Chimney-mounted system for pollutant reduction and oxygen generation

Abstract

An emission control and oxygen generation system mounted on a chimney, consisting of a housing that can be attached to an industrial chimney, a filter unit located in the housing with at least one HEPA filter and an activated carbon layer for the separation of fine dust and the adsorption of harmful gases, a downstream electrostatic separation module for the removal of fine particles by means of charged wires and collecting plates, and a catalytic conversion chamber for the neutralization of remaining toxic gases by chemical reactions.

Description

AREA OF INVENTION

[0001] The invention relates to industrial emission control devices that integrate particle and gas filtration, electrostatic separation, catalytic conversion, bio- / photocatalytic CO2 utilization, oxygen release and IoT monitoring in a retrofittable housing that can be attached to chimneys. BACKGROUND OF THE INVENTION

[0002] Industrial plants emit particulate matter, volatile organic compounds (VOCs), acid gases, and nitrogen oxides, the multi-stage capture of which is necessary to comply with legal requirements and improve local air quality. Typical plants utilize mechanical pre-filters, fine filtration, electrostatic precipitators, and catalytic reactors to efficiently treat the various fractions. HEPA filters capture particulate matter, while activated carbon adsorbs many organic substances and acid gases. Upstream of the electrostatic precipitators, the remaining submicron particles are collected on plates and wires. Downstream catalysts (e.g., oxidation or selection reactions) neutralize the remaining pollutants.In parallel, research and practice have further developed bioreactors and artificial photosynthesis processes—such as algal bioreactors and photocatalytic materials—to convert CO2 into O2 and biomass or chemical intermediates, thus enabling partial carbon utilization at point sources. A compact, integrated device, mounted on an existing chimney, sequentially performs fine filtration, ESP collection, catalytic treatment, and CO2-to-O2 conversion with oxygen release and sensor-controlled regulation, offering a retrofittable option for reducing pollutants and replenishing oxygen locally, while remotely monitoring performance. SUMMARY OF THE INVENTION

[0003] The invention relates to a system comprising a housing for mounting on an industrial chimney, a filter unit housed therein with at least one HEPA filter and an activated carbon layer for separating particulate matter and adsorbing harmful gases, a downstream electrostatic precipitator (ESP) module for removing particulate matter by means of charged wires and collection plates, and a catalytic conversion chamber for neutralizing remaining toxic gases through chemical reactions tailored to the system profile. The system further includes a bioreactor chamber with algae or artificial photosynthetic material for converting CO2 to O2 under controlled illumination and flow, an oxygen delivery module for releasing the generated oxygen into the environment or into a local plenum room, and an IoT-based monitoring and control unit for monitoring sensors and actuators and for reporting.The multi-stage architecture allows for modular adjustment of the capacity and chemical composition of each unit, while the mounting housing is suitable for quick installation on various chimney geometries. DETAILED DESCRIPTION

[0004] The mounting housing includes flange adapters and gaskets for coaxial mounting on a chimney outlet or for integration into a bypassable sideflow. Internal baffles distribute the flow evenly across the filter unit to prevent channeling and reduce local velocity peaks that could impair separation performance. The filter unit consists of a serviceable HEPA stage designed for the chimney's flow rate and temperature, followed by an activated carbon bed in replaceable cartridges optimized for the target gases. Differential pressure and gas sensors detect fouling and breakthrough, and a service hatch allows for safe maintenance. The ESP module contains corona wires and grounded plates arranged in multiple bays.A high-voltage power supply ensures stable corona discharge with current limiting and spark detection, while tapping or vibration cleans the plates into a dust container. The ESP controller integrates interlocks with upstream and downstream modules to prevent re-tapping during the tapping cycles. The catalytic conversion chamber contains a catalyst bed (e.g., oxidation catalysts or custom formulations) whose temperature is regulated via electrical or waste heat exchangers to maintain the activation ranges. Removable cassettes allow for the exchange of the chemical composition to adapt to emission profiles, and protective beds prevent catalyst poisoning. The bioreactor chamber contains microalgae in illuminated panels or a photobioreactor manifold, or uses artificial photosynthetic materials.Air / exhaust gas is mixed and conditioned (temperature, humidity, CO2 content) before contact to maintain conversion rates while protecting organisms or materials. Nutrient dosing, biofouling control, and purging devices ensure stable operation, and biomass is harvested regularly as needed. An oxygen delivery module with check valves and diffusers safely discharges O2-enriched gas, with O2 sensors monitoring concentration and flow. Excess O2 can be vented locally or directed to a system plenum. The IoT monitoring and control unit aggregates data from particulate matter sensors, electrochemical / NDIR gas sensors (e.g., for NOx, CO, SO2, CO2, O2), electrostatic precipitator voltage / current, catalyst bed temperature / pressure changes, bioreactor pH / concentration / optical density (for algae), light intensity, and fan / valve status.Control algorithms modulate fan speeds, electrostatic precipitator power, catalyst heating, bioreactor lighting and flow, and bypass valves to ensure targeted emission reductions and stable oxygen production. A sideflow bypass and emergency vent protect the system in case of malfunctions. All high-voltage and hot surfaces are shielded, and maintenance access is secured with lockout / marking points. Modular sections allow for scaling by adding parallel filtration / electrostatic precipitator / catalyst units and bioreactor modules to adapt to chimney flows. Standardized electrical and data interfaces facilitate deployment in various plants. Data is logged and securely connected to dashboards for compliance reporting, predictive maintenance (filter loading, catalyst life), and performance optimization (e.g.,ESP performance compared to PM load, lighting plans compared to O2 yield) transferred.

Claims

[1] An emission control and oxygen generation system mounted on a chimney, consisting of a housing that can be attached to an industrial chimney, a filter unit located in the housing with at least one HEPA filter and an activated carbon layer for the separation of fine dust and the adsorption of harmful gases, a downstream electrostatic separation module for the removal of fine particles by means of charged wires and collecting plates, and a catalytic conversion chamber for the neutralization of remaining toxic gases by chemical reactions. [2] System according to claim 1, further comprising a bioreactor chamber with algae or artificial photosynthetic material configured to convert carbon dioxide into oxygen under controlled illumination and flow, and an oxygen release module configured to release the oxygen produced. [3] System according to claim 1 or 2, wherein an IoT-based monitoring and control unit is configured to acquire pollutant, flow, temperature, voltage / current and oxygen measurements and to control fan speeds, ESP power, catalyst bed temperature, bioreactor operating conditions and bypass valves to meet emission reduction and oxygen generation targets. [4] System according to any of the preceding claims, wherein modular filtration, ESP, catalyst and bioreactor sections are arranged in parallel rows to increase capacity, with replaceable cartridges, catalyst cassettes and lighting panels, and with maintenance interlocks and bypass to ensure safe operation during maintenance.