Systems and methods for the treatment of carbon dioxide in flue gas

Abstract

Embodiments include a system and method for treating and recovering carbon dioxide from flue gas. An improved system for controlling a flue gas treatment device will be described, in which sensors are used for both the control of a carbon recovery device and the monitoring of the progress of a carbon recovery reaction.

Description

Technical Field

[0001] (Related Application) This application claims priority based on U.S. Provisional Application No. 63 / 344,379, entitled "Systems and Methods for Processing Flue Gas Carbon Dioxide," filed on May 20, 2022 and currently pending. The entire content of U.S. Provisional Application No. 63 / 344,379 is incorporated herein by reference.

[0002] The examples described in this specification relate to systems and methods for controlling and monitoring a flue gas treatment device, and some examples include the treatment and recovery of carbon dioxide. An improved system for controlling and monitoring a flue gas treatment device is described, and sensors are used as part of a system and method for controlling a carbon recovery device and monitoring the progress of a carbon recovery reaction. In the examples of the systems and methods described, an improvement in operating efficiency is achieved.

Background Art

[0003] In the past, systems have been described that react a chemical such as an anhydrous metal hydroxide with carbon dioxide (CO 2 ) from flue gas. For example, a system for reacting flue gas with a metal hydroxide to recover carbon dioxide from the flue gas is described in U.S. Application No. 15 / 928,741, filed on March 22, 2018, entitled "Flue Gas Carbon and Heat Capture and Recirculation System," and issued on January 21, 2020 as U.S. Patent No. 10,537,851 (referred to herein as "Cardiff '851"). The entire content of U.S. Application No. 15 / 928,741 is incorporated herein by reference.

[0004] As described in Cardiff '851, waste flue gas may be obtained from a flue gas source that is a hydrocarbon fuel heating device / apparatus such as a boiler, furnace, or water heater. High-concentration CO 2 A portion of the waste flue gas containing 2 can be introduced into a reactor containing a solid reactant such as an anhydrous metal hydroxide (e.g., sodium hydroxide or potassium hydroxide). In the reactor, CO 2 reacts exothermically with the solid reactant to produce heat, water, and reaction products (e.g., the corresponding carbonate). The heat from the reaction with the flue gas can be recovered for reuse in another system, such as for heating air and / or water for domestic, industrial, or commercial use, and the reaction products are recovered as useful by-products. Further, depleted flue gas with reduced CO 2 emissions from the heating device / apparatus to the atmosphere is also produced. 2

[0005] In a typical flue gas capture system (FGCS), when the anhydrous metal hydroxide is the reactant, the reaction to the corresponding carbonate progresses over time when exposed to the flue gas. This reaction is affected by various operating and environmental factors.

[0006] Improvements to such systems and / or processes are desired. SUMMARY OF THE INVENTION

[0007] An object of the present disclosure is to avoid or mitigate at least one drawback of conventional carbon capture and heat recovery systems.

[0008] In a first aspect, a system is described, the system comprising a flue gas inlet for connection to a flue gas source, a mixing system configured to mechanically agitate a solid reactant within a reactor, a gas outlet, a reactor having a flue gas return system for connection to a flue, a fan configured at the gas outlet for drawing flue gas from the reactor through the reactor to the flue gas return system, the fan being operable at a fan speed, at least one flue gas parameter sensor configured at any one or a combination of the flue gas inlet, the flue gas source or the flue, at least one processor configured with the at least one flue gas parameter sensor and the fan, and a tangible non-transitory computer-readable medium having program instructions executable by the at least one processor such that the system is configured such that when at least one flue gas parameter threshold is exceeded, the processor increases the fan speed, and when the at least one flue gas parameter threshold is not exceeded, the processor decreases the fan speed.

[0009] In some embodiments, the at least one processor activates a standby mode and remains in the standby mode while not exceeding at least one flue gas parameter threshold, and in the standby mode is configured to maintain the fan speed at a base fan speed.

[0010] In some embodiments, the at least one processor is configured to start a cumulative timer and calculate a total cumulative time that at least one flue gas parameter threshold has been exceeded in response to the at least one flue gas parameter threshold being exceeded.

[0011] In some embodiments, the at least one processor is configured to activate an agitation mode in response to the total cumulative time exceeding a cumulative time threshold.

[0012] In some embodiments, the processor is configured to reset the cumulative timer to zero in response to activation of the agitation mode.

[0013] In some embodiments, at least one processor is configured to start a stirring mode timer and activate the mixing system in response to activation of the stirring mode.

[0014] In some embodiments, at least one processor is configured to stop the fan in response to activation of the stirring mode.

[0015] In some embodiments, at least one processor is configured to stop the stirring system in response to the stirring mode timer exceeding a stirring mode time threshold.

[0016] In some embodiments, at least one processor is configured to stop the stirring system and operate the fan at a base speed in response to the stirring mode timer exceeding a stirring mode time threshold.

[0017] In some embodiments, at least one processor is configured to stop the stirring system and operate the fan at a base speed after a delay time in response to the stirring mode timer exceeding a stirring mode time threshold.

[0018] In some embodiments, at least one processor is configured to activate a reaction management mode in response to the total cumulative time not exceeding a cumulative time threshold.

[0019] In some embodiments, the system further comprises at least one reaction parameter sensor configured in a reactor, and at least one processor is configured to determine whether at least one reaction parameter has been exceeded in response to activation of the reaction management mode, and increase the fan speed if exceeded.

[0020] In some embodiments, at least one processor is configured to determine whether at least one reaction parameter has been exceeded in response to activation of the reaction management mode, and if not exceeded, reduce the fan speed.

[0021] In some embodiments, at least one flue gas parameter sensor includes a temperature sensor.

[0022] In some embodiments, at least one flue gas parameter sensor includes a carbon dioxide concentration sensor.

[0023] In some embodiments, at least one reaction parameter sensor includes a humidity sensor.

[0024] In some embodiments, the processor is configured to control the fan speed based on a linear correlation to the absolute humidity measurement between a low humidity threshold and a high humidity threshold, where a low fan speed correlates with a low absolute humidity measurement.

[0025] In some embodiments, the processor is configured to control the fan speed based on a non - linear correlation to the absolute humidity measurement between a low humidity threshold and a high humidity threshold, such that as the absolute humidity measurement increases, the fan speed proportionally increases.

[0026] In some embodiments, at least one reaction parameter sensor includes a viscosity sensor.

[0027] In some embodiments, at least one processor starts a standby timer in standby mode and is configured to enter the stirring mode when the standby timer threshold is exceeded.

[0028] In some embodiments, the system further includes at least one network interface configured in at least one processor, and the at least one network interface and the at least one processor are configured to report sensor data to a central computer system via at least one network and receive instructions from the central computer system.

[0029] In some embodiments, the system further comprises an image acquisition system configured in at least one processor for acquiring image data of the system.

[0030] In some embodiments, the system further comprises a sound acquisition system configured in at least one processor for acquiring sound data of the system.

[0031] In some embodiments, the system further comprises a movement acquisition system configured in at least one processor for acquiring movement data of the system.

[0032] In some embodiments, the system further comprises a user interface configured in at least one processor for displaying system data to the user and enabling the user to input data.

[0033] In another aspect, a method for controlling a flue gas recovery system is described. The method includes, in a flue gas recovery system having at least one processor operable in a standby mode, a tangible non-transitory computer-readable medium having program instructions executable by the at least one processor, a mixing system, a fan, and at least one flue gas parameter sensor configured in a flue gas source, the steps of increasing the fan speed in response to exceeding at least one flue gas parameter threshold and decreasing the fan speed in response to not exceeding at least one flue gas parameter threshold.

[0034] In some embodiments, the method further includes maintaining a base fan speed when at least one processor is operating in standby mode.

[0035] In some embodiments, when at least one flue gas parameter exceeds a threshold, the method further includes starting a cumulative timer and calculating a total cumulative time that at least one flue gas parameter has exceeded the threshold.

[0036] In some embodiments, in response to the total cumulative time exceeding a cumulative time threshold, the method further includes activating a stirring mode.

[0037] In some embodiments, in response to activating the stirring mode, the method further includes resetting the cumulative timer to zero.

[0038] In some embodiments, in response to activating the stirring mode, the method further includes starting a stirring mode timer and activating a mixing system.

[0039] In some embodiments, in response to activating the stirring mode, the method further includes stopping the fan.

[0040] In some embodiments, in response to the stirring mode timer exceeding a stirring mode time threshold, the method further includes stopping the stirring system.

[0041] In some embodiments, in response to the stirring mode timer exceeding a stirring mode time threshold, the method further includes stopping the stirring system and operating the fan at a base speed.

[0042] In some embodiments, in response to the stirring mode timer exceeding a stirring mode time threshold, the method further includes stopping the stirring system and operating the fan at a base speed after a delay time.

[0043] In some embodiments, in response to the total cumulative time not exceeding a cumulative time threshold, the method further includes the step of activating a reaction management mode.

[0044] In some embodiments, the flue gas recovery system further includes at least one reaction parameter sensor configured in the reactor, and in response to the activation of the reaction management mode, the method further includes the step of increasing the fan speed when at least one reaction parameter is exceeded.

[0045] In some embodiments, in response to the activation of the reaction management mode, the method further includes the steps of determining whether at least one reaction parameter is exceeded and decreasing the fan speed if not exceeded.

[0046] In some embodiments, at least one flue gas parameter sensor includes a temperature sensor, and the method further includes the step of monitoring the temperature of the flue gas.

[0047] In some embodiments, at least one flue gas parameter sensor includes a carbon dioxide concentration sensor, and the method further includes the step of monitoring the concentration of carbon dioxide in the flue gas.

[0048] In some embodiments, at least one reaction parameter sensor includes a humidity sensor, and the method further includes the step of monitoring the humidity of the flue gas.

[0049] In some embodiments, at least one reaction parameter sensor includes a viscosity sensor, and the method further includes the step of monitoring the viscosity of the reactant.

[0050] In some embodiments, the processor is configured to start a standby timer in standby mode, and when the threshold of the standby timer is exceeded, the method further includes the step of entering a stirring mode.

[0051] In another aspect, a system is described, the system comprising: (a) a reaction chamber including a gas inlet coupled to a gas source and a gas outlet; a sensor coupled to the gas source; a fan coupled to the gas outlet, the fan being operable at at least a first fan speed and a second fan speed, the second fan speed being greater than the first fan speed; at least one processor; and a tangible non-transitory computer-readable medium having program instructions executable by the at least one processor to receive, via the sensor, a parameter signal indicative of a parameter corresponding to the gas source when operating at the first fan speed, determine whether the parameter corresponding to the gas source exceeds a parameter threshold level based on the received parameter signal, and cause the fan to transition from operating at the first fan speed to operating at the second fan speed based on a determination that the parameter exceeds the parameter threshold level.

