sectional view of a regenerative thermal oxidizer of the present invention;

[0008] Figure 2 Shown through Figure 1 a cross-sectional view of the combustion chamber taken along line 2-2;

[0009] Figure 3 Shown through Figure 1 a cross-sectional view of the second housing taken along line 3-3;

[0010] Figure 4 showing a cross-sectional view of an alternative embodiment of the second housing;

[0011] Figure 5 Shown through Figure 4 a cross-sectional view of the second housing taken along line 5-5;

[0012] Figure 6 A perspective view showing a modular design of multiple cooperable thermal oxidizers;

[0013] Figure 7 Shown through Figure 6 Line 7-7 is a side cross-sectional view of a modular system of a plurality of cooperable thermal oxidizers;

[0014] Figure 8 A cross-sectional view showing an alternative regenerative thermal oxidizer of the present invention;

[0015] Figure 9 Shown through Figure 1 A cross-sectional view of the second housing taken along line 9-9;

[0016] Figure 10 Shown through Figure 1 A cross-sectional view of an alternative second housing taken along line 10-10. DETAILED DESCRIPTION

[0017] refer to Figure 1 The regenerative thermal oxidizer of the present application is generally indicated at 10. The oxidizer 10 includes a first housing member 12 and a second housing member 14. The first housing member 12 defines a regeneration portion 16 and a combustion chamber 18. The second housing member 14 defines an inlet chamber 20 and an outlet chamber 22.

[0018] A regenerator 24 is disposed within the regeneration portion 16 of the first housing member 12. The regenerator 24 is formed of a ceramic material and defines a passage 26 that allows gas to pass between the second housing member 14 and the combustion chamber 18 defined by the first housing member 12, the purpose of which will be further explained herein and below. The ceramic material used to form the regenerator 24 is capable of being heated by the oxidative combustion occurring within the combustion chamber 18 and transferring this heat to the incoming gas received from the inlet chamber 20 to enhance the efficiency of the oxidizer 10.

[0019] The regenerator 24 defines a first housing axial opening 28 that extends into the combustion chamber 18. Similarly, the second housing member 14 defines a second housing axial opening 30 that is coaxial with the first housing axial opening 28. A tubular member 32 extends through the second housing axial opening 30 and is received by the first housing axial opening 28. Thus, it should be understood that the tubular member 32 is axially aligned with both the first housing axial opening 28 and the second housing axial opening 30.

[0020] A heat element 34 extends through the tubular member 32 into the combustion chamber 18. In one embodiment, the heat element 34 includes electrical wires 36 that provide electrical current to a heating coil 38 located within the combustion chamber 18. In an alternative embodiment, the heat element 34 includes an inlet tube interconnected with a source of combustible gas to direct the combustible gas into the combustion chamber 18, thereby providing sufficient combustion energy to the combustion chamber 18. Using either an electrical or gas heat element 34, the heat element 34 must provide sufficient thermal energy to the combustion chamber 18 to oxidize the dirty gas entering the combustion chamber 18 through the inlet chamber 20. A temperature probe 40 also extends through the tubular member 32 into the combustion chamber 18 to monitor the temperature within the combustion chamber 18. A seal 41, or gasket, is disposed within the tubular member 32 to prevent gas from escaping the combustion chamber 18. The seal 41 defines a number of openings therein to allow the heat element electrical wires 36 and the temperature probe 40 to pass through the openings and into the combustion chamber 18.

[0021] The tubular member 32 includes a drive element 42 that engages a driver 44. The driver 44 transfers rotational motion from a drive motor 46 to the drive element 42 for rotating the tubular member 32 about the pivot axis. The tubular member 32 is attached to the first housing member 12 so that the rotational motion can be transferred from the driver 44 to the first housing member 12.

[0022] A plurality of bearings 48 are disposed within the second housing axial opening 30 between the second housing member 14 and the tubular member 32, which allows the tubular member 32 to rotate without transmitting the rotational motion to the second housing member 14. Thus, it should be understood that the first housing member 12 rotates about the pivot axis defined by the tubular member 32 while the second housing member 14 remains stationary. Furthermore, the second housing member 14 is separated from the regenerator 24 by a space 50 and, therefore, from the first housing member 14, to prevent any rotational torque from being transmitted from the rotating first housing member 12 to the stationary second housing member 14.

