Modular thermal machine and their uses

Abstract

The present disclosure relates to a modular thermal machine and their uses. It is disclosed a modular thermal machine comprising at least one control box and at least one module unit, wherein the at least one module unit comprises a support base on which a set of at least four pillars with the same size rests; a heat source; an insulation ceiling; at least one temperature sensor; a back wall comprising a cooling fan; at least three thermally insulated walls placed in relation to the back wall in order to circumscribe a certain volume of space; at least one device for distributing indoor air comprising an air speed sensor; wherein the temperature sensor and air speed sensor are connected to said at least one control box to control the cooling fan operation.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a modular thermal machine and their uses.BACKGROUND

[0002] Modular industrial ovens are designed for a wide range of industrial applications, including heat treatment, drying, curing, melting, among others.

[0003] Their modular designation comes from the fact that this type of industrial oven is built from sections or modules that can be easily assembled, disassembled or reconfigured to meet the specific production or space needs of an installation, which makes them versatile and adaptable to different industrial processes.

[0004] The advantages of this type of industrial oven are linked to configuration flexibility, energy efficiency, optimised performance, applications, transport easiness, among others.

[0005] In terms of configuration flexibility, modular industrial ovens allow for great modularity and customisation of the size and shape of the oven to adapt to different production volumes or product forms. Modules can be added or removed as required and can be designed to adapt to a wide range of industrial processes, including heat treatment, drying, curing and sintering.

[0006] In terms of energy efficiency, modular industrial ovens use advanced insulation materials to minimise heat loss, thus reducing energy consumption. In some cases, this energy efficiency is further enhanced by the use of induction, electric resistance or gas combustion heating technologies, chosen on the basis of energy efficiency and the specific application, in addition to the application of advanced temperature control technology that allows fine temperature adjustments, improving the efficiency and quality of the industrial process.

[0007] The performance of this type of industrial furnace is optimised through the application of internal atmosphere control systems, whether inert, reducing or oxidising. This control is essential for processes that require specific conditions to prevent oxidation or other types of chemical reactions. This optimisation can also involve the way ventilation and exhaust systems are designed, which can be designed to remove gases and fumes from processes, improving safety and environmental compliance. In addition to these subsystems, sensors and monitoring systems can also be included for real-time monitoring of operating conditions, which facilitates predictive maintenance and process optimisation.

[0008] Modular industrial ovens are used in a wide variety of industries, including metallurgy, ceramics, chemistry, food, among others. They are especially useful in environments that require great production flexibility or that undergo frequent changes in the volume or type of product manufactured.

[0009] Document WO2019056081 discloses a mobile kiln comprising at least one associative modular segment, a system for firing ceramic articles and products and a process for controlling the firing of ceramic articles and products. Specifically, the invention described in this document comprises a system for the forced exhaustion of kiln gases, means for controlling the exhaustion of gases, means for controlling the supply of the heat source and monitoring physical parameters inside the kiln, allowing for greater resolution and control of the temperature gradient inside the kiln independently in each modular segment. The mobile oven described also includes a solid floor without a sieve. Compared to the solution presented here, the mobile oven described in the document is a piece of equipment built on rails, modular but on a gantry, with a logic of changing factory capacity and not a logic of construction and expansion like the modular oven disclosed in this application.

[0010] Document EP3029404 discloses an industrial oven system comprising an integrated modular system for electrically heated industrial ovens with a housing structure, at least one thermal insulation layer and heat-resistant supports as basic modules for at least one wall surface module, at least one edge module and / or at least one corner module, with sealing elements and / or at least one system adapter for integrating individual special elements. The basic modules are dimensionally stable and can be assembled with similar external connection points to form a complete cooking chamber with a square basic grill. Compared to the solution now being presented, the document cited focuses on the edge and corner modules, rather than a complete construction solution such as the one now being disclosed.

[0011] These facts are disclosed in order to illustrate the technical problem addressed by the present disclosure.GENERAL DESCRIPTION

[0012] The present disclosure relates to a modular thermal machine and their uses. The modular thermal machine, now disclosed, comprises at least one module unit which comprises: a support base on which a set of at least four pillars with the same size rests; a heat source; at least one temperature sensor; a back wall comprising a cooling fan that can operate counterclockwise or in clockwise motion; an insulation ceiling; at least three thermally insulated walls placed in relation to the back wall in order to circumscribe a certain volume of space; at least one device for distributing indoor air comprising an air speed sensor; wherein the cooling fan comprises at least one carbon dioxide sensor.

[0013] The distinguishing feature of the modular thermal machine is its flexibility, since it is modular, but without compromise the energy efficiency. This approach allows customers to purchase a small oven, based on a single module unit and, as required, add additional modules.

[0014] Other advantages of the modular thermal machine now disclosed is that the modular units are fully transportable in a sea container, for example, not requiring special transport. There is also no construction work during installation at the customer's premises, which reduces costs and impact on work management of the client.

[0015] An aspect of the disclosure comprises a modular thermal machine comprising at least one control box and at least one module unit, wherein the at least one module unit comprises a support base on which a set of at least four pillars with the same size rests; a heat source; at least one temperature sensor; a back wall comprising a cooling fan; an insulation ceiling; at least three thermally insulated walls placed in relation to the back wall in order to circumscribe a certain volume of space; at least one device for distributing indoor air comprising an air speed sensor; wherein the temperature sensor and air speed sensor are connected to said at least one control box to control the cooling fan operation.

[0016] In an embodiment, the cooling fan of the modular thermal machine operates in clockwise motion.

[0017] In an embodiment, the cooling fan of the modular thermal machine operates in counterclockwise motion.

[0018] In an embodiment, the cooling fan of the modular thermal machine comprises at least one carbon dioxide sensor.

[0019] In an embodiment, at least one joint of the at least one module unit comprises a coating.

[0020] In an embodiment, the cooling fan of the modular thermal machine operates at a maximum cooling rate of up to 300 m 3< / h, preferably from 200 m 3< / h to 275 m 3< / h; more preferably from 225 m 3< / h to 275 m 3< / h.

[0021] In an embodiment, the at least one module unit of the modular thermal machine comprises a security door switch.

[0022] In an embodiment, the at least one module unit of the modular thermal machine is constructed in a material selected from a list consisting of metallic, composite, stainless steel, refractory metal, ceramic, nickel-based super alloy, carbon and graphite, polymers, and their combinations.

[0023] In an embodiment, the heat source of the modular thermal machine is selected from a group consisting of induction heating element, electrical resistance heating element, combustion-based heating element, and their combinations.

[0024] In an embodiment, the heat source of the modular thermal machine comprises an energy supply based on grid power.

[0025] In an embodiment, the heat source of the modular thermal machine comprises an energy supply based on infrared catalytic panels.

[0026] In an embodiment, the modular thermal machine further comprises a supply plenum.

[0027] In an embodiment, the modular thermal machine further comprises a return plenum.

[0028] In an embodiment, the modular thermal machine further comprises at least one interior light source.

[0029] In an embodiment, the modular thermal machine further comprises at least one window to the interior of the at least one module unit.

[0030] In an embodiment, the modular thermal machine further comprises at least one back door.

[0031] In an embodiment, the modular thermal machine further comprises a protection of the cooling fan.

[0032] In an embodiment, the at least one carbon dioxide sensor of the modular thermal machine comprises a material selected from a list consisting of zirconium, tin oxide, zinc oxide, titanium dioxide, polyaniline, polypyrrole, polythiophene, ionic liquid, graphene, carbon nanotube, activated carbon, nanocomposite, metal-organic framework, semiconductor quantum dot, and their combinations.

[0033] In an embodiment, the at least one module unit of the modular thermal machine further comprises connection means to another module unit.

[0034] In an embodiment, the connection means of the modular thermal machine comprises mechanical fasteners for physical attachment of the at least one module unit to another module unit and / or electrical connectors for providing energy supply to each of said module unit.

[0035] In an embodiment, the modular thermal machine further comprises a monitoring system to independently operate each of said modular units.

[0036] In an embodiment, the modular thermal machine further comprises an atmosphere control system for creating and maintaining a controlled atmosphere within each of said at least one module unit.

[0037] In an embodiment, the atmosphere control system of the modular thermal machine is capable of create atmospheres selected from a list consisting of inert, reducing and oxidizing atmospheres.

[0038] It is also disclosed the use of the modular thermal machine in heat treatment, drying, curing and melting processes.

[0039] It is also disclosed a method for customizing an industrial furnace system using the modular thermal machine comprising the steps of: selecting a plurality of module units based on a desired industrial heating process; attaching the plurality of module units using connection means to form a furnace configuration; connecting heating elements within said modular units to a power source; applying insulation around said modular units; and configuring a control system to operate said furnace configuration.

[0040] In an embodiment, the method further comprises the steps of: adjusting the temperature within each of said modular units independently using a temperature control system; creating a controlled atmosphere within each of said modular units using an atmosphere control system.BRIEF DESCRIPTION OF THE DRAWINGS

[0041] The following figures provide preferred embodiments for illustrating the disclosure and should not be seen as limiting the scope of invention. Figure 1: Schematic representation of an embodiment of a module unit of a modular thermal machine. Figure 2: Photographic representation of two module units of a modular thermal machine that are connected to each other. Figure 3: Photographic representation of half of two module units not yet attached to each other. Figure 4: Schematic representation of the implementation of the cooling fan on an embodiment of the modular thermal machine.

[0042] Throughout the figures indicated above, the following elements are indicated with the respective references: 1 - Cooling fan; 2 - Cable mat; 3 - Insulation ceiling; 4 - Radiating tube; 5 - Upper deflector; 6 - Insulation wall; 7 - Pillar; 8 - Lower deflector; 9 - Soil; 10 - Full semi tube for radiant enclosure; 11- Electrical and management board; 12 - Back wall or door; 13 - Transport support pillar; 14 - Air expiration passageway; 15 - Air inspiration passageway; 16 - Wall transport path. DETAILED DESCRIPTION

[0043] The present disclosure relates to a modular thermal machine and their uses.

[0044] The modular thermal machine, now disclosed, comprises at least one control box and at least one module unit, wherein the at least one module unit comprises a support base on which a set of at least four pillars (7) with the same size rests; a heat source; at least one temperature sensor; a back wall or door (12) comprising a cooling fan (1); an insulation ceiling (3); at least three thermally insulated walls (6) placed in relation to the back wall or door (12) in order to circumscribe a certain volume of space; at least one device for distributing indoor air comprising an air speed sensor; wherein the temperature sensor and air speed sensor are connected to said at least one control box to control the cooling fan (1) operation. The insulation ceiling (3) is installed at the top of the machine and has it's own protective layer to ensure heat retention. It is made from the same materials of wall and it ensures also the minimisation of heat loss to the environment.

[0045] In an embodiment, the cooling fan (1) of the modular thermal machine operates in clockwise motion, for better results.

[0046] In an embodiment, the cooling fan (1) of the modular thermal machine operates in counterclockwise motion, for better results.

[0047] In an embodiment, the cooling fan (1) of the modular thermal machine comprises at least one carbon dioxide sensor, for better results.

[0048] In an embodiment, at least one joint of the at least one module unit comprises a coating, for better results.

[0049] In an embodiment, the cooling fan (1) of the modular thermal machine operates at a maximum cooling rate of up to 300 m 3< / h, preferably from 200 m 3< / h to 275 m 3< / h; more preferably from 225 m 3< / h to 275 m 3< / h, for better results.

[0050] In an embodiment, the at least one module unit of the modular thermal machine comprises a security door switch, for better results.

[0051] In an embodiment, the at least one module unit of the modular thermal machine is constructed in a material selected from a list consisting of metallic, composite, stainless steel, refractory metal, ceramic, nickel-based super alloy, carbon and graphite, polymers, and their combinations, for better results.

[0052] In an embodiment, the heat source of the modular thermal machine is selected from a group consisting of induction heating element, electrical resistance heating element, combustion-based heating element, and their combinations, for better results.

[0053] In an embodiment, the heat source of the modular thermal machine comprises an energy supply based on grid power, for better results.

[0054] In an embodiment, the heat source of the modular thermal machine comprises an energy supply based on infrared catalytic panels, for better results.

[0055] In an embodiment, the modular thermal machine further comprises a supply plenum, for better results.

[0056] In an embodiment, the modular thermal machine further comprises a return plenum, for better results.

[0057] In an embodiment, the modular thermal machine further comprises at least one interior light source, for better results.

[0058] In an embodiment, the modular thermal machine further comprises at least one window to the interior of the at least one module unit, for better results.

[0059] In an embodiment, the modular thermal machine further comprises at least one back door (12), for better results.

[0060] In an embodiment, the modular thermal machine further comprises a protection of the cooling fan (1), for better results.

[0061] In an embodiment, the at least one carbon dioxide sensor of the modular thermal machine comprises a material selected from a list consisting of zirconium, tin oxide, zinc oxide, titanium dioxide, polyaniline, polypyrrole, polythiophene, ionic liquid, graphene, carbon nanotube, activated carbon, nanocomposite, metal-organic framework, semiconductor quantum dot, and their combinations, for better results.

[0062] In an embodiment, the at least one module unit of the modular thermal machine further comprises connection means to another module unit, for better results.

[0063] In an embodiment, the connection means of the modular thermal machine comprises mechanical fasteners for physical attachment of the at least one module unit to another module unit and / or electrical connectors for providing energy supply to each of said module unit, for better results.

[0064] In an embodiment, the modular thermal machine further comprises a monitoring system to independently operate each of said modular units, for better results.

[0065] In an embodiment, the modular thermal machine further comprises an atmosphere control system for creating and maintaining a controlled atmosphere within each of said at least one module unit, for better results.

[0066] In an embodiment, the atmosphere control system of the modular thermal machine is capable of create atmospheres selected from a list consisting of inert, reducing and oxidizing atmospheres, for better results.

[0067] It is also disclosed the use of the modular thermal machine in heat treatment, drying, curing and melting processes.

[0068] It is also disclosed a method for customizing an industrial furnace system using the modular thermal machine comprising the steps of: selecting a plurality of module units based on a desired industrial heating process; attaching the plurality of module units using connection means to form a furnace configuration; connecting heating elements within said modular units to a power source; applying insulation around said modular units; and configuring a control system to operate said furnace configuration.

[0069] In an embodiment, the method further comprises the steps of: adjusting the temperature within each of said modular units independently using a temperature control system; creating a controlled atmosphere within each of said modular units using an atmosphere control system, for better results.

[0070] In the basic version, which has been tested, a group of five module units in a configuration 2x3, was equipped with a 75 kW propane / GN burner, controlled modularly system for air and gas via an automaton, leading to low consumption and high efficiency, with losses of less than 5%. In this embodiment, the modular units have been designed to operate at an optimum working temperature of 250°C, but they can reach 320°C. Due to their modular nature, build quality and engineering, the industrial greenhouses are put into production at the customer's site in 4 hours.

[0071] In another embodiment, each module unit can have at least one burner. If we use different heating systems (e.g. resistors, catalytic) we always have the at least one burner installed in the side channel, in the area where the air descends.

[0072] In another embodiment, one burner is applied to each five module units in a configuration 2x3.

[0073] In an embodiment, the modular thermal machine comprises a cable mat (2). Each module can have its own individual cable mat (pathway). It allows cables to be conducted and protected and sufficiently distant from heat.

[0074] In an embodiment, the modular thermal machine comprises at least one radiating tube (4). In any modular thermal machine in which there is heat source, such as a burner, there is the need to ensure a better heat transfer between burned gases and the internal atmosphere, as well as the encapsulation of the flame that allows its path prediction, which is the technical effect of using the radiating tube (4).

[0075] In an embodiment, the modular thermal machine comprises at least one upper deflector (5). In order to ensure air "touches" the heat source, in an embodiment the radiating tube (4), and a better convection with it, a perfect conduction of air is needed. This air conduction is done by the upper deflector (5) that makes air pass through a narrow space neighbour of the radiating tube (4).

[0076] In an embodiment, the modular thermal machine comprises at least one lower deflector (8). The at least one lower deflector (8) ensures a smooth rotation of the air towards the process chamber, minimizing head loss.

[0077] In an embodiment, the modular thermal machine comprises a full semi tube for radiant enclosure (10). This full semi tube for radiant enclosure (10), that works like a "dome", allows air to make a cushion between the radiating tube (4) and the rest of the top of the machine. This ensures that the top zone of the radiating tube (4) is insulated from the rest of the machine, also maintaining heat that allows for energy drops.

[0078] In an embodiment, the modular thermal machine further comprises at least one upper deflector (5) and at least one lower deflector (8), wherein the air speed that passes through the at least one upper deflector (5) and at least one lower deflector (8) is controlled by the air speed sensor that is connected to said at least one control box to control the cooling fan (1) operation.

[0079] In figure 1, it is disclosed a schematic representation of an embodiment of a module unit of a modular thermal machine, where the following elements are illustrated: cooling fan (1), cable mat (2), insulation ceiling (3), radiating tube (4), upper deflector (5), insulation wall (6), pillar (7), lower deflector (8), soil (9).

[0080] In figure 2, it is disclosed a photographic representation of two module units of a modular thermal machine that are connected to each other. In said figure, the transport support pillar (13) is still attached and the middle sections presents the full semi tube for radiant enclosure (10). Back end or door (12) is already in place, as well as the electrical and management board (11).

[0081] In figure 3, it is disclosed a photographic representation of half of two module units not yet attached to each other. In said vision, it is possible to see the atmosphere control system, through the use of one air expiration passageway (14) and one air inspiration passageway (15).

[0082] In figure 4, it is disclosed a schematic representation of the implementation of the cooling fan (1) on an embodiment of the modular thermal machine, with 6 modules per bank. In such embodiment, the total length is 7.4m by 2.4m across and it has a single burner and door allowing treatment of 6m long parts.

[0083] The term "comprising" whenever used in this document is intended to indicate the presence of stated features, integers, steps, components, but not to preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

[0084] The disclosure should not be seen in any way restricted to the embodiments described and a person with ordinary skill in the art will foresee many possibilities to modifications thereof. The above-described embodiments are combinable.

[0085] The following dependent claims further set out particular embodiments of the disclosure.

Claims

1. A modular thermal machine comprising at least one control box and at least one module unit, wherein the at least one module unit comprises: a support base on which a set of at least four pillars with the same size rests; a heat source; at least one temperature sensor; a back wall comprising a cooling fan; an insulation ceiling; at least three thermally insulated walls placed in relation to the back wall in order to circumscribe a certain volume of space; at least one device for distributing indoor air comprising an air speed sensor; wherein the temperature sensor and air speed sensor are connected to said at least one control box to control the cooling fan operation.

2. The modular thermal machine according to the previous claim, wherein the cooling fan operates in clockwise motion.

3. The modular thermal machine according to the previous claim 1, wherein the cooling fan operates in counterclockwise motion.

4. The modular thermal machine according to any of the previous claims, wherein the cooling fan comprises at least one carbon dioxide sensor, preferably operating at a maximum cooling rate of up to 300 m3 / h, preferably from 200 m3 / h to 275 m3 / h; more preferably from 225 m3 / h to 275 m3 / h.

5. The modular thermal machine according to any of the previous claims, wherein at least one joint of the at least one module unit comprises a coating.

6. The modular thermal machine according to any of the previous claims, wherein the at least one module unit comprises a security door switch, preferably wherein the at least one module unit is constructed in a material selected from a list consisting of metallic, composite, stainless steel, refractory metal, ceramic, nickel-based super alloy, carbon and graphite, polymers, and their combinations.

7. The modular thermal machine according to any of the previous claims, wherein the heat source is selected from a group consisting of induction heating element, electrical resistance heating element, combustion-based heating element, and their combinations, preferably wherein the heat source comprises an energy supply based on grid power or on infrared catalytic panels.

8. The modular thermal machine according to any of the previous claims, further comprising at least one window to the interior of the at least one module unit.

9. The modular thermal machine according to any of the previous claims, further comprising a protection of the cooling fan.

10. The modular thermal machine according to any of the previous claims 4 to 9, wherein the at least one carbon dioxide sensor comprises a material selected from a list consisting of zirconium, tin oxide, zinc oxide, titanium dioxide, polyaniline, polypyrrole, polythiophene, ionic liquid, graphene, carbon nanotube, activated carbon, nanocomposite, metal-organic framework, semiconductor quantum dot, and their combinations.

11. The modular thermal machine according to any of the previous claims, wherein the at least one module unit further comprises connection means to another module unit, preferably wherein the connection means comprises mechanical fasteners for physical attachment of the at least one module unit to another module unit and / or electrical connectors for providing energy supply to each of said module unit .

12. The modular thermal machine according to any of the previous claims, further comprising an atmosphere control system for creating and maintaining a controlled atmosphere within each of said at least one module unit, preferably wherein the atmosphere control system is capable of create atmospheres selected from a list consisting of inert, reducing and oxidizing atmospheres.

13. A use of the modular thermal machine described in any of the claims 1 to 12 in heat treatment, drying, curing, melting processes.

14. A method for customizing an industrial furnace system using the modular thermal machine described in any of the previous claims 1 to 12, comprising the steps of: selecting a plurality of module units based on a desired industrial heating process; attaching the plurality of module units using connection means to form a furnace configuration; connecting heating elements within said modular units to a power source; applying insulation around said modular units; and configuring a control system to operate said furnace configuration.

15. The method according to the previous claim, further comprising the steps of: adjusting the temperature within each of said modular units independently using a temperature control system; creating a controlled atmosphere within each of said modular units using an atmosphere control system.

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