NZ748509B2 - Cyclonic condensing and cooling system - Google Patents
Cyclonic condensing and cooling system Download PDFInfo
- Publication number
- NZ748509B2 NZ748509B2 NZ748509A NZ74850917A NZ748509B2 NZ 748509 B2 NZ748509 B2 NZ 748509B2 NZ 748509 A NZ748509 A NZ 748509A NZ 74850917 A NZ74850917 A NZ 74850917A NZ 748509 B2 NZ748509 B2 NZ 748509B2
- Authority
- NZ
- New Zealand
- Prior art keywords
- cyclone
- coolers
- vapor
- cooler
- type cyclone
- Prior art date
Links
- 238000001816 cooling Methods 0.000 title abstract description 43
- 239000000446 fuel Substances 0.000 claims abstract description 62
- 241000723353 Chrysanthemum Species 0.000 claims description 4
- 239000007789 gas Substances 0.000 abstract description 57
- 238000009833 condensation Methods 0.000 abstract description 15
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N carbon Chemical group [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 abstract description 14
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- 238000000197 pyrolysis Methods 0.000 abstract description 11
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- 238000005516 engineering process Methods 0.000 description 4
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- 229910001220 stainless steel Inorganic materials 0.000 description 4
- 239000012080 ambient air Substances 0.000 description 3
- UHOVQNZJYSORNB-UHFFFAOYSA-N benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
- 230000001808 coupling Effects 0.000 description 3
- 238000010168 coupling process Methods 0.000 description 3
- 238000005859 coupling reaction Methods 0.000 description 3
- 239000002828 fuel tank Substances 0.000 description 3
- 239000003502 gasoline Substances 0.000 description 3
- 238000005057 refrigeration Methods 0.000 description 3
- 235000011121 sodium hydroxide Nutrition 0.000 description 3
- 230000003068 static Effects 0.000 description 3
- 239000004215 Carbon black (E152) Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 230000005587 bubbling Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
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- 238000005336 cracking Methods 0.000 description 2
- 230000005574 cross-species transmission Effects 0.000 description 2
- RTZKZFJDLAIYFH-UHFFFAOYSA-N diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 2
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- 231100000719 pollutant Toxicity 0.000 description 2
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- 241000274177 Juniperus sabina Species 0.000 description 1
- SUKJFIGYRHOWBL-UHFFFAOYSA-N Sodium hypochlorite Chemical compound [Na+].Cl[O-] SUKJFIGYRHOWBL-UHFFFAOYSA-N 0.000 description 1
- 229910000746 Structural steel Inorganic materials 0.000 description 1
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- 230000015556 catabolic process Effects 0.000 description 1
- KZBUYRJDOAKODT-UHFFFAOYSA-N chlorine Chemical compound ClCl KZBUYRJDOAKODT-UHFFFAOYSA-N 0.000 description 1
- 239000000460 chlorine Substances 0.000 description 1
- 229910052801 chlorine Inorganic materials 0.000 description 1
- ZAMOUSCENKQFHK-UHFFFAOYSA-N chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
- 239000011280 coal tar Substances 0.000 description 1
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- 238000007710 freezing Methods 0.000 description 1
- 230000014509 gene expression Effects 0.000 description 1
- 150000002334 glycols Chemical class 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000003345 natural gas Substances 0.000 description 1
- 239000003247 radioactive fallout Substances 0.000 description 1
- 238000010992 reflux Methods 0.000 description 1
- 230000002441 reversible Effects 0.000 description 1
- 230000000630 rising Effects 0.000 description 1
- 102220043690 rs1049562 Human genes 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 235000001520 savin Nutrition 0.000 description 1
- 238000005201 scrubbing Methods 0.000 description 1
- 230000001340 slower Effects 0.000 description 1
- 239000011780 sodium chloride Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000002123 temporal effect Effects 0.000 description 1
- 238000004227 thermal cracking Methods 0.000 description 1
- 238000009834 vaporization Methods 0.000 description 1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D5/00—Condensation of vapours; Recovering volatile solvents by condensation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D5/00—Condensation of vapours; Recovering volatile solvents by condensation
- B01D5/0003—Condensation of vapours; Recovering volatile solvents by condensation by using heat-exchange surfaces for indirect contact between gases or vapours and the cooling medium
- B01D5/0006—Coils or serpentines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D5/00—Condensation of vapours; Recovering volatile solvents by condensation
- B01D5/0078—Condensation of vapours; Recovering volatile solvents by condensation characterised by auxiliary systems or arrangements
- B01D5/0081—Feeding the steam or the vapours
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
- C10G2300/20—Characteristics of the feedstock or the products
- C10G2300/201—Impurities
- C10G2300/208—Sediments, e.g. bottom sediment and water or BSW
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
- C10G2400/02—Gasoline
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
- C10G2400/04—Diesel oil
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
- C10G2400/06—Gasoil
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
- C10G2400/08—Jet fuel
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G31/00—Refining of hydrocarbon oils, in the absence of hydrogen, by methods not otherwise provided for