[0023] First conductor 52 is integrally formed with tubular member 32, allowing conductor 52 to rotate with tubular member 32. Conductor 52 receives current from wire 54 via first conductive vane 56, which is in contact with first conductor 52 but remains stationary relative to the rotating conductor 52. Wire 36 is fixedly attached to first conductor 52, allowing first conductor 52 to provide current to thermal element 34 via thermal element wire 36. Therefore, it should be understood that thermal element 34 rotates with tubular member 32. Similarly, temperature probe 40 is fixedly attached to second conductor 58, which receives current from wire 54 via conductive vane 56. Therefore, temperature probe 40 also rotates with tubular member 32. Thermal element wire 36 transfers sufficient electrical energy from conductor 52 to thermal element 34 to provide oxidation energy to combustion chamber 18 defined by first housing member 12. As explained above, first housing member 12 rotates with tubular member 32, thermal element 34, and temperature probe 40, while second housing member 12 remains stationary.

[0024] Now refer to Figure 2 , showing the passage through Figure 1 2. The thermal element 34 disposed within the combustion chamber 18 is in the form of a coil that substantially surrounds the first housing axial opening 28 defined by the regenerator 24. In this embodiment, the regenerator 24 defines an axial passage 26 that extends from the combustion chamber 18 to a space 50 that separates the second housing member 14 from the regenerator 24, as described above.

[0025] The first housing member 12 defines an outer annular wall 60 that surrounds an inner annular wall 62 such that the combustion chamber 18 is enclosed within the inner annular wall 62. An insulator 64 is disposed between the inner annular wall 62 and the outer annular wall 60 to contain oxidation heat within the combustion chamber 18. Furthermore, the insulator 64 reduces the amount of heat reaching the outer annular wall 60 to prevent heat from radiating from the outer annular wall 60.

[0026] Now refer to Figure 3 , showing the passage through Figure 1 FIG3 is a cross-sectional view of the second housing member 14 taken along line 3-3 of FIG3 . An inlet conduit 66 delivers contaminated gas into the inlet chamber 20 defined by the second housing member 14. Similarly, an outlet conduit 68 is fluidly connected to the outlet chamber 22 to transfer oxidized clean gas outward from the second housing member 14. The second housing member 14 further defines an opposed fresh air inlet chamber 72 that separates the inlet chamber 20 from the outlet chamber 22. Fresh air is delivered to the fresh air inlet chamber 72 through the fresh air inlet 70.

[0027] In one embodiment, a pump or fan creates a negative pressure within the outlet duct 68, which in turn creates a negative pressure within the combustion chamber 18. Creating a negative pressure in this manner facilitates the flow of gas through the oxidizer 10 and by drawing gas from the inlet chamber 20 into the combustion chamber 18. It is also contemplated that the pump or fan creates sufficient pressure to prevent gas from escaping through the space 50 provided between the first housing member 12 and the second housing member 14.

[0028] It will be apparent that the relative positions of any of the inlet chamber 20, the outlet chamber 22, and the fresh air inlet chamber 68 with respect to the regenerator 24 can be varied. Thus, different portions of the regenerator 24 continuously receive incoming gas due to alignment with the inlet chamber 20, while opposing portions of the regenerator 24 transfer outlet gas from the combustion chamber 18 to the outlet chamber 22. Due to the rotation, the portion of the regenerator 24 that previously discharged contaminated gas into the combustion chamber 18 rotates through the fresh air inlet chamber 72 to discharge clean gas into the outlet chamber 22. Thus, by rotating that portion of the regenerator that was previously heated by clean gas exiting the combustion chamber 18 into an orientation for receiving contaminated gas from the inlet chamber 20, the contaminated gas is preheated and the energy required to achieve the oxidation reaction within the combustion chamber 18 is reduced.

[0029] exist Figure 4An additional embodiment is generally shown at 110 of FIG. , wherein like elements from the previous embodiment are numbered with the same element numbers but in the 100 series. To further adjust the flow rate into and out of the combustion chamber 18, the first housing member 112 can be reconfigured to provide opposed inlet chambers 120 separated by opposed outlet chambers 122. Thus, each inlet chamber 120 includes a separate inlet conduit 166, and each outlet chamber 122 includes a separate outlet conduit 168. As in the previous embodiment, each inlet chamber 120 is separated from each outlet chamber 122 by a fresh air inlet chamber 172, which is used to provide purge gas to the regenerator 124. Thus, in this embodiment, four fresh air inlet chambers 172 are included, each chamber receiving fresh air via a fresh air inlet 170. Otherwise, this second embodiment functions in the same manner as the first embodiment, but the regenerator 24 passes through the inlet and outlet chambers 120, 122 more frequently.

[0030] It is within the scope of the present invention that multiple oxidizers 10 may be interconnected to increase the cleaning potential for various operations that may require oxidation rates higher than a single oxidizer 10 can provide. Figure 6 and 7 , a plurality of oxidizers are shown enclosed within a housing 74. The housing 74 defines a common contaminated gas inlet 76 and a common clean gas outlet 78. This configuration interconnects each oxidizer 10 in parallel, as will be explained further below.