[0052] In one embodiment, the sensor is a first sensor, the system further comprising a second sensor, and the program instructions executable by the at least one processor include receiving, via the second sensor, a humidity signal indicative of a humidity level corresponding to the reaction chamber when the fan is operating at the second fan speed, determining whether the humidity level corresponding to the reaction chamber exceeds a humidity threshold level based on the received humidity signal, and causing the fan to transition from operating at the second fan speed to operating at a third fan speed based on a determination that the humidity level exceeds the humidity threshold level, the third fan speed being greater than the second fan speed.

[0053] In one embodiment, the humidity signal is a first humidity signal, and program instructions executable by at least one processor are to receive a second humidity signal via a second sensor when the fan is operating at a third fan speed, determine whether the humidity level corresponding to the reaction chamber is lower than a humidity threshold level based on the received second humidity signal, and cause the fan to shift from operating at the third fan speed to operating at a fourth fan speed based on the determination that the humidity level is lower than the humidity threshold level, the fourth fan speed being less than the third fan speed, and the system having further program instructions executable by at least one processor so as to be configured as such.

[0054] In one embodiment, the fourth fan speed is the same as the second fan speed.

[0055] In one embodiment, the system further includes a stirring system, and the program instructions executable by at least one processor further include program instructions executable by at least one processor so that after shifting the fan from operating at a first fan speed to operating at a second fan speed, the system is further configured to (a) stop the fan and (b) start the stirring system.

[0056] In one embodiment, starting the stirring system includes starting at least one motor of the stirring system, the at least one motor being configured to drive at least one stirring paddle.

[0057] In one embodiment, the program instructions executable by at least one processor further include program instructions executable by at least one processor so that the system is configured to determine whether an elapsed cumulative operation time has passed after shifting the fan from operating at a first fan speed to operating at a second fan speed and determine that the determined cumulative operation time is greater than a cumulative operation time threshold before stopping the fan and starting the stirring system.

[0058] In one embodiment, program instructions executable by at least one processor further include program instructions executable by at least one processor such that the system is configured to stop the fan, start the agitation system, and after starting the agitation system, determine whether a cumulative agitation time has elapsed, determine whether the determined cumulative agitation time is greater than a cumulative agitation time threshold, and after determining whether the determined cumulative agitation time is greater than the cumulative agitation time threshold, stop the operation of the agitation system.

[0059] In one embodiment, the sensor is a first sensor, the system further includes a second sensor, and program instructions executable by at least one processor further include program instructions executable by at least one processor such that the system is configured to receive, via the second sensor, a humidity signal indicating a humidity level corresponding to the reaction chamber before determining that a parameter corresponding to the gas source exceeds a parameter threshold level, determine based on the received humidity signal that the humidity level corresponding to the reaction chamber exceeds a humidity threshold level, and based on determining that the humidity level exceeds the humidity threshold level, shift the fan from operating at a first fan speed to operating at a second fan speed, where the second fan speed is greater than the first fan speed.

[0060] In one embodiment, the system further includes at least one network interface, and program instructions executable by at least one processor further include program instructions executable by at least one processor such that the system is configured to receive an indication of the first fan speed via the network interface through at least one wide area network (WAN) before the fan operates at the first fan speed.

[0061] In one embodiment, the system further includes at least one user interface, and program instructions executable by at least one processor further include program instructions executable by at least one processor so that the system is further configured to receive an indication of the first fan speed via the at least one user interface before the fan operates at the first fan speed.

[0062] In one embodiment, the system further includes at least one network interface, and program instructions executable by at least one processor further include program instructions executable by at least one processor so that the system is configured to transmit an indication of the first fan speed to the computing system via the network interface through at least one wide area network (WAN) while the fan operates at the first fan speed.

[0063] In one embodiment, the system further includes at least one network interface, and program instructions executable by at least one processor further include program instructions executable by at least one processor so that the system is further configured to transmit an indication of the second fan speed to the computing system via the network interface through at least one WAN after the fan transitions from operating at the first fan speed to operating at the second fan speed.

[0064] In one embodiment, it further includes at least one network interface, and the program instructions executable by at least one processor further include program instructions executable by at least one processor such that after receiving a parameter signal indicating a parameter corresponding to a gas source, the system is further configured to transmit an indication of the parameter corresponding to the gas source to a computing system via the network interface through at least one wide area network (WAN).

[0065] In one embodiment, the sensor comprises a temperature sensor, and the parameter corresponding to the gas source includes the temperature corresponding to the gas source.

[0066] In one embodiment, the sensor connected to the gas source includes a sensor connected to at least one of (A) a flue gas source facility, (B) a flue, and (C) a bypass flue.

[0067] Various objectives, features, and advantages will become apparent from the following description of specific embodiments as shown in the accompanying drawings. The drawings are not necessarily to scale and emphasis is placed on explaining the principles of the various embodiments. Like reference numerals indicate like components.

Brief Description of the Drawings

[0068]

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[0069] (Overview) There is a need for systems and methods to improve the operation of a flue gas capture system (FGCS).

[0070] As described herein, various operating and environmental variables can affect the efficiency and / or overall progress of reactions within the FGCS. Therefore, it is desirable to design the FGCS and / or its monitoring / control system such that those variables are managed in a way that improves the overall efficiency of the operation of the FGCS, including the recovery of carbon dioxide from flue gas, the heat recovered from the FGCS, and the quality of the products obtained from the FGCS.

[0071] One consideration related to the operation of the FGCS is that it is desirable for the FGCS to operate without affecting the operation of the flue gas source equipment (e.g., boilers and furnaces).

[0072] Another consideration is the quality of the product obtained from the FGCS, including the viscosity and water content of the product.

[0073] In view of the above, another consideration is that the operation timing of the flue gas source facility is intermittent, and as a result, the supply of flue gas to the FGCS becomes intermittent, which may directly affect the conditions inside the FGCS device that can potentially affect reaction kinetics, the viscosity of the reactants, and thus the quality of the reaction products. That is, the irregular (i.e., on / off or variable heating) operation of the connected flue gas source facility means large temporal variations in temperature, pressure, flow rate, and carbon dioxide concentration. It is desirable that some or each of these variables be directly or indirectly monitored and that the FGCS device respond to changes in these variables so that the reaction and the overall process are carried out efficiently, problems are reduced, and the reaction can reliably produce high-quality products.

[0074] The FGCS described in Cardiff '851 is effective, but as mentioned above, the operation of the FGCS depends on the source facility, and its intermittent operation may cause various operational problems in the operation and control of the FGCS device for obtaining high-quality products. Ultimately, variations in flue gas parameters, including any or all of temperature, pressure, heat, flow rate, and carbon dioxide concentration of the flue gas, can lead to various operational inefficiencies, including low-quality products (e.g., lumpy carbonates) and / or the need for personnel involvement to ensure continuous operation of the FGCS.

[0075] Considering such variations, there is a problem that the degree and / or state of the reaction between the flue gas and the solid reactant during the operation of the FGCS are not accurately grasped or explained. Other environmental variables, including ambient humidity, may also affect the reaction.

[0076] That is, when the power supply of the flue gas source facility is turned on or off, the conversion reaction between the flue gas and the solid reactant similarly starts or stops (and the rate increases or decreases) based on the availability of the flue gas, resulting in fluctuations in the physical state of the reactant at different times. Specifically, water is generated by the reaction of the anhydrous metal hydroxide and CO 2 and the water generated binds to the solid reactant within the FGCS. During the reaction process, initially the solid anhydrous metal hydroxide changes to a viscous semi-solid / liquid aqueous mixture and then may change to a complete liquid, returning to a dry solid carbonate when the reaction is complete. Such fluctuations in the reaction state and / or other conditions related to the reaction may be referred to as reaction parameters. The reaction parameters may directly or indirectly measure the conditions within the reactor and provide an indication of the state / status of a particular reaction at a particular point in time. For example, the direct measurement may be the measurement of the viscosity of the reactant and / or the temperature of the reactant, and an example of an indirect measurement may be the measurement of the humidity within the reaction chamber.

[0077] When the viscosity of the reactant changes, it may affect the reaction rate and the handling of the material. For example, the viscous intermediate mixture reduces the surface area available for contact with the flue gas, resulting in a slower reaction. Further, the handling of the viscous mixture is also difficult. Additionally, if not properly managed, the viscous mixture may dry out when exposed to heat, forming a solid block within the reactor, ruining a given batch, posing a risk of significant damage to the FGCS, and / or requiring a great deal of human effort to remove.

[0078] To address the issues of surface area and handling, it is desirable to stir the mixture. However, when the reactants are in fine powder form, stirring can cause excessive reactants to float in the air, leading to an undesirable possibility that a certain amount of reactants will be lost as the reaction progresses. As a result, the reactants may move into the flue gas flow path in the reactor, flow out of the reactor into the main flue together with the flue gas, and be released into the atmosphere. Although various filters can be incorporated into the FGCS, the filters are prone to clogging and may have an undesirable impact on the operation of the flue gas source facility and / or the FGCS. Therefore, there is a need for a system that can minimize reactant loss and filter clogging while coping with irregular operation of the source facility.

[0079] Other issues include ensuring that the operation of the FGCS does not adversely affect the operation of the source facility, and operating the FGCS only under conditions that do not affect the operation of the source equipment.

[0080] Specifically, there is a need for a system and a processing method in which flue gas parameters such as the temperature of the flue gas from the source facility are monitored to guide the flue gas to the FGCS when favorable conditions such as temperature and CO 2 concentration are available for the operation of the FGCS. For example, it may be desirable to operate the FGCS when the source facility is on and generating CO 2 and / or when the temperature of the flue gas in the flue exceeds the threshold temperature. Additionally, it should be noted that the flue gas temperature can serve as a substitute for a sufficient CO 2 concentration and the heat available for moisture management. There may also be cases where it is desirable to manage heat (e.g., reaction heat) within the FGCS to optimize the recovered heat from the associated heat exchanger.

[0081] Another problem is to manage reaction parameters such as moisture / humidity / viscosity within the FGCS, for example, to operate the FGCS to maintain favorable moisture / humidity conditions. As described above, the viscosity of the solid reactant can change during the operation of the FGCS as a result of heat from the flue gas, heat generated from the reaction, and water, which can also cause a change in humidity within the FGCS. For example, in the case of reaction conditions where the reactants within the FGCS become "wet" and the viscosity of the reactants changes to a viscous liquid, it is desirable to remove moisture from the FGCS to convert the liquid reactants into dry powder. Therefore, there is a need for a system and method in which reaction parameters such as moisture / humidity / viscosity within the FGCS are monitored as inputs for controlling the operation of the FGCS in order to manage the viscosity of the solid reactant, the progress of the reaction, the processing of the reactants, and the handling within the FGCS, and desirably, to manage the quality of the product.

[0082] [FGCS, Source Equipment and Operation] In the drawings, the same reference numbers generally indicate similar and / or identical elements. To facilitate the description of specific elements, the most significant digit of the reference number refers to the figure in which that element first appears. For example, element 100 is first introduced and described with reference to FIG. 1, and element 200 is first introduced and described with reference to FIG. 2.

[0083] Many of the details, dimensions, angles, and other features shown in the figures are merely illustrative of specific embodiments or examples of the disclosed technology. Accordingly, other embodiments may have other components, details, dimensions, angles, and features without departing from the spirit or scope of the present disclosure. Additionally, those skilled in the art will understand that further embodiments of the various disclosed technologies can be implemented by combining and / or arranging the described components or details in other manners or orders, using additional components or details, and / or without using some of the components and / or details described below.

[0084] FIG. 1 shows an example of an operating environment that includes an exemplary FGCS 100 connected to a flue gas source facility 104 (also referred to herein as the "source facility"). Although FIG. 1 shows a representative operating environment, it should be understood that the described aspects of the operating environment, including other details of the environment in which the source facility and / or FGCS operate, may vary widely.

[0085] For example, the flue gas source facility 104 may have wide variations in various parameters, such as maximum and average heat output, flue gas flow rate under different operating conditions, large variations in the cycle time during which the device is operated and / or the time between cycles, and the associated flue size, height, and flow rate.

[0086] The FGCS may be configured to operate with various categories of flue gas source facilities, including non-condensing gas combustion equipment such as Category 1 or Category 3. Category 1 equipment can be defined as equipment that operates with a non-positive vent static pressure and a vent gas temperature such that excessive condensation in the vent is avoided. Category 3 equipment can be defined as equipment that operates with a positive vent static pressure and a vent gas temperature such that excessive condensation in the vent is avoided. The FGCS can also accommodate other categories of gas combustion equipment, such as cogeneration or combined heat and power systems, or gas combustion equipment operating under non-condensing conditions. As an example, the FGCS may be used with equipment having a vent with a minimum of 4 inches and a pressure differential in the vent system that is not affected by more than 0.02 inches of water column.

[0087] The environment, building, and / or machinery room in which the source facility is configured and / or installed may have a wide range of environmental parameters that can affect the operation of the source facility, such as temperature range and humidity range. Such conditions can also vary by season.

[0088] Furthermore, the size and capacity of the FGCS 100 may likely vary based on the operating parameters of the source facility and the environmental parameters described herein.

[0089] Referring to FIG. 1, an FGCS 100, a flue gas source facility 104, a flue 106, a flue gas bypass system 108, and a flue gas recovery system 109 are shown. Each is depicted as consisting of a plurality of components, as shown by the dotted lines for purposes of schematic illustration. It is understood that the illustrated components of each system may be modified as described herein and understood by those skilled in the art.

[0090] The FGCS 100 reacts flue gas consisting of CO 2 , heat and steam with a metal hydroxide in a reactor 102 connected to a flue gas source facility 104. The flue gas source facility 104 may be, for example, a furnace or a water heater / boiler having a burner that burns natural gas (among other possible examples) to generate heat for heating air or water. Combustion products from the source facility are conveyed from the source facility via the flue 106 and exhausted (e.g., to the atmosphere 104c). As similarly described in Cardiff ’851, which is incorporated herein by reference (see, for example, FIGS. 1 and 4 of Cardiff ’851 and the corresponding descriptions), the FGCS 100 is configured in the flue 106 via a bypass flue 108 that allows at least a portion 110 of the flue gas from the source facility to be diverted from the flue 106 and enter the FGCS 100. Flue gas from the FGCS 100 is returned to the flue 106 via a downstream flue gas recovery system 109.

[0091] The source facility 104 may include, for example, a flue gas source 104a (e.g., a gas fuel burner) and a draft hood 104e connected to the source facility 104. The draft hood 104e introduces additional air 104b into the flue 106 to promote a desired draft within the flue 106.

[0092] As a selected example and as depicted in FIG. 1, the FGCS100 may include a number of components including a reactor 102 for containing a solid reactant 102a, a stirring system 102b having one or more stirring paddles 102c, a motor drive unit 102d operable to drive the stirring paddle 102c, a filter 102e, a heat exchanger system 120, and a fan 102g.

[0093] The heat exchanger system 120 may include a gas / liquid heat exchanger 120a (e.g., a shell and tube heat exchanger) having an associated cold water supply 120b, a pump P1, and a hot water output 120c.

[0094] A further depiction of an exemplary FGCS201 is shown in FIG. 2. The FGCS201 can generally be understood to be similar and / or the same as the FGCS100 shown in FIG. 1, although different or similar respective aspects are explicitly depicted in each representation. Thus, FIG. 2 depicts some of the components shown in relation to FIG. 1, as well as additional exemplary components of an exemplary FGCS, as part of a representative schematic of the FGCS201.

[0095] [Reactor] As shown in FIG. 2, the FGCS201 includes a reactor 202 having a stirring system 202b, stirring paddles 202c, and one or more motor drive units 202d, a filter 202e, a heat exchanger system 202f, a fan 202g, and a connector 202h for attaching the FGCS to other components and / or devices such as source equipment.

[0096] [Electronic Equipment] The FGCS201 may include additional and / or alternative components including an electronic device 200 including a processor 200a, a memory 200b, software components 200c, a network interface 200d (e.g., a wireless interface 200d1 and / or a wired interface 200d2), and other components 200e.

[0097] Among the candidates for sources of other signals, the electronic device 200 can be configured to receive signals from the user interfaces 202, 202a and / or the sensor 204, process those signals, and ultimately control the FGCS 201 including any of the individual components. The electronic device 200 and the related sensor 204 may be collectively referred to as a monitoring system herein. In some examples, such a monitoring system may include components in addition to the electronic device 200 and the sensor 204.

[0098] In one example, the electronic device 200 optionally includes one or more other devices 200e (e.g., a power supply, one or more sensors (in addition to the sensor 204), a video display, a touch screen, etc.).

[0099] [Processor] The processor 200a may have a clock-driven computing device configured to process data, and the memory 200b may have a computer-readable medium (e.g., a tangible non-transitory computer-readable medium, a data storage carrying one or more software components 200c) configured to store instructions for performing various operations and / or functions. The processor 200a is configured to execute instructions stored on the memory 200b to perform one or more operations. The operations may include causing the FGCS to transition between various operating modes such as, for example, "off", "on", and / or "standby" and other modes. Such operations may include causing a change in the speed of the fan 202g based on one or more signals received from one or more sensors 204. There are also other examples of such operations, some of which will be described below.

[0100] [Memory] In one example, the memory 200b is further configured to store data related to the FGCS 201, such as various operating characteristics such as device version information, installation location, and / or other information regarding the broader operating environment in which it is installed. The stored data may be updated periodically and may include one or more state variables used to describe the state of the FGCS 201. The memory 200b may include data related to the state of one or more other devices (e.g., the flue gas source facility 104 shown in FIG. 1) and / or other data regarding the operating environment (e.g., temperature, (predicted or current) weather data, etc.). Data regarding the state of other devices may be received, for example, via one or more sensors 204 and / or one or more network interfaces 200d.

[0101] [Software Component] The electronic device may be configured with operating software stored in the memory 200b and executable by the processor 200a to perform the operation of the FGCS 201 in the various operating modes described herein.

[0102] [Communication / Network Interface] In one embodiment, the FGCS 201 has one or more network interfaces 200d. The network interface 200d is generally configured to facilitate the transmission and reception of data between the FGCS 201 and one or more other devices on a data network, such as, for example, a local area network (LAN) and / or a wide area network (WAN) or other examples of networks.

[0103] In one example, network interface 200d is configured to transmit and receive data corresponding to a signal (e.g., a non-transitory signal) having digital packet data including a source address based on the Internet Protocol (IP) and / or a destination address based on IP. Network interface 200d may analyze the digital packet data so that the electronic device of the FGCS correctly receives and processes the data addressed to FGCS201.

[0104] Network interface 200d may have one or more wireless interfaces 200d1. Such a wireless interface (e.g., a suitable interface having one or more antennas) may be configured to wirelessly communicate with one or more devices (e.g., device 202a) communicatively coupled via a network in accordance with a suitable wireless communication protocol (e.g., NFC, WiFi, Bluetooth®, Wireless Direct, other proprietary wireless protocols, LTE, or any wireless standard corresponding to, for example, IEEE 802.11a, 802.11b, 802.11c, 802.11g, 802.11n, 802.11ac, 802.15, 4G cellular communication standards, and / or other network systems and protocols that enable one-way or two-way communication with a central computer system). In certain embodiments, network interface 200d includes a wired interface 200d2 (e.g., an interface or receptacle configured to receive a network cable such as Ethernet, USB-A, USB-C, and / or Thunderbolt cable) configured to communicate with other devices through a wired connection in accordance with a suitable wired communication protocol. In a particular embodiment, network interface 200d includes a wired interface and does not include a wireless interface. In one example, FGCS201 does not include network interface 200d as a whole and transmits and receives media content and / or other data via other communication paths.

[0105] [User Interface] In various embodiments, the user interfaces 202, 202a can include one or more buttons, knobs, dials, touch-sensitive surfaces, displays, and / or touchscreens that enable a user to interface with the FGCS 201 via a wired or wireless connection and / or via one or more computer systems within a connected computer network. User interaction via the interfaces 202, 202a can provide input control data to the FGCS for, e.g., test runs, maintenance, reporting, control, etc., and / or to receive / send data between one or more computer systems (e.g., a central computer system) as described herein.

[0106] [Sensor] The FGCS 201 may include sensors 204 such as, for example, temperature 204a, pressure 204b, humidity 204c, concentration 204d, image capture 204e (e.g., a camera), sound 204f (e.g., a microphone), motion 204g (e.g., an accelerometer), viscosity 204h, and other sensors 204i. The sensors may be applied at different locations on the FGCS, source equipment, connectors, and / or other locations.

[0107] For example, various sensors and sensor pairs may be configured on the FGCS to enable operation of the FGCS as described herein and to obtain data for a monitoring system for control of the FGCS.

[0108] As shown in FIG. 1, the various sensors may include any one or more (or all) of the following. ·One or more humidity sensors, for example, humidity sensor H2 configured in the flue bypass 108 to measure the humidity of flue gas at the outlet of the source facility. H2 is coupled / comparison with humidity sensor H1 to provide a humidity difference measurement, which may be beneficial for improving the control of the system, especially when the system operates in a high humidity environment and the air in the draft hood is humid. FGCS may further include H3 outside the device to measure the ambient humidity. ·One or more pressure sensors and pressure sensor pairs. The pressure sensors may be configured at various locations to measure the absolute pressure or pressure difference across various regions of the system. For example, the pressure sensor pair may be arranged across a fan (e.g., ΔP1), a filter (e.g., ΔP2), and / or the entire bypass pipe (e.g., ΔP3). ·One or more temperature sensors and temperature sensor pairs. The temperature sensors may be configured to cross a heat exchanger (e.g., T3 and T4) to control the flow of cold water to the pump P1 and the heat exchanger. Temperature sensor T2 may be configured to exit from the pipe near the fan and may be paired with T1 to measure the temperature difference across the FGCS during operation. ·The carbon dioxide sensor (e.g., "Concentration" 204d or "Other" 204i in FIG. 2) may be configured to determine, for example, for the flue and / or flue bypass, when to activate the FGCS and increase the flow rate of carbon dioxide to the FGCS. ·The motor power (e.g., current and / or voltage) sensor 204h may be configured in the stirring system to monitor the relative viscosity of the reactants. For example, as the reaction progresses and the viscosity of the reactants increases, more power is required by the motor to stir the viscous mixture in the chamber. Similarly, when the reactants dry out and become "used", the viscosity decreases and the power required to maintain a constant stirring speed decreases.

[0109] The sensor 204 is connected to the processor 200a via a suitable connection, which may be wired or wireless.

[0110] The threshold parameters for each sensor or set of sensors may be pre-set by the manufacturer, may be set based on normal operating conditions at a specific installation location, may be set values manually entered by the installer, or may be input values from other sensors and / or via a connected computer system. Some of the thresholds described herein may be determined by the difference between two similar sensors (e.g., temperature difference or pressure difference) or a combination of two different sensors (e.g., temperature measurement in conjunction with pressure measurement). Alternatively, when the threshold parameter is set for a single sensor, the threshold of the sensor described herein may be determined based on the value (or other such signal) indicated by that single sensor at any given time.

[0111] In various embodiments, as described below, data collected from various sensors can be transmitted to a central computer system via the cloud / Internet (e.g., as described below in connection with FIG. 3) for monitoring and / or analysis, and may have set values adjustable by the central system.

[0112] As an example, a negative temperature coefficient (NTC) thermistor is implemented as a temperature sensor. An NTC thermistor is a resistor with a negative temperature coefficient, and its resistance value decreases as the temperature rises. It may also be used as a resistance temperature sensor or a current limiting device. The temperature sensitivity coefficient is about 5 times that of a silicon temperature sensor (silisitor) and about 10 times that of a resistance temperature detector (RTD). The NTC sensor may be used in the range of -55 to +200 °C.

[0113] Other sensors may be configured in an FGCS including any one or more (or all) of them. · A sound (e.g., microphone) 204f monitors sound, such as fluctuations in a movable part. For example, active listening for changes in the operating volume of the FGCS can be used to remotely diagnose maintenance problems such as failures in various subsystems including fans, motor bearings, or other subsystems, and / or to confirm that correct maintenance has been completed. · It is a movement (e.g., accelerometer) 204g for monitoring the movement during the operation of the FGCS. For example, changes in vibration may be utilized to remotely diagnose maintenance problems as described above. · An image (e.g., camera) 204e for visually checking / inspecting the system may be used, for example, for remote diagnosis of problems.

[0114] Furthermore, each of the above may be used to confirm that correct maintenance has been completed.

[0115] [Examples of Networks / Communications] In one embodiment, as shown in FIG. 3, the FGCS 300 is depicted within a communication network (e.g., WAN 308 and / or LAN 306).

[0116] In various embodiments, the FGCS 300 may communicate with a central computer system (CCS) 310 using one or more of various communication systems and protocols.

[0117] As shown in FIG. 3, the FGCS includes user interfaces 302, 302a including a wired interface 304a and a wireless interface 304b, and a network interface 304. The user interface 302, when directly configured to the FGCS, may be an appropriate combination of a display, a dial, a knob, etc. that enables a technician / user to view data from the FGCS and / or input data into the FGCS. The user interface 302a may be a stand-alone electronic device such as a laptop, a tablet, a smartphone, etc. configured to communicate with the FGCS via a network interface through appropriate application software executed on the electronic device.

[0118] The central computer system 310 may include a cloud-based data processing center and / or an independent computer system 312 (e.g., subscribers) for receiving and analyzing system data. The communication system may be one-way from each FGCS to the central system, one-way to each individual FGCS, or a two-way system. The connection system may change over time.

[0119] The interfaces 302, 302a may be connected to the FGCS 300 via the wired interface 304a or the wireless interface 304b, enabling a technician to interface with the FGCS for various purposes and / or functions including, for example, system installation, commissioning, and maintenance. Depending on the specific configuration, the technician may execute installation, commissioning, and maintenance procedures through the user interfaces 302, 302a.

[0120] [Exemplary Processor] FIG. 4 shows a representative embodiment of an FGCS processor 400 that may be configured to receive inputs from one or more sensors attached to an FGCS (and elsewhere) as described herein and to control the operation of the FGCS. As shown in FIG. 4 and as described herein, representative sensors may include one or more humidity measurement signals (e.g., H1, H2, H3), temperature signals (e.g., T1-T4), pressure signals (e.g., ΔP1, ΔP2, ΔP3), pump signals (e.g., P1), and motor signals (e.g., M1 including on / off, voltage, amperage). The sensors may be configured as individual sensors and / or sensor pairs connected to different regions of the source gas device 104, flue 106, flue bypass 108, heat exchanger system 120, flue gas return 109, and FGCS 100.

[0121] [Reaction Examples in the Reactor] As introduced above, for example, waste flue gas from a hydrocarbon fuel heating device such as a boiler, furnace, or water heater can be introduced into the reactor of the FGCS containing the anhydrous metal hydroxide, and CO 2 reacts in an exothermic reaction to produce heat and carbonate. The anhydrous metal hydroxide in the reactor may be one or more of, for example, potassium hydroxide, sodium hydroxide, calcium hydroxide, and magnesium hydroxide.

[0122] Examples of exothermic chemical reactions in the reactor 102 are as follows. Anhydrous metal hydroxide + CO 2 → H 2 O + Carbonate + Heat EQ(1) During operation, the flue gas exits the reactor 102 as treated flue gas, passes through the filter 102e, passes through the heat exchanger 120a, and heat is recovered for other uses. The system includes a fan 102g for drawing the flue gas into the reactor 102, passing it through the reactor 102, and returning the treated flue gas to the flue 106.

[0123] [Installation Example and Establishment of Basic Flow Rate] Returning to FIG. 1, the FGCS 100 may be operated adjacent to a source facility 104 having a main function (e.g., heating air or water within a building). The installation of the FGCS 100 generally is required to substantially not interfere with the normal operation of the source facility 104 when the FGCS 100 is configured, and in particular, to have substantially minimal (or no) impact on the flow of flue gas from the flue 106.

[0124] Connecting an FGCS that diverts a portion of the flue gas away from the main flue results in a decrease in both the amount of flue gas and heat within the main flue. Further, the change in direction results in a flow restriction that increases the resistance to flow. As a result, the installation is required to establish a connection and basic operating conditions that do not substantially affect the operation of the flue 106, whether or not the source facility is operating and whether or not the FGCS is operating.

[0125] As an example, the furnace may have a 50-foot vertical flue. The hot flue gas generated during operation of the furnace, along with additional ambient air 104b drawn into the flue through the configured draft hood 104e (e.g., air drawn into the flue 106 through the draft hood 104e), rises within the flue 106 at a rate that varies depending on the output of the furnace at a given time. If a portion of the flue gas is drawn out of the flue, there may not be enough heat in the remaining portion of the flue gas to induce sufficient draft in the flue. That is, since the flue gas cools within the 50-foot flue, there may be insufficient flow within the flue.

[0126] Therefore, for two main reasons: a) to minimize the impact of the FGCS on the operation of the flue, and b) to minimize the curing of reactants under certain environmental conditions, it is desirable to have at least a certain basic level of air movement through the FGCS most of the time. For example, in relation to the latter, ambient air contains a certain amount of moisture, ranging from dry ambient air (such as in cold regions) to humid ambient air (such as in warm regions). If constantly exposed to static ambient air under various environmental conditions, the reactants may cure depending on the moisture content of the ambient air. In some situations, continuously or substantially continuously moving ambient air through the reactor can help mitigate this undesirable result.

[0127] For example, a basic flow rate of air (e.g., 80 - 160 cubic feet per minute (cfm)) may be established through the FGCS so that flue performance is not affected under all operating conditions of the furnace and FGCS. To determine the basic flow rate, various operating and environmental parameters of the source equipment are considered, such as the outside air temperature adjacent to the flue, the design cooling day, the height of the flue, the flue temperature, and the flue draft pressure during system operation and non - operation.

[0128] Installation can consider factors such as the available space adjacent to the flue gas source equipment, such as the space in the machinery room that enables the installation of the FGCS, access to the machinery room via access from outside the building, the requirements for the correct gas combustion rating plate, and an appropriate ventilation system.

[0129] Typically, the technician or installer in charge of installation must first measure the flue vent rated pressure at least 12 inches downstream of the source equipment and ensure that the pressure difference does not adversely affect the operation of the source equipment before FGCS installation and does not adversely affect the temperature of the flue gas before installation.

[0130] The installation example may include the following procedures. a) Test the draw pressure of the flue gas source equipment without the FGCS. b) Determine the tie-in points for the flue gas bypass and the flue gas return, and connect the FGCS to the flue. These tie-in connections have, for example, an interval of about 12 inches. c) Test the effect of the FGCS on the operation of the flue gas source equipment and the flue under various operating conditions. Examples include setting sensors at the tie-in points and measuring the pressure in the flue when bypassing the flue gas through the FGCS at different fan rates. This may include operating the source equipment in an output range including low output (e.g., 10%) and high output (e.g., 100%), and measuring the pressure drop between pressure sensors at different FGCS fan speeds. c) Determine the basic FGC fan speed and the FGCS upper fan speed so that the pressure difference does not exceed about 0.02 inches of water column pressure under typical operating conditions of the source equipment due to the influence of the FGCS.

[0131] For example, when the source equipment is operating at 10%, if the FGCS is not configured, the draw pressure of the source equipment may be -1.0 inches of water column. As described above, the influence of connecting the FGCS to the flue should not affect the water column pressure by more than 0.02 inches. Therefore, in this example, the basic speed of the FGCS fan may be set (e.g., by increasing the FGC fan speed from zero) so that a sufficient amount of gas passes through the FGCS so that the pressure difference does not exceed 0.02 inches of water column when the source equipment is operating.

[0132] In some examples, the basic flow rate of the FGCS may be "set" and / or "configured" by a service technician responsible for installing the FGCS, perhaps via the user interfaces 202, 202a, after observing and / or testing the conditions at the installation site and determining the appropriate settings. In other examples, the basic flow rate of the FGCS may be "set" and / or "configured" remotely from a remote computing device, perhaps via one or more networks, and received by the FGCS via a control signal received by the FGCS via the network interface 200d. In any case, in some examples, the FGCS may be manufactured and shipped with a "default" basic flow rate stored in the memory 200b, which the FGCS operates at until the basic flow rate is updated or until the basic flow rate is updated.

[0133] Generally, after the FGCS is configured in the flue 106 and the FGCS is turned "on", the FGCS operates in a standby mode where the fan 102g operates at the basic flow rate to maintain a standby or basic level flow of air through the FGCS that is subject to variations as described below.

[0134] [Monitoring System and Operating Modes] Figures 5-10 are representative logic flow diagrams illustrating examples of monitoring systems that enable the operation of the FGCS in various modes.

[0135] In one example, the logic described in connection with each of Figures 5-9 may be implemented as instructions stored in a memory (e.g., memory 200b of Figure 2) and executed by one or more processors (e.g., processor 200a of Figures 1 and 2) of the FGCS (e.g., FGCS of Figures 1 and 2).

[0136] Generally, the exemplary logic, methods, and / or functions described below in connection with FIGS. 5-9 may be implemented within or associated with an operating environment including, for example, the operating environment depicted in FIG. 1, a FGCS such as the exemplary FGCS100 depicted in FIG. 1, a FGCS such as the exemplary FGCS201 depicted in FIG. 2, a FGCS such as the exemplary FGCS300 depicted in FIG. 3, and / or any other device, interface, and / or component depicted in connection with FIGS. 1-4 of this specification. In an embodiment, the logic, methods, and / or functions described below in connection with FIGS. 5-9 may be implemented by a FGCS itself such as the exemplary FGCS100 depicted in FIG. 1, a FGCS such as the exemplary FGCS201 depicted in FIG. 2, or a FGCS such as the exemplary FGCS300 depicted in FIG. 3. In other examples, only certain logic, methods, and / or techniques may be executed by such a FGCS, and other logic, methods, and / or techniques may be executed by other devices. For example, some logic, methods, and / or techniques may be executed by another device such as CCS310 that communicates with the FGCS via one or more networks such as LAN306 and / or WAN308. Further, the logic, methods, and / or functions described below in connection with FIGS. 5-9 may include one or more operations, functions, or actions exemplified by one or more of the blocks included in these figures. Although the blocks are illustrated in sequential order, these blocks may be executed in parallel and / or in an order different from the order described herein. Also, various blocks may be combined into fewer blocks, divided into additional blocks, and / or removed based on the desired implementation.

[0137] A further functional example of an exemplary FGCS including various monitoring systems (e.g., electronic device 200 and associated sensor 204) and various aspects including standby mode 530, operating mode 531, agitation mode 532, and reaction management mode 533 will be described.

[0138] [Standby mode 530] In an embodiment, as shown with reference to FIG. 5, after the installation of the FGCS and the determination of the basic fan speed, the FGCS is started 500 and enters the standby mode 530 with the fan operating at the basic fan speed. It should be noted that FIG. 5 depicts the standby mode 530 and the standby state 500a in which the fan of the FGCS operates at the basic speed. However, in another embodiment, during the standby state 500a, the fan may not operate at all. That is, in some examples, the fan may not operate during the standby state 500a, or the fan may operate intermittently while operating in the standby state 500a at the basic speed.

[0139] In the standby mode 530, a monitoring system including one or more sensors configured in the flue and / or the FGCS monitors the operating conditions / parameters, and finally determines the state of those conditions / parameters, which can be used as a basis for causing the FGCS to enter different modes. For example, the FGCS can monitor whether one or more flue gas parameters exceed the flue gas parameter threshold 500b. If the flue gas parameter is not greater than the flue gas parameter threshold 500b, the monitoring system remains in the standby state 500a. However, if the flue gas parameter is greater than or equal to the threshold 500b, the FGCS transitions, for example, to operation in the operating mode 531 (described further below) where the fan speed is increased to a speed greater than the basic speed of the standby state 500a.

[0140] There are various examples of flue gas parameters, such as those being considered in relation to block 500b. In an embodiment, the flue gas parameter may provide an indication of whether the connected source facility is achieving and producing a desired level of carbon dioxide. Thus, one such suitable flue gas parameter may be a measurement of temperature related to the connected source facility, such as the temperature of the gas contained within the flue and / or within the flue adjacent to the connected source facility. Other suitable flue gas parameters may be the actual carbon dioxide level (measured by a carbon dioxide sensor) within the gas in the flue adjacent to the connected source facility. There are other examples of suitable flue gas parameters, including, for example, pressure and flow rate, and / or using two or more other flue gas parameters.

[0141] In an example where the flue gas parameter being monitored is the flue gas temperature, the FGCS 100 may be configured to have a first temperature sensor T1 near the source facility 104 (e.g., at the tie-in point 110 between the flue 106 and the bypass connector 108) as shown in FIG. 1. In accordance with this embodiment, other arrangements of the temperature sensor T1 may be suitable. Further, in other examples, a plurality of temperature sensors may be used, and the absolute value and / or the temperature difference may be used as a basis for establishing a threshold value.

[0142] In such an embodiment, T1 monitors the temperature of the flue gas exiting the source facility. In one embodiment, when the source facility has been off for a sufficient period of time, T1 measures the ambient temperature experienced at the installation. For example, if T1 is near a building at a high latitude and it is winter, the minimum base temperature measured at T1 may be an outside air temperature of about -40°C, and if T1 is always inside a warm building, the base temperature may be about +40°C. Over time, the temperature measured at T1 can range from the ambient temperature when the source facility has been off for a long period of time, to the maximum flue gas temperature when the source facility is operating at maximum power output, and all the temperatures in between as the flue is heated and cooled.

[0143] When the source facility is turned on, the temperature measured at T1 rises as hot flue gas flows out of the source facility due to the combustion process within the source facility. The monitoring system uses, for example, a threshold temperature of 100°C to initiate or otherwise monitor the various operating cycles of the FGCS100. In one embodiment, the threshold temperature is established based on the determination of an appropriate flow rate of the hot flue gas such that the bypass gas passing through the system maintains sufficient flow within the flue. The threshold temperature may be set at the factory and / or adjusted by a technician during installation or maintenance to be appropriate for a particular environment.

[0144] In one embodiment, the monitoring system does not implement a threshold temperature that causes the fan speed 501 to automatically increase from the moment the source facility is turned on (ultimately diverting more flue gas through the FGCS). Instead, the FGCS may increase the fan speed 501 (increasing the flow rate through the FGCS) when sufficient heat, pressure, and flow rate have been generated by the source facility such that the flue gas continues to exit the flue properly after the source facility has been operating for a certain period of time.

[0145] Furthermore, a temperature rise above the threshold temperature may indicate that carbon dioxide is being generated at a sufficient level to be processed by the FGCS with a desired effect and / or efficiency. Thus, the flue gas parameter threshold may be set at the point where, when the threshold is achieved or exceeded, the FGCS transitions to the operating mode 531. Alternatively, the flue gas parameter threshold may be set at the point where, when the flue gas parameter threshold is achieved or exceeded, the FGCS waits for a predetermined time and then transitions to the operating mode 531.

[0146] In various illustrative examples shown in FIGS. 5 and 6, when T1 measures a temperature drop below the threshold temperature, this indicates that the source facility is off and the generation of carbon dioxide and / or heat for processing in the FGCS is insufficient. When the source facility is turned off, the generation of carbon dioxide in the flue gas in the flue decreases. However, a certain amount of heat remains in the source facility, and the available heat can be recovered from the source facility for a certain period after the source facility is turned off. Therefore, when the temperature drops below the threshold temperature, the FGCS may return to the standby mode 530 or standby state 500a, 601 in which the fan operates at the basic speed immediately or after a predetermined period.

[0147] Therefore, as described, in embodiments where T1 measures a temperature above the threshold temperature, the monitoring system increases the fan speeds 501, 603 to bypass an increased amount of gas through the FGCS (further described in relation to the operating mode). When T1 measures a temperature below the threshold temperature, the system returns the fan speed to the basic speed of the standby modes 500a, 601.

[0148] [Operating Mode 531] As described, when the flue gas parameter threshold is achieved 500b, the monitoring system may enter the operating mode 531. When entering the operating mode 531, the monitoring system increases the fan speed to provide an additional flue gas flow through the FGCS.

[0149] After increasing the fan speed 501, a source facility cumulative timer may be started 502 and the total cumulative time may be checked 502a. The source facility cumulative timer (also referred to herein as the "cumulative timer") determines the time during which the flue gas parameter threshold has been exceeded during a reset (described below). The cumulative timer provides a direct or indirect measurement of the actual or approximate time that the source facility has been operating and the total time that the FGCS has been operating during a cumulative timer reset.

[0150] It is determined whether the total cumulative time is greater than the cumulative time threshold 503. If the total cumulative time is greater than the cumulative time threshold, the monitoring system may enter the stirring mode 532. If the total cumulative time is less than the cumulative time threshold, a new cumulative time is calculated 504, and the monitoring system continues to monitor the total cumulative time 502a, 503 until the cumulative threshold time is achieved.

[0151] As introduced above and further described below, the cumulative timer provides an indication of the time that the FGCS has operated in the operating mode 531 and / or the following reaction management mode 533. Generally, after operating in these modes for a predetermined period, it may be desirable to transfer the FGCS to the stirring mode 532, in which the fan is turned off and the reactants in the reactor are stirred (i.e., agitated / mixed) for a certain period, and then return to the standby mode 530 and / or ultimately the operating mode 531. Execution of the stirring mode 532 may decompose solid reactants that may be partially dry and / or may stir semi-liquid reactants.

[0152] The increased fan speed 501 may vary depending on the size of the FGCS, the installation of the source equipment, and / or the environmental characteristics of the environment in which the FGCS is installed, and may be affected by the source equipment to which the FGCS is connected (e.g., the size and "class" of the source equipment). The fan speed may be a predetermined fan speed (e.g., the first speed, the second speed, etc.), or may be continuously variable, for example, between 0 and a high speed.

[0153] As described, generally, it is desirable for the FGCS not to undesirably affect the operation of the connected source equipment / flue. In one example, the operating mode fan speed is set to a certain level, similar to the standby mode, and the operation in operating mode 530 does not result in an unacceptable change in the pressure difference measured between the upstream and downstream of the FGCS. In one embodiment, the fan speed in the operating mode is set to a level such that the operation results in a pressure difference greater than 0.02 inches of water column across the FGCS installation. In one embodiment, the fan speed is set to a level corresponding to the level that moves air through the FGCS at 80 - 160 cubic feet per minute in operating mode 531.

[0154] In an embodiment, when the source equipment is turned on and the FGCS eventually enters operating mode 531, the monitoring system increases the fan speed above the base fan speed. Further, in the operating mode, the monitoring system measures the cumulative time associated with the flue gas equipment that has exceeded the threshold value, and the threshold value may be used to make an operational decision, such as whether to enter agitation mode 532 or reaction management mode 533. When the cumulative operating time of the source equipment exceeds the cumulative time threshold value, the monitoring system may enter agitation mode 532. Conversely, when the cumulative operating time of the source equipment does not exceed the cumulative time threshold value, the monitoring system may enter reaction management mode 533.

[0155] The exemplary cumulative threshold time may be in the range of 10 - 120 minutes. However, such a threshold may be determined considering multiple parameters. Such parameters may be set and / or updated by service technicians, machine learning algorithms, and / or central computer systems, locally and / or remotely.

[0156] [Reaction Monitoring Mode 533] As described above, while the total cumulative time is less than or equal to the cumulative time threshold, the monitoring system may enter the reaction monitoring mode 533. In the reaction monitoring mode, the monitoring system monitors one or more reaction parameters to determine whether the reaction parameter is greater than the reaction threshold 505. If the reaction parameter is greater than the reaction threshold 505, the fan speed may be increased 506. If the reaction parameter is less than the reaction threshold 507, the fan speed may be decreased 508. When the fan speed increases 506 or decreases 508, the monitoring system checks whether the flue gas parameter is greater than the flue gas parameter threshold 523. If it exceeds the flue gas parameter threshold (for example, if the source facility remains on), the monitoring system returns to the operation mode 531 to calculate a new cumulative time 504. If it does not exceed the flue gas parameter threshold (for example, if the source facility is off), the monitoring system returns to the standby mode 530.

[0157] As will be further described below, the reaction parameters to be monitored take various suitable forms. In an embodiment, the reaction parameter is selected to provide an indication of whether the fan speed of the FGCS should be maintained constant and / or increased / decreased. For example, the reaction parameter may provide an indication of whether the reaction in the reactor is assisted or otherwise improved by increasing or decreasing the fan speed. In one embodiment, the reaction parameter is the measured humidity level in the reactor (for example, using the humidity sensors H1, H2 in FIG. 1). Thus, if it is determined that a high humidity exists in the reactor, it may be desirable to further increase the fan speed to remove moisture. On the other hand, if it is determined that a low humidity exists in the reactor, it may be desirable to decrease the fan speed.

[0158] For example, as the reaction progresses, moisture is generated within the reactor, and the moisture generally combines with the reactants to turn the reactants into a viscous liquid, reducing the surface area and thereby decreasing the reaction ability of carbon dioxide. The humidity within the FGCS rises due to the generation of moisture. By increasing the fan speed, additional heat is introduced through the FGCS by the increased flow rate, and the humidity is removed from the FGCS. This aids in returning the reactants to a drier form and ultimately aids in producing a high-quality product. The humidity dropping below a certain level is an indication that the reactants are in a dry (reacted or unreacted) form and that moisture removal is not necessary at that instant.

[0159] Another reaction parameter is the relative viscosity of the reactants measured within the FGCS. In one example, the viscosity may be measured by the power required to stir the reactants, which can be measured by the stirring system during the stirring cycle, or by a separate viscosity measurement system (e.g., 102f, 204h). For example, the stirring system may include a fixed-speed motor (e.g., 102d or 202d). The power required to maintain a constant speed may vary depending on the relative viscosity of the reactants, and more viscous reactants require higher power to maintain a constant speed.

[0160] In one example, the FGCS is configured with a humidity sensor H1 downstream of the reactor 102 to measure the humidity of the treated flue gas. In other examples, the humidity sensor H1 may be located at any other suitable location, such as within the reactor for example. As the reaction progresses, water / water vapor is generated within the reactor, increasing the humidity of the treated flue gas such that H1 measures a higher humidity compared to the humidity of the flue gas exiting the source facility. Thus, at a "high" level of humidity, this indicates that the reaction is progressing and / or the viscosity of the reactants is changing. The difference in humidity measurements between humidity sensors may be used as a criterion for determining whether a threshold is met.

[0161] As described above, the viscosity of the solid reactant changes through the reaction and has different viscosities over time. For example, a typical solid reactant is initially a "dry flake" when introduced into the reactor and then changes to a viscous thickening mixture as the reaction progresses. Without stirring / mixing, the viscous mixture can change to a dried "lump" under heating and may even become a solid block. Ultimately, it is desirable for the spent reactant to be a dry powder.

[0162] For example, when the humidity rises above a humidity threshold (e.g., 40% relative humidity), the monitoring system dries the reactant by increasing the flow rate of the flue gas through the reactor to promote the gas flow over the reactant and increasing the fan speed to increase the heat flow into the reactor. The fan is operated for a certain period of time, and when the humidity drops below the humidity threshold, the fan speed may be decreased to a lower fan speed. When the detected humidity drops below a lower humidity threshold (e.g., 10% relative humidity), it may be used to indicate that the reactant is spent.

[0163] Since the ambient relative humidity may be higher than 40%, the monitoring system may be configured with an external humidity sensor (e.g., H3) so that the monitoring system can determine whether the humidity in the FGCS is the true reactor humidity or the humidity resulting from the ambient humidity. That is, when the monitoring system is in standby mode for a long time and the ambient humidity is high, humid air may be sucked into the FGCS through the draft hood, causing the measured humidity to be high. In one embodiment, the monitoring system measures and takes into account the ambient humidity when enabling and disabling various processing modes, as will be further described later in connection with FIG. 9. For example, the monitoring system may measure the ambient humidity 902 and adjust the threshold values of the reaction parameters based on the ambient humidity. For example, when the measured ambient humidity is measured at 90%, the monitoring system may adjust the threshold values, where other decisions may be made, for at least a certain period of time to establish "steady state" conditions within the FGCS before returning to other threshold values.

[0164] In one embodiment, the set fan speed may be linearly correlated with an absolute humidity measurement where an increase in the fan speed is proportional to an increase in the absolute humidity. Alternatively, the fan speed may be non-linearly correlated with the absolute humidity measurement. For example, an absolute humidity measurement exceeding a threshold value may be used to increase the fan speed at a proportionally higher rate compared to a linear correlation. Such a control scheme may be desirable to match the relative reaction rate with the reactor when the reaction rate is known to be non-linear considering the input parameters.

[0165] In one embodiment, the FGCS is composed of viscosity sensors (e.g., 102f, 204h), and the reaction parameter is the measured viscosity. In another embodiment, the power input to the stirring system is measured during the stirring cycle and stored in a memory (e.g., 200b), and is utilized as a reaction parameter when the monitoring system next enters the reaction management mode and until a new viscosity measurement value is determined when the monitoring system next enters the stirring mode.

[0166] [Stirring mode 532] When the total cumulative time exceeds the time threshold 503, the monitoring system may enter the stirring mode 532. In the stirring mode, the monitoring system activates one or more components within the reactor to stir or mix the contents of the reactor (i.e., the reactants). As will be described further below, in one example, the stirring mode may include activating the stirring system 202b as described above in relation to FIG. 2. Activating the stirring system may include supplying power to or otherwise turning on one or more motor drive units 202d that drive one or more respective stirring paddles 202c.

[0167] In some examples, the FGCS may enter the stirring mode 532 immediately after it is determined that the total cumulative time is greater than the cumulative time threshold 503 (not shown in FIG. 5). In an alternative example, the FGCS may enter the stirring mode both after it is determined that the total cumulative time exceeds the cumulative time threshold and after it is determined that the connected source device is not currently driving. This is because if the FGCS is not operated in the stirring mode (where the fan is stopped 514) while the connected source device is operating, it may be possible to improve the overall operating efficiency of the system.

[0168] In one example, when the FGCS first enters the stirring mode 532, the cumulative timer is reset to zero 510. As a result, the monitoring system transitions to operation in the stirring mode 532 based on the period during which the FGCS was operating in the operating mode 531. Notably, if the FGCS later re-enters the operating mode 531, the monitoring system restarts (restarts) the cumulative timer 502 to provide a new indication of the time the FGCS was in the operating mode after the reset of the cumulative timer.

[0169] Furthermore, after the monitoring system enters the stirring mode 532, a stirring mode timer is started 512. The stirring mode timer generally accumulates while the monitoring system is operating in the stirring mode. Thus, the stirring mode timer indicates how long the monitoring system has been in the stirring mode. As will be described later, the stirring mode timer may be referenced in connection with the determination 518 of whether the stirring mode timer exceeds or does not exceed the stirring time threshold.

[0170] Furthermore, after the monitoring system enters the stirring mode, the fan 514 is stopped. The stoppage of the fan reduces and further stops or substantially stops the total amount of air flow passing through the reactor 102, flowing out of the reactor 102, and into and through the downstream components including the filter 102e. As a result, the amount of material, reactants, or other solids carried from the reactor 102 to downstream components such as the filter 102e may be reduced. This is desirable to the extent that the stirring motor operates in the next block 516. That is, since the stirring motor generally stirs the reactants, it is desirable to first turn off the fan 514 to help minimize the amount of stirred reactants / materials exiting the reactor and / or being carried into the filter.

[0171] Completely stopping the fan during stirring can significantly improve the filter life because, during stirring when the likelihood / concentration of particles in the air is highest, the fan does not actively draw particles into the filter.

[0172] It should be noted that in one embodiment, when the monitoring system is configured to start the stirring cycle immediately upon reaching the total cumulative time threshold, if the source facility is either a) on, b) off, or c) on again during the stirring cycle, there is no bypass of the flue gas to the FGCS because the fan is not operating, and thus substantially all of the flue gas rises through the flue 106 and does not carry particulates to the filter.

[0173] As described above, next, the monitoring system turns on a stirring system including operating a motor 516 (e.g., one or more motor drive devices 202d that drive corresponding stirring devices such as paddles in the reactor).

[0174] When the motor 516 is turned on, the monitoring system monitors whether the stirring mode timer is less than the time threshold 518. If the stirring mode timer is less than the threshold, the motor continues to be driven 516. If the stirring mode timer is greater than the threshold, the motor is stopped 520.

[0175] When the stirring motor is stopped 520, the monitoring system may wait for a time before returning to the standby mode 500a 522 and reset the stirring mode timer to zero 520a. One advantage of waiting before returning to the standby mode would be to provide an opportunity to more completely settle the suspended reactants or other materials within the reactor before restarting the fan. As a result, the monitoring system further reduces the amount of material lost outside the reactor and / or captured by the filter.

[0176] In one embodiment, as described above, the FGCS enters the stirring mode 532 after determining that the cumulative operating time of the source facility (presumably within the operating mode and / or other modes) has exceeded the cumulative time threshold. Generally, entering the stirring mode after a certain operating period can provide various operating advantages, such as efficiently progressing the reaction within the reactor or avoiding the "accumulation" of operationally unfavorable conditions over a long period. In various embodiments, the stirring mode is performed to achieve the following four exemplary purposes, among other potential purposes and advantages. · Stir the liquid / solid reactants to manage the viscosity of the reactants. · Increase the surface area of the reactants available to the flue gas. · Operate the FGCS in a way that reduces reactant loss. · Operate the FGCS to reduce filter clogging.

[0177] [Embodiments including measurement of the operating time of the source facility] In one example, instead of directly monitoring the total cumulative time that the FGCS operates in operation mode 531 (in accordance with block 503), the monitoring system may instead or additionally measure the total cumulative time that the source equipment is operating, and initiate the stirring mode after the source equipment has operated through one or more heating cycles. In one embodiment, by way of example, each time T1 measures a temperature rise above a threshold temperature, the monitoring system calculates the total elapsed time that the temperature is above the threshold temperature until the temperature drops below the threshold temperature. Since the time above the threshold temperature is an indication of the time that the source equipment is operating, the system can determine the total cumulative operating time of the source equipment, which may be an approximation or an absolute value. When the total cumulative threshold time is reached, the monitoring system starts the stirring mode 532.

[0178] For example, the furnace may operate for 5 minutes, then shut off for 10 minutes, operate again for 7 minutes, shut off again for 8 minutes, and operate for 4 minutes the third time. In this example, the total cumulative operating time is 16 minutes. The monitoring system may be set such that when the total cumulative time exceeds, for example, 15 minutes, the FGCS enters the stirring mode when the source equipment is next turned off. That is, if the total cumulative time is 15 minutes or more and the temperature is lower than the threshold temperature, the monitoring system executes the stirring cycle. In various embodiments, during the stirring mode 532, the stirring cycle is executed immediately when the total cumulative time threshold is reached, regardless of whether the source equipment is on or off, or only when the source equipment is next turned off.

[0179] In various embodiments, the adjustment of the set value may be determined based on seasonal variations and / or atmospheric conditions in the operation of the source equipment. For example, furnaces and boilers may operate at widely different intervals throughout the year, and various parameters including cumulative time, motor time, temperature, and humidity thresholds may be adjusted according to different seasons.

[0180] [Additional Example] In an embodiment, the FGCS may be executed based on data received from sensors configured in the FGCS, associated source equipment, flue ducts, and the environment. Although various functions and alternative operating modes have been described above, it should be understood that certain ones of these functions may be executed alone or in different orders and combinations based on specific sensors or combinations of sensors that may be configured. FIGS. 6-9 provide additional illustrations of various function examples and operating modes.

[0181] FIG. 6, as described with reference to FIG. 5, illustrates a mode 600 in which a monitoring system can increase or decrease the fan speed based on the detection of flue gas parameters 602, which is another example of the transition from the standby mode to the operating mode. In this example, if the flue gas parameter 602 exceeds the threshold, the fan speed is increased 603, and if the flue gas parameter 602 is below the threshold, the fan speed is maintained or returned to the basic speed 601.

[0182] FIG. 7 illustrates a mode 700 in which the monitoring system monitors particularly the temperature 701 and humidity. In this mode, the monitoring system may increase 703 or decrease 705 the fan speed based on the detection of humidity parameters 702, 704. In this case, if the humidity parameter 702 exceeds the threshold, the fan speed is increased 703, or if the humidity parameter 704 is below the threshold, the fan speed is decreased 705. In either case, the temperature threshold is checked again 701 to repeat the humidity measurements 702, 704 or return to the basic speed 706. FIG. 7 shows a mode that measures particularly humidity as a reaction parameter as compared to a more generalized method of measuring one or more reaction parameters described in relation to FIG. 5.

[0183] Figure 8 illustrates mode 800 in which the monitoring system determines whether to enter operation mode 805 or stirring mode 806 based on the source facility and FGCS parameters. In this example, from standby mode 801, the monitoring system may determine whether to enter operation mode 805 or stirring mode 806 by activating standby timer 802 until the standby time threshold is reached. The standby timer may be reset 807 after stirring mode 806 is executed. This mode 800 may be executed when the source facility is not operated regularly and stirring of the reactor is desired regularly. For example, this operation mode may be desired when the source facility (e.g., furnace) is off for a longer period such that the time during the on-cycle is longer, for example, during spring, summer, and autumn. In this mode, the standby time threshold may be set to 24 hours, and if the source facility does not come on for 24 hours, the monitoring system enters the stirring mode to stir the reactants in the FGCS. This mode may be desired in locations where the ambient humidity is high and the basic fan speed introduces humidity into the FGCS and the reactants may solidify into blocks without stirring. Thus, in this mode, regardless of whether the source facility has been on for a certain period, the monitoring system stirs the reactants regularly.

[0184] Figure 9 shows an operation mode 900 in which the monitoring system adjusts a threshold value (e.g., humidity threshold value) in consideration of the ambient humidity. For example, similar to FIG. 5, when the monitoring system enters an operation mode and / or a reaction management mode based on the fact 901 that the flue gas parameter exceeds the threshold value, the monitoring system determines whether to increase the fan speed 905 (when the humidity is greater than the adjusted threshold value 904) or decrease the fan speed 907 (when the humidity is lower than the adjusted threshold value 906) by measuring the ambient humidity 902 and adjusting the threshold value 903 based on the ambient humidity. For example, when the measured ambient humidity is high (e.g., 90%), the monitoring system may adjust the threshold value at which other decisions may be made for at least a certain period to establish a "steady state" state within the FGCS before returning to other threshold values. If the humidity does not fall below the adjusted threshold value, the monitoring system may return to measuring the ambient humidity 902. When the flue gas parameter is less than the flue gas parameter threshold value, the monitoring system may operate the fan at the basic speed 908.

[0185] [Exemplary Embodiments] By way of example, the Applicant currently offers (or has offered) for sale a particular flue gas recovery system including CarbinX (registered trademark), including, for example, versions 3.0, 3.1, 3.2, 3.3, 3.4, and 3.5. Other suitable flue gas recovery systems may be used additionally or alternatively to implement aspects of the exemplary flue gas recovery systems described herein.

[0186] Although the invention has been described and illustrated with respect to preferred embodiments and preferred uses, it is to be understood that modifications and changes can be made within the full intended scope of the invention as will be understood by those skilled in the art, and the invention is not so limited.

[0187] For example, without limitation, some embodiments include, among other features, (i) a reactor having a flue gas inlet for connection to a flue gas source, a mixing system configured to mechanically agitate a solid reactant within the reactor, a gas outlet, and a flue gas recovery system for connection to a flue, (ii) a fan configured at the gas outlet for drawing flue gas through and out of the reactor and into the flue gas recovery system, the fan being operable at a fan speed, (iii) at least one flue gas parameter sensor configured at any one or a combination of the flue gas inlet, the flue gas source, or the flue, (iv) at least one processor configured with the at least one flue gas parameter sensor and the fan, and (v) a tangible non-transitory computer-readable medium including program instructions executable by the at least one processor, the system being configured such that, in particular, the processor increases the fan speed in response to at least one flue gas parameter threshold being exceeded and decreases the fan speed in response to at least one flue gas parameter threshold not being exceeded.

[0188] In one embodiment, the at least one processor activates a standby mode and remains in the standby mode while not exceeding at least one flue gas parameter threshold, and in the standby mode, the fan speed is configured to be maintained at a base fan speed.

[0189] In one embodiment, the at least one processor is configured to start a cumulative timer in response to at least one flue gas parameter threshold being exceeded and calculate a total cumulative time when at least one flue gas parameter threshold is exceeded.

[0190] In one embodiment, the at least one processor is configured to activate an agitation mode in response to the total cumulative time exceeding a cumulative time threshold.

[0191] In one embodiment, the processor is configured to reset the cumulative timer to zero in response to activation of the agitation mode.

[0192] In one embodiment, at least one processor is configured to start an agitation mode timer and activate the mixing system in response to activation of the agitation mode.

[0193] In one embodiment, at least one processor is configured to stop the fan in response to activation of the agitation mode.

[0194] In one embodiment, at least one processor is configured to stop the agitation system in response to the agitation mode timer exceeding an agitation mode time threshold.

[0195] In one embodiment, at least one processor is configured to stop the agitation system and operate the fan at a basic speed in response to the agitation mode timer exceeding an agitation mode time threshold.

[0196] In one embodiment, at least one processor is configured to stop the agitation system and operate the fan at a basic speed after a delay time in response to the agitation mode timer exceeding an agitation mode time threshold.

[0197] In one embodiment, at least one processor is configured to activate a reaction management mode in response to the total cumulative time not exceeding a cumulative time threshold.

[0198] Some embodiments further include at least one reaction parameter sensor configured in the reactor. In some such embodiments, at least one processor is configured to determine whether at least one reaction parameter is exceeded in response to activation of the reaction management mode, and increase the fan speed if it is exceeded.

[0199] In one embodiment, at least one processor is configured to determine whether at least one reaction parameter has been exceeded in response to activation of a reaction management mode, and if not, to reduce the fan speed.

[0200] In one embodiment, the at least one flue gas parameter sensor includes any one or more (or all) of (i) a temperature sensor, (ii) a carbon dioxide concentration sensor, and / or (iii) a humidity sensor.

[0201] In one embodiment including a humidity sensor, the processor is configured to control the fan speed based on a linear correlation to an absolute humidity measurement between a low humidity threshold and a high humidity threshold, where a lower fan speed correlates to a lower absolute humidity measurement.

[0202] In one embodiment including a humidity sensor, the processor is configured to control the fan speed based on a non-linear correlation to an absolute humidity measurement between a low humidity threshold and a high humidity threshold, where a higher absolute humidity measurement results in a proportionally higher fan speed.

[0203] In one embodiment, the at least one reaction parameter sensor includes a viscosity sensor.

[0204] In one embodiment, at least one processor is configured to start a standby timer in standby mode and enter an agitation mode when a threshold of the standby timer is exceeded.

[0205] Some embodiments further include at least one network interface communicatively coupled to at least one processor. In some such embodiments, the at least one network interface and the at least one processor are configured to report sensor data to a central computer system via at least one network and receive instructions from the central computer system.

[0206] Some embodiments further include an image acquisition system configured in at least one processor to acquire image data of a system.

[0207] Some embodiments further include a sound acquisition system configured in at least one processor to acquire sound data of a system.

[0208] Some embodiments further include a movement acquisition system configured in at least one processor to acquire movement data of a system.

[0209] Some embodiments further include a user interface configured in at least one processor to display system data to a user and enable the user to input data.

[0210] Some embodiments include, additionally or alternatively, a method of operating a flue gas recovery system, the flue gas recovery system including: (i) at least one processor operable in a standby mode; (ii) a tangible, non-transitory computer-readable medium comprising program instructions executable by the at least one processor; (iii) a hybrid system; (iv) a fan; and (v) at least one flue gas parameter sensor configured in a flue gas source. In some such embodiments, the method includes, among other features: (a) increasing a fan speed in response to a flue gas parameter threshold being exceeded; and (b) decreasing the fan speed in response to at least one flue gas parameter threshold not being exceeded.

[0211] Some embodiments further include maintaining a base fan speed when at least one processor is operating in a standby mode.

[0212] Some embodiments further include starting a cumulative timer and calculating a total cumulative time after determining (or perhaps in response to) that at least one flue gas parameter threshold has been exceeded.

[0213] In one embodiment, the method further includes activating a stirring mode after determining that the total cumulative time exceeds a cumulative time threshold (or perhaps in response thereto).

[0214] In one embodiment, the method further includes resetting the cumulative timer to zero after activating the stirring mode (or perhaps in response thereto).

[0215] In one embodiment, the method further includes starting a stirring mode timer and activating the mixing system after activating the stirring mode (or perhaps in response thereto).

[0216] In one embodiment, the method further includes stopping the fan after activating the stirring mode (or perhaps in response thereto).

[0217] In one embodiment, the method further includes stopping the stirring system after the stirring mode timer exceeds a stirring mode time threshold (or perhaps in response thereto).

[0218] In one embodiment, the method further includes stopping the stirring system and operating the fan at a basic speed after the stirring mode timer exceeds a stirring mode time threshold (or perhaps in response thereto).

[0219] In one embodiment, the method further includes stopping the stirring system and operating the fan at a basic speed after a delay time after determining that the stirring mode timer exceeds a stirring mode time threshold (or perhaps in response thereto).

[0220] In one embodiment, the method further includes activating a reaction management mode after determining that the total cumulative time does not exceed a cumulative time threshold (or perhaps in response thereto).

[0221] In one embodiment, the flue gas recovery system further includes at least one reaction parameter sensor configured in the reactor. In some such embodiments, the method further includes increasing the fan speed after (or perhaps in response to) activation of the reaction management mode.

[0222] In one embodiment, after activation of the reaction management mode (or perhaps in response to it), it includes determining whether at least one reaction parameter is exceeded. And after determining that at least one reaction parameter is not exceeded (or perhaps in response to it), the fan speed is decreased.

[0223] In one embodiment, at least one flue gas parameter sensor includes a temperature sensor, and the method further includes monitoring the temperature of the flue gas via the temperature sensor.

[0224] In one embodiment, at least one flue gas parameter sensor includes a carbon dioxide concentration sensor, and the method further includes monitoring the carbon dioxide concentration of the flue gas via the carbon dioxide concentration sensor.

[0225] In one embodiment, at least one reaction parameter sensor includes a humidity sensor, and the method further includes monitoring the humidity of the flue gas via the humidity sensor.

[0226] In one embodiment, at least one reaction parameter sensor includes a viscosity sensor, and the method further includes monitoring the reactant viscosity via the viscosity sensor.

[0227] In one embodiment, at least one processor is configured to start a standby timer in standby mode. In some such embodiments, the method further includes entering the stirring mode after determining that the threshold of the standby timer has been exceeded (or perhaps in response to it).

[0228] In an operation, any of the flue gas system components described in any of the exemplary embodiments (or other embodiments disclosed herein), and / or any of the method steps described in any of the exemplary embodiments (or other embodiments disclosed herein) can be combined in any suitable combination.

Claims

1. A reaction chamber having (i) a gas inlet connected to a gas source and (ii) a gas outlet, at least one sensor, at least one fan operable at at least a first fan speed and a second fan speed higher than the first fan speed, at least one processor, wherein the system when the at least one fan is operating at the first fan speed, receives a parameter signal indicating a parameter corresponding to the gas source via the at least one sensor, determines, based on the received parameter signal, that the parameter corresponding to the gas source exceeds a parameter threshold level, and a tangible non-transitory computer-readable medium having program instructions executable by the at least one processor configured to cause the at least one fan to transition from operating at the first fan speed to operating at the second fan speed based on a determination that the parameter exceeds the parameter threshold level.

2. The at least one sensor includes a first sensor, the system further includes a second sensor, and the program instructions executable by the at least one processor wherein the system when the at least one fan is operating at the second fan speed, receives a humidity signal indicating a humidity level corresponding to the reaction chamber via the second sensor, determines, based on the received humidity signal, that the humidity level corresponding to the reaction chamber exceeds a humidity threshold level, and further includes additional program instructions executable by the at least one processor configured to cause the at least one fan to transition from operating at the second fan speed to operating at a third fan speed higher than the second fan speed based on a determination that the humidity level exceeds the humidity threshold level. The system according to claim 1.

3. The humidity signal includes a first humidity signal, and the program instructions executable by the at least one processor wherein the system when the at least one fan is operating at the third fan speed, receives a second humidity signal via the second sensor, Based on the received second humidity signal, it is determined that the humidity level corresponding to the reaction chamber is below the humidity threshold level, Based on the determination that the humidity level is below the humidity threshold level, the at least one fan is further configured to cause a transition from operating at the third fan speed to operating at a fourth fan speed lower than the third fan speed, and the system according to claim 2, having further program instructions executable by the at least one processor. **Claim 4** The system according to claim 3, wherein the fourth fan speed is the same as the second fan speed. **Claim 5** Further comprising a stirring system, The program instructions executable by the at least one processor The system is After causing the at least one fan to transition from operating at the first fan speed to operating at the second fan speed, the system according to claim 1, having further program instructions executable by the at least one processor, further configured to (a) stop the at least one fan and (b) start the stirring system. **Claim 6** The program instructions executable by the at least one processor, further configured such that the system starts the stirring system, The system has program instructions executable by the at least one processor, configured to start at least one motor of the stirring system, The system according to claim 5, wherein the at least one motor is configured to drive at least one stirring paddle. **Claim 7** The program instructions executable by the at least one processor The system is Before stopping the at least one fan and starting the stirring system, it is determined that the cumulative operation time has elapsed after causing the at least one fan to transition from operating at the first fan speed to operating at the second fan speed, The system according to claim 6, having further program instructions executable by the at least one processor, further configured to determine that the determined cumulative operation time is greater than a cumulative operation time threshold. **Claim 8** The program instructions executable by the at least one processor are such that the system stops the at least one fan, starts the agitation system, and after starting the agitation system, determines that a cumulative agitation time has elapsed, determines that the determined cumulative agitation time is greater than a cumulative agitation time threshold, and further comprises additional program instructions executable by the at least one processor to stop the agitation system after determining that the determined cumulative agitation time is greater than the cumulative agitation time threshold, the system of claim 5. **Claim 9** wherein the at least one sensor includes a first sensor, the system further comprises a second sensor, the program instructions executable by the at least one processor are such that the system receives, via the second sensor, a humidity signal indicative of a humidity level corresponding to the reaction chamber before determining that a parameter corresponding to the gas source exceeds the parameter threshold level, determines, based on the received humidity signal, that the humidity level corresponding to the reaction chamber exceeds a humidity threshold level, and further comprises additional program instructions executable by the at least one processor to cause the at least one fan to transition from operating at the first fan speed to operating at a second fan speed higher than the first fan speed based on the determination that the humidity level exceeds the humidity threshold level, the system of claim 1. **Claim 10** further comprising at least one network interface, and the program instructions executable by the at least one processor further comprise additional program instructions executable by the at least one processor to cause the system to receive, via the network interface on at least one wide area network (WAN), an indication of the first fan speed before the at least one fan operates at the first fan speed, the system of claim 1. **Claim 11** further comprising at least one user interface, The program instructions executable by the at least one processor further include additional program instructions executable by the at least one processor such that the system is further configured to receive an indication of the first fan speed via the at least one user interface before the at least one fan operates at the first fan speed, for the system according to claim 1.

12. further comprising at least one network interface, The program instructions executable by the at least one processor further include additional program instructions executable by the at least one processor such that the system is further configured to transmit an indication of the first fan speed to a computing system via the network interface over at least one wide area network (WAN) while the at least one fan is operating at the first fan speed, for the system according to claim 1.

13. further comprising at least one network interface, The program instructions executable by the at least one processor further include additional program instructions executable by the at least one processor such that the system is further configured to transmit an indication of the second fan speed to the computing system via the network interface over the at least one WAN after the at least one fan transitioning from operating at the first fan speed to operating at the second fan speed, for the system according to claim 12.

14. further comprising at least one network interface, The program instructions executable by the at least one processor further include additional program instructions executable by the at least one processor such that, after the system receives the parameter signal indicating the parameters corresponding to the gas source, the system is further configured to transmit an indication corresponding to the gas source to a computing system via the network interface over at least one wide area network (WAN). The system according to claim 1.

15. The at least one sensor includes a temperature sensor, The parameter corresponding to the gas source includes the temperature corresponding to the gas source. The system according to claim 1.

16. The at least one sensor includes at least one sensor connected to at least one of (i) the gas source, (ii) the flue, or (iii) the bypass flue. The system according to claim 1.

17. The at least one sensor is connected to the gas source. The system according to claim 1.

18. The at least one fan is connected to the gas outlet. The system according to claim 1.

19. While at least one fan of the flue gas treatment system is operating at a first fan speed, receiving, via at least one sensor, a parameter signal indicating a parameter corresponding to a gas source connected to the flue gas treatment system; Based on the received parameter signal, determining that the parameter corresponding to the gas source exceeds a parameter threshold level; Based on the determination that the parameter exceeds the parameter threshold level, causing the at least one fan to transition from operating at the first fan speed to operating at a second fan speed higher than the first fan speed. A method comprising.

20. While the at least one fan is operating at the second fan speed, receiving, via a second sensor, a humidity signal indicating a humidity level corresponding to a reaction chamber of the flue gas treatment system; Based on the received humidity signal, determining that the humidity level corresponding to the reaction chamber exceeds a humidity threshold level; Based on the determination that the humidity level exceeds the humidity threshold level, causing the at least one fan to shift from operating at the second fan speed to operating at a third fan speed that is higher than the second fan speed, the method according to claim 19, further comprising.

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