- C10G31/06—Refining of hydrocarbon oils, in the absence of hydrogen, by methods not otherwise provided for by heating, cooling, or pressure treatment
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G31/00—Refining of hydrocarbon oils, in the absence of hydrogen, by methods not otherwise provided for
- C10G31/10—Refining of hydrocarbon oils, in the absence of hydrogen, by methods not otherwise provided for with the aid of centrifugal force
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G9/00—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
- C10G9/002—Cooling of cracked gases
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
- F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
- F25J1/0002—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the fluid to be liquefied
- F25J1/0022—Hydrocarbons, e.g. natural gas
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
- F25J2215/00—Processes characterised by the type or other details of the product stream
- F25J2215/04—Recovery of liquid products
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D1/00—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/0061—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for phase-change applications
- F28D2021/0063—Condensers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/0075—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for syngas or cracked gas cooling systems
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D7/00—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D7/02—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being helically coiled
- F28D7/024—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being helically coiled the conduits of only one medium being helically coiled tubes, the coils having a cylindrical configuration
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D7/00—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D7/02—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being helically coiled
- F28D7/026—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being helically coiled the conduits of only one medium being helically coiled and formed by bent members, e.g. plates, the coils having a cylindrical configuration
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D7/00—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D7/16—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being arranged in parallel spaced relation
- F28D7/1607—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being arranged in parallel spaced relation with particular pattern of flow of the heat exchange media, e.g. change of flow direction
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D7/00—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D7/16—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being arranged in parallel spaced relation
- F28D7/1684—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being arranged in parallel spaced relation the conduits having a non-circular cross-section
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F1/00—Tubular elements; Assemblies of tubular elements
- F28F1/10—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses
- F28F1/12—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element
- F28F1/14—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element and extending longitudinally
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F13/00—Arrangements for modifying heat-transfer, e.g. increasing, decreasing
- F28F13/06—Arrangements for modifying heat-transfer, e.g. increasing, decreasing by affecting the pattern of flow of the heat-exchange media
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
- F28F9/026—Header boxes; End plates with static flow control means, e.g. with means for uniformly distributing heat exchange media into conduits
- F28F9/0265—Header boxes; End plates with static flow control means, e.g. with means for uniformly distributing heat exchange media into conduits by using guiding means or impingement means inside the header box
Abstract
Fractionation is the process used by refineries to break down carbon chains of petroleum compounds so that the desired carbon compound can be achieved. This process typically involves high heat, distillation, re-boiling, and energy intensive cooling processes. This application discloses an invention that will condense vapor produced by a pyrolysis reactor. This system uses one standard cyclone; three cascading cyclones with internal cyclonic rotation fins that force incoming vapor to maintain a fixed amount of rotation regardless of the vapor's velocity, heat sinks that increase condensation, reversing fins that force gases to reverse direction inside the cyclone decreasing vapor velocity to increase heat loss; a main collection tank that allows for the controlling of the fuel flash point; a compact low temperature coil cooler that uses 100 percent of the cooling surface that allows for the production of higher quality fuel; and, bubblers/scrubbers that produce back pressure into the pyrolysis reactor. that will condense vapor produced by a pyrolysis reactor. This system uses one standard cyclone; three cascading cyclones with internal cyclonic rotation fins that force incoming vapor to maintain a fixed amount of rotation regardless of the vapor's velocity, heat sinks that increase condensation, reversing fins that force gases to reverse direction inside the cyclone decreasing vapor velocity to increase heat loss; a main collection tank that allows for the controlling of the fuel flash point; a compact low temperature coil cooler that uses 100 percent of the cooling surface that allows for the production of higher quality fuel; and, bubblers/scrubbers that produce back pressure into the pyrolysis reactor.