[0031] See now Figure 7 , we will now explain the Figure 6 7. In this embodiment, the oxidizers 10 are arranged in parallel. Thus, the inlet conduit 66 of each oxidizer 10 is fluidly connected to a common inlet 76. Similarly, the outlet conduit 68 of each oxidizer 10 is fluidly connected to a common outlet 78. The diameter of each inlet conduit 66 and each outlet conduit 68 can be adjusted to control the flow rate of the various gases entering and leaving each oxidizer 10. Alternatively, valves can be used to balance the flow rate entering and leaving each oxidizer 10. The housing 74 may also include housing insulation 80 to further reduce heat loss from the combustion chamber 18 of each oxidizer 10.

[0032] It should be understood that while six oxidizers 10 are shown in this embodiment, more or fewer oxidizers 10 may be included for specific purposes. Furthermore, as VOC output increases and additional reductions are required, a facility can add additional oxidizers 10 or modules including multiple oxidizers 10. Thus, the low-cost, economical oxidizers 10 of the present invention provide a fully modular solution capable of reducing greenhouse gases that was previously unattainable for smaller facilities.

[0033] exist Figure 8 、 Figure 9 and Figure 10 An alternative embodiment of the invention of the present application is shown in FIG, wherein similar elements of the previous embodiment include the same element numbers but in the series of 100. For the sake of brevity, these elements will not be described again. However, it should be understood that these elements are interchangeable in each embodiment.

[0034] Now refer to Figure 8 , an alternative embodiment is shown generally at 100. The alternative assembly 100 includes a first housing member 112 and a second housing member 114. The first housing member 112 defines an outer annular wall 160 and an inner annular wall 162.

[0035] The insulation 180 is disposed between the outer annular wall 160 and the inner annular wall 162. In one embodiment, the insulator 180 is microporous. The microporous insulation 162 provides extremely low thermal conductivity over a wide temperature range. Microporous insulation 180 is employed, such as, for example, pyrogenic silica powder, also known as fumed silica, and an opacifier in the form of a pourable powder. The microporous insulation may contain an opacifier to reduce the transmission of radiant heat within the insulation. In one embodiment, the microporous insulation includes an average interconnected pore size that is comparable to or less than the mean free path of air molecules or between 64-68 nm. The light weight of the microporous insulation will reduce the physical load on the drive mechanism 46, 146 and the rotating element 184. However, it will be understood by those of ordinary skill in the art that other lightweight insulation is also within the scope of the present invention.

[0036] The outer annular wall 160 is surrounded by a ring gear 180. The ring gear 180 engages a spider gear 182 or equivalent drive gear, which receives the rotational motion of the drive motor 146. Although the terms "spider gear" and "ring gear" are used throughout this specification, it should be understood that alternative drive mechanisms may be implemented to transmit the rotational motion to the first housing member 112. This may include driving one or more vertical support wheels 186 or horizontal support wheels 188.

[0037] First housing member 112 is pivotally supported by support elements 184. In one embodiment, support elements 184 include vertical supports 186 and horizontal supports 188. In another embodiment, multiple rotational elements 184 are spaced about first housing member 112. Vertical supports 186 include vertical support wheels, and horizontal supports 188 include horizontal support wheels. Alternative supports 186, 188 that include low-friction, stationary, non-pivoting supports are within the scope of the present invention.

[0038] In the alternative embodiment 100, the thermal element 134 extends through the first housing member 112 into the combustion chamber 118. Thus, the thermal element 134 rotates with the first housing member 118. In the same manner as the first embodiment, the thermal element 134 includes electrical wires 134 and an electrical heating coil 138 to convert electrical energy into thermal energy within the combustion chamber 118. Electrical current is received by the electrical wires 134 from a conductor 152 via a conductive vane 156. The conductor 152 receives current via conventional electrical wires 154 in a known manner. In this embodiment, the conductor 152 pivots with the first housing member 112 while maintaining constant electrical contact with the vane 156, which remains stationary. It should be understood that the reverse arrangement, in which the vane 156 pivots with the first housing member 112 while the conductor 152 remains stationary, is also within the scope of the present invention.

[0039] The temperature probe 140 extends through the first housing member 112 into the combustion chamber 118 and is electronically connected to the second conductor 158. The second conductor 158 pivots with the first housing member 112. Thus, the probe blade 194 provides an electronic connection to the thermal controller to monitor and regulate the temperature within the combustion chamber 118.

[0040] An alternative regenerator 124 is disposed within the regeneration portion 116 of the first housing member 112. The alternative regenerator 124 is formed of a ceramic material defining a passage 126 that allows gas to pass between the second housing member 114 and the combustion chamber 118 defined by the first housing member 112, and functions in the same manner as the first embodiment. The ceramic material used to form the regenerator 124 is capable of being heated by the oxidative combustion occurring within the combustion chamber 118 and transferring this heat to the incoming gas received from the inlet chamber 120 to enhance the efficiency of the oxidizer 110. Unlike the first embodiment, which defines an axial opening, the regenerator 124 presents a continuous upper surface within the combustion chamber 118. The regenerator 124 rotates with the first housing member 112.

[0041] The second housing member 114 is stationary relative to the first housing member 112 and defines an inlet chamber 120 and an outlet chamber 122 that function in the same manner as the first embodiment. Thus, the inlet chamber 120 delivers dirty or contaminated gas to the combustion chamber 118 and discharges clean gas through the outlet chamber 122. A fresh air inlet chamber 172 is disposed between the inlet chamber 120 and the outlet chamber 122 and functions in the same manner as the first embodiment. Rotation of the first housing member 112 relative to the second housing member 114 also continuously changes the position of the inlet chamber 120, the outlet chamber 122, and the fresh air inlet chamber 172 relative to the regenerator 126 in the same manner as the first embodiment.

[0042] The present invention has been described in an illustrative manner; many modifications and variations of the present invention are possible. Therefore, it should be understood that in the description, the reference numerals are used for convenience only and are not limiting in any way, and that the present invention may be practiced otherwise than as specifically described. Therefore, the present invention may be practiced otherwise than as specifically described within the scope of the claims set forth in accordance with this first disclosed embodiment.

Claims

1. A regenerative thermal oxidizer assembly comprising: a first housing member and a second housing member; the first housing member defining a regeneration portion and a combustion chamber; the second housing member defining an inlet chamber and an outlet chamber; a regenerator disposed within the regeneration portion of the first housing member; a thermal element extending into the combustion chamber, the thermal element providing heat to the combustion chamber to induce combustion within the combustion chamber; a drive motor drivably engaged with the first housing member for pivoting the first housing member relative to the second housing member to continuously pivot the regenerator relative to the inlet chamber and the outlet chamber; and The first housing member is rotatable relative to the second housing member about an axis defined by the axial opening, thereby rotating the regenerator relative to the inlet chamber and the outlet chamber defined by the second housing member.

2. The assembly according to claim 1, wherein The first housing member includes a ring gear disposed on an outer surface thereof, and the drive motor includes a worm gear drivingly engaged with the ring gear to provide pivotal movement to the first housing member.

3. The assembly according to claim 1, wherein One or more support wheels are in driving engagement with the drive motor to provide pivotal movement to the first housing member.

4. The assembly according to claim 1, wherein The first housing member defines an outer annular wall and an inner annular wall with a thermal insulator disposed therebetween.

5. The assembly according to claim 2, wherein The thermal insulator comprises a microporous insulator defining an average interconnected pore size that is less than the mean free path size of air molecules.

6. The assembly according to claim 2, wherein The microporous insulator includes at least one of fumed silica powder and a light shielding agent.

7. The assembly according to claim 1, wherein The thermal element extends through the first housing member into the combustion chamber.

8. The assembly according to claim 2, wherein The thermal element is an electrical element that receives electrical current via a conductor that slidably engages a conductive blade for transferring electrical energy from an electrical source to the thermal element.

9. The assembly of claim 1, wherein: The second housing member defines a purge chamber disposed between the inlet chamber and the outlet chamber for providing purge gas to the regenerator.

10. The assembly of claim 1, wherein: The first housing member is rotatably supported by a rotating element.

11. The assembly according to claim 10, wherein The rotating element includes a vertical support and a horizontal support.

12. The assembly of claim 1, wherein: The second housing member defines a sealed compartment including a seal disposed therein for sealing the first housing to the second housing.

13. The assembly of claim 12, wherein: The seal includes a sealing fluid provided to the sealed compartment by a sealing fluid source.

14. The assembly of claim 1, wherein: The first housing is spaced apart from the second housing member.

15. The assembly of claim 1, wherein The combustion chamber includes a negative pressure below atmospheric pressure.

16. The assembly of claim 15, wherein: The outlet chamber is fluidly connected to one of a pump and a fan for generating negative pressure within the outlet chamber and the first housing member.

17. The assembly of claim 1 further comprising a temperature sensor disposed within the combustion chamber for regulating current to the thermal element.

18. The assembly of claim 1, wherein Multiple components are interconnected through a common entrance.

19. The assembly of claim 18, wherein The plurality of components are disposed within a housing that defines the common inlet.

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