Description
CYCLONIC CONDENSING AND G SYSTEM
Field of the ion
The present invention relates generally to a device for heat ged technology.
More ularly, it relates to a device for economically condensing hydrocarbon vapors in a
renewable energy plant
Background of the Invention
The use of heat exchangers as cooling systems is well established in industry.
Examples of known devices include U.S. patent No. 4,858,681 to Sclzberger, U.S. patent No.
8,365,812 to Al·Hadhrami, U.S. patent No. 4,060,127 to Savin et. al., U.S. patent No.
3,168,136 to Ammon, and U.S. patent No. 3,258,068 to Hollister. These patents teach multistage
heat exchangers to slowly cool a vapor. The disclosed systems of these patents use
condensers that are bolted end to end on a slope so any liquid accumulating as a result of
vapor condensation will flow down a slope or gradient.
However, existing designs of convention systems often require an nate
amount of space to odate the structure of the cooling system. In addition, such
tional cooling system configurations merely produce a low surface area inside the
condensers thereby limiting their efficiency. Furthermore, the aforementioned designs do not
allow for easy linkage and ication of its components such as in a daisy-chain
configuration design. As a result, condensation of usable and re-useable fuel vapors may not
be optimized. Accordingly, prior art designs may lead to char build-up and plugging of
internal tubes within the condenser y reducing effectiveness of the system.
Thus, there is a need for producing a more efficient heat ge g system
that provides capability for optimizing usable and re-usable fuel vapors. There is also a need
for providing improved systems that reduce contaminants without employing added
expenditures of additional equipment (such as external heat sources, electrical input or
cooling media apparatus) for achieving the same.
SUMMARY
According to first broad aspect, the present invention es an apparatus for
processing reusable fuel comprising a first-type cyclone cooler having a first configuration.
The apparatus also es one or more second-type cyclone coolers, wherein each one or
11733982_1 (GHMatters) P110127.NZ
more second-type e coolers has a substantially identical second configuration to
respective other one or more second-type e coolers, wherein the second configuration
is different than the first configuration. The apparatus may also provide an air cooled heat
exchanger, a coil condenser and one or more bubblers. The first-type cyclone cooler and the
one or more second-type cyclone coolers are connected. One of the one or more second-type
e coolers is connected to the air cooled heat exchanger. The air cooled heat exchanger
is connected to the coil ser. The coil condenser is ted to the one or more
bubblers.
According to a second broad aspect, the present invention provides an apparatus
for processing reusable fuel comprising a first-type cyclone cooler having a first
uration. The apparatus may also provide one or more second-type cyclone coolers,
wherein each one or more -type cyclone coolers has an identical second configuration,
wherein the second configuration is different than the first configuration. The apparatus may
include an air cooled heat exchanger, a coil condenser, and one or more bubblers. The one or
more second-type cyclone coolers comprise a first set of g fins arranged in a first
direction. The one or more second-type cyclone coolers comprise a second set of turning fins
arranged in a second direction from the first ion. The first-type cyclone cooler and the
one or more second-type cyclone s are connected. The one of the one or more type
cyclone coolers is connected to the air cooled heat exchanger. The air cooled heat
exchanger is connected to the coil condenser. The coil condenser is connected to the one or
more rs.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated herein and constitute part of
this specification, illustrate exemplary embodiments of the invention, and, together with the
general description given above and the detailed description given below, serve to n the
features of the invention.
is a schematic illustration of a cyclonic condensing and cooling system
according to one embodiment of the present invention.
illustrates an assembled, an exploded and an internal view of cyclones B, C,
and D of ing to one embodiment of the present invention.
11733982_1 (GHMatters) P110127.NZ
illustrates an assembled view, an exploded view and an internal view of a
coil condenser according to one embodiment of the t invention.
illustrates an assembled and ed view of a forced air
cooling/condensing system according to one embodiment of the present invention.
[0012] illustrates an assembled and lly assembled view of a scrubber/bubbler
unit according to one embodiment of the present invention.
illustrates an assembled and exploded view of a main liquid fuel collection
tank and a flash tank for removal of hydro-carbon gases according to one embodiment of the
present ion.
[0014] is a schematic of the s flow of the condensing/cooling process
according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
Where the definition of terms departs from the commonly used meaning of the
term, applicant intends to utilize the definitions provided below, unless specifically ted.
It is to be understood that the foregoing general description and the following
detailed description are exemplary and explanatory only and are not ctive of any subject
matter claimed. In this application, the use of the singular includes the plural unless
specifically stated otherwise. It must be noted that, as used in the specification and the
appended , the singular forms “a,” “an” and “the” include plural referents unless the
context clearly dictates otherwise. In this ation, the use of “or” means “and/or” unless
stated ise. Furthermore, use of the term “including” as well as other forms, such as
“include”, “includes,” and “included,” is not limiting.
For purposes of the present invention, the term “comprising”, the term “having”,
the term “including,” and ions of these words are intended to be open-ended and mean
that there may be additional elements other than the listed elements.
For purposes of the present invention, directional terms such as “top,” “bottom,”
“upper,” “lower,” “above,” “below,” “left,” “right,” “horizontal,” “vertical,” “up,” “down,”
etc., are used merely for convenience in describing the various embodiments of the t
11733982_1 (GHMatters) P110127.NZ
invention. The embodiments of the present invention may be oriented in various ways. For
example, the diagrams, apparatuses, etc., shown in the drawing FIG.s may be flipped over,
rotated by 90º in any direction, reversed, etc.
For purposes of the present ion, a value or property is “based” on a ular
value, property, the satisfaction of a condition, or other factor, if that value is derived by
performing a mathematical calculation or logical decision using that value, property or other
factor.
For purposes of the present ion, it should be noted that to provide a more
concise description, some of the quantitative expressions given herein are not qualified with
the term “about.” It is understood that whether the term “about” is used explicitly or not,
every quantity given herein is meant to refer to the actual given value, and it is also meant to
refer to the approximation to such given value that would reasonably be inferred based on the
ordinary skill in the art, including approximations due to the experimental and/or
measurement conditions for such given value.
[0021] For the purposes of the present invention, the term “ambient air temperature” refers
to generally to the ature of the surrounding nment and more particularly the
temperature of the nding environment of the disclosed cyclonic sing and
cooling system.
For the purposes of the present ion, the term “bubbler” refers to an apparatus
that directs gas flow beneath a liquid in which gas bubbles through a liquid to filter, scrub
and/or dissolve out l gasses/pollutants. In addition, the bubbler may serve as a back
flame arrestor or a back pressure regulator.
For the purposes of the present invention, the term “coil condenser” refers to a
coiled tube utilized as the basic energy ge medium between a vapor to be condensed
and a liquid to be condensed. Typical surrounding liquids that may be utilized to achieve
lower freezing points or inhibit rust build up may include water or water mixed with glycol.
For the purposes of the present invention, the term “chiller” refers to an al
refrigeration unit used to lower/reduce the temperature of a liquid used in condensation to be
subsequently pumped such as through a coil condenser.
[0025] For the es of the t invention, the term “cyclone cooler” refers to a
non-electric drawing condensing device that rotates air mass in a cyclonic rotation. In
11733982_1 (GHMatters) P110127.NZ
application the cyclonic rotation may e a rapid inward circulation of air masses about a
low-pressure center.
For the purposes of the present invention, the term “daisy chain configuration”
refers to an assembly wherein components are connected in sequence. The sequential
connection may include a series configuration of connections of several components wherein
one component is connected to the next component in line.
For the purposes of the t ion, the term “fin” refers to a thin component
or appendage attached to a larger body or structure. Fins typically function as foils that
produce lift or thrust, or provide the ability to steer or stabilize motion while traveling in
water, air, or other fluid media. Fins are also used to increase surface areas for heat transfer
purposes.
For the purposes of the present invention, the term “heat exchanger” refers to a
device designed to transfer heat from one matter to another. In application, the heat
ger may be utilized to transfer heat n a solid object and a fluid (a liquid or a
gas), or between two or more fluids. The fluids may be separated (such as by a solid wall) to
prevent mixing or they may be in direct contact.
For the purposes of the present invention, the term “identical” refers to being
similar in every detail; exactly alike.
For the purposes of the present invention, the term “flash point” of a volatile
material refers to the lowest temperature at which vapors of the material will ignite when
given or d to an ignition source.
For the purposes of the present ion, the term “naphtha” refers to any of
several highly volatile, flammable liquid mixtures of hydrocarbons distilled from eum,
coal tar, and natural gas and used as fuel, as solvents, and in making various chemicals. Also
called benzine, ligroin, petroleum ether, white gasoline.
For the purposes of the present invention, the term “series” refers to a number of
things coming one after another in spatial or temporal succession.
For the purposes of the t ion, the term “scrubber” refers to a device
used to remove and/or dissolve rable pollutants from a gas or exhaust stream.
11733982_1 (GHMatters) P110127.NZ
For the purposes of the present invention, the term “substantially” refers to to a
great or significant ; for the most part; ially.
Description
While the invention is susceptible to various modifications and alternative forms,
specific embodiment thereof has been shown by way of example in the drawings and will be
described in detail below. It should be understood, however that it is not intended to limit the
invention to the particular forms sed, but on the contrary, the invention is to cover all
modifications, equivalents, and alternatives falling within the spirit and the scope of the
invention.
[0036] Fractionation includes the separating of a mixture of hydro-carbon chains into a
group of carbon chains or fractionations. l cracking is the process used by refineries
to break down carbon chains of petroleum compounds so that the desired carbon compound
can be ed. This process typically involves high heat, distillation, re-boiling, and energy
intensive cooling processes. This application discloses an invention that will condense vapor
produced by a reactor (e.g., a pyrolysis reactor). In doing so, the disclosed system utilizes a
standard cyclone; a plurality of specialized cascading cyclones with internal cyclonic rotation
fins that force incoming vapor to maintain a fixed amount of rotation regardless of the vapor's
velocity, heat sinks that se condensation, reversing fins that force gases to reverse
direction inside the cyclone decreasing vapor ty to increase heat loss; a main collection
tank that allows for the controlling of the fuel flash point; a compact low temperature coil
cooler that uses 100 percent of the cooling surface that allows for the production of higher
y fuel; and, bubblers/scrubbers that produce back pressure into the pyrolysis reactor.
The disclosed subject matter improves on heat exchanged technology by providing
a more efficient heat exchange cooling system that provides capability for optimizing usable
and re-usable fuel vapors. Such vapors may be captured and utilized on any device able to
run on gaseous fuel such as any ndensable petroleum fuel.
In addition, the disclosed t matter discussed herein s from the prior art
as it employs modified rotation fins, internal e heat sinks, forced gas direction reversal
inside of each cyclone, the y to control fuel flash points without an external heat source,
separation of the collected fuels without an al het source, and compact low temperature
coil cooler that uses one hundred percent of the cooling surface.
82_1 (GHMatters) P110127.NZ
Furthermore, the disclosed subject matter s a chain design
configuration so that the condensation of usable re-useable fuel vapors in optimized. The
disclosed cyclonic condensing and cooling system is part of a re-useable energy technology
and the prior art designs would lead to Char build-up and plugging of the tubes within the
condenser reducing effectiveness.
Turning to the disclosed subject matter is directed to a cooling system
ting of a plurality of e coolers (e.g., one standard cyclone cooler and one or more
specialized e coolers) thereby forming the disclosed ic condensing and cooling
system 100. According to disclosed ments, the standard cyclone cooler may be
considered to be a first-type cyclone cooler having a first configuration, as explained herein.
The one or more specialized cyclone coolers may be considered to be second-type cyclone
coolers. Thus, the one or more second-type coolers may have a substantially identical second
configurations to respective other one or more second-type e coolers, as explained
below. Yet, the first-type e cooler having the first configuration is different from the
second-type cyclone coolers having the second configurations, as explained below.
By way of example, one standard e cooler is depicted as A in In an
exemplary embodiment three specialized cyclone coolers are illustrated as B, C and D in FIG
1. Each of the specialized cyclone s B, C and D are of the type rated, for example,
in An exemplary embodiment of the standard cyclone cooler may comprise a first
configuration. An exemplary embodiment of the specialized cyclone coolers may comprise a
second configuration, each of the second configurations being alike one another but different
from the first configuration of the standard cyclone cooler. The disclosed cyclonic
condensing and cooling system 100 may include a chiller 300, an air heat exchanger 400, two
liquid bubblers/scrubbers 500, a main holding or main liquid fuel collection tank 136, and an
expansion tank 142.
In an exemplary application, a pyrolysis r processes plastic waste material
which may be shredded and fed n. Applying heat above 350 degrees Celsius will cause
the shredded plastic material to melt and vaporize. The up-stream reactor es back
pressure to assist in the thermal cracking of the carbon chains present in the plastic material.
The cyclonic condensing and g system 100 may be employed to produce the required
back pressure required by the pyrolysis reactor. Such back pressure is achieved due to the
11733982_1 (GHMatters) P110127.NZ
static friction of the pipe and cyclone s of the sed subject matter in addition to the
water column re produced in the bubblers/scrubbers 500 (e.g., depicted in .
Turning to the first cyclone cooler is illustrated at 120a. First cyclone
cooler is a standard e cooler. A standard cyclone cooler ts of an inlet section,
body wall, cone to discharge and an internal tube. When the vapor or gas stream enters the
cyclone it s around the body and down the cone, then up through the tube and out of the
cyclone. The amount of rotation on the incoming gas, dictates the amount of rotation and
centripetal force it es and particles being conveyed with the gas. This force separates
the particles from the gas and drops through the cone, then out of the cyclone. The gas rotates
and drops down the cone, increasing in velocity and pressure due to the smaller and smaller
diameter on the cone. This action packs the gas stream at the bottom of the cone and forces it
to rise back up and through the internal tube, then out of the e to the next cyclone. The
rotations of the vapor within first cyclone cooler 120a are based on the velocity of the gas as
it enters first cyclone cooler 120a. In the disclosed subject matter, a cyclone inlet is depicted
in at 134 and at 134. Inlet 134 has a diameter of about 6 inches wherein its inlet
velocity can accommodate a vapor or gas stream of about 3,234 feet per minute based upon
the pyrolysis reactor's rate capability based upon the following values: approximately 2,000
pounds of shredded plastic material processed per hour at about 1,150 degrees Fahrenheit. As
the pyrolysis r has about a 7 percent char rate, the remaining volume of shredded
plastic processed (after the char is removed) is about 1,860 pounds per hour processed into a
gaseous state. The gas weighs 0.78 ounces per cubic foot. Thus, standard cyclone cooler 120a
receives gas at a rate of about 635 cubic feet per minute. The ambient temperature is assumed
to be about 70 degrees Fahrenheit for purposes of exposure to heat loss.
The vapor remains in first cyclone cooler 120a for about 4 seconds. This allows for
a heat loss of between about 3 and 8 s Fahrenheit. The fuel collected at a bottom 15la
of first cyclone cooler 120a contains carbon chains that are C-28 or larger. First cyclone
cooler 120a also collects large char particles that may have travelled into cyclonic condensing
and cooling system 100. These char particles will drop out of the vapor stream and will be
deposited to the rge hopper at the bottom 151a where it mixes with fuel containing
carbon chains that are C-28 and larger. This fuel char mixture may be returned and re-fed into
the pyrolysis reactor for further thermo cracking via a high temperature pump 137. The
vapors leaving rd cyclone cooler 120a are traveling at a velocity of about 3,224 feet per
82_1 (GHMatters) P110127.NZ
minute and will travel through a cross over pipe 135 for about 2.9 seconds. Due to the thin
wall of cross over pipe 135, heat loss of the vapor as the vapor travels through cross over pipe
135 will be approximately 2 s Fahrenheit. This heat loss lowers the inlet vapor volume
of the vapor entering the second cyclone cooler 120b.
[0045] Turning to a cross section of specialized e coolers 120b, 120c, and
120d (second cyclone cooler, third cyclone cooler and fourth cyclone cooler, tively) of
illustrates the internal structure of specialized cyclone coolers (120b, 120c, and 120d)
that forces gas vapors to follow a cyclonic path to maximize vapor contact with outer the
outer body of the cyclone cooler (that is uous to ambient temperature) in order to
dissipate heat and to effect condensation.
Accordingly, second cyclone cooler 120b (FIGS. 1 and 2) is a specialized cyclone
cooler ucted with a unique configuration different from the standard/first cyclone
cooler 120a. As illustrated in second cyclone cooler assembly 120b is illustrated in an
assembled view 200, and ed view 202 and an internal view 204. Second e cooler
may include a body portion 145 joined to a cone 150 in a final assembled state. Contrary to
the standard cyclone cooler, the second cyclone cooler has onal internal components in
a disclosed arrangement of the disclosed subject matter. Specifically, in tion, body
portion 145 and cone 150 house an internal structure or internal tube comprising an outer
tube structure 210 and inner tube structure 212. Inner tube structure may be regarded as an
inner filler drum 148. Outer tube structure 210 has a cavity 214. In a final assembly, inner
tube structure 212 is disposed within a cavity 214 of outer tube structure 210. Inner tube
structure 212 comprises a cavity 216 for accommodating disbursed gases hrough.
The body 154 of outer tube structure 210 includes a first set of turning fins 149
ed along its exterior in a first rotational direction, as described below. A configuration
of turning fins 149 may include an internal cyclonic rotation fin configuration. Inner tube
structure 212 includes a second set of turning fins 147 disposed along its exterior traversing
in a second rotational direction. A configuration of g fins 147 may e an internal
cyclonic rotation fin configuration. In one embodiment, the second rotational direction may
include a reverse or opposite cyclonic rotational fin direction to turning fins 149, as further
described below.
Thus, in a final assembly, inner tube structure is disposed in cavity 214 of outer
tube structure 210 to form an internal tube assembly. The al tube assembly is further
11733982_1 (GHMatters) P110127.NZ
disposed within the cavity of the joined body portion 145 and cone 150. In the final assembly
configuration, a first channel 206 is formed between an exterior of the outer tube structure
210 and the interior of the body portion 145. Additionally, a second channel is formed
between an exterior of the inner tube structure 212 and an interior of the outer tube structure
210 within cavity 214. Turning fins 149 are disposed within first channel 206 in a first
direction and turning fins 147 are disposed within second channel 208 in the second
direction, as discussed below.
In select ments, the disclosed subject matter provides second cyclone cooler
120b designed with about 158 feet of turning fins 149. The distance between turning fins 149
is about 4 inches (the pitch) with the width of the flight being about 3 inches. Turning fins
149 may be designed having 12 spiral rotations with a 36 inch outside radius. Fins 147 placed
on inner tube structure 212 may include 6 spiral rotations with the same pitch and width as
turning fins 149. Turning fins 149 are attached inside the body 145 of second e cooler
120b to force the amount of rotations of received gases. This makes the gases come into
contact with body 145 a fixed amount of times before entering a cone 150 disposed below.
The travel time through second cyclone cooler 120b is about 3.8 seconds based on the
process rate of the reactor of about 2000 pounds of shredded c per hour. There is heat
loss in second cyclone cooler 120b due to the friction produced by fins 149 as the fins act as
heat sinks. As vapors cool, they condense and lose volume; loss of volume reduces the
velocity of gas ng its velocity and creating more retaining time. This s in further
heat loss within the cyclone coolers. (provides a schematic of the remaining cyclonic
cooling system calculated losses for the disclosed subject matter.)
Third cyclone cooler 120c (FIGS. 1 and 2) is cal to second e cooler
120b. Likewise, third cyclone cooler 120c is a lized cyclone cooler being constructed
with a unique configuration different from the standard/first cyclone cooler 120a. The process
involved in third cyclone cooler 120c is identical to second cyclone cooler 120b; third
cyclone cooler 120c being ed and constructed in the same manner as second cyclone
cooler 120b. In ion, vapors leave second cyclone cooler 120b and travel to third
e cooler 120c via cross over pipe 126a. The g process continues reducing the
volume of the vapor and reducing the velocity of the vapor.
Fourth cyclone cooler 120d (FIGS. 1 and 2) is identical to second cyclone cooler
120b and third cyclone cooler 120c. Likewise, fourth cyclone cooler 120d is a specialized
11733982_1 (GHMatters) P110127.NZ
cyclone cooler being constructed with a unique configuration different from the standard/first
cyclone cooler 120a. Fourth cyclone cooler 120d is designed and constructed in the same
manner as second cyclone cooler 120b and third cyclone cooler 102c. In operation, vapors
leave third cyclone cooler 120c and travel to fourth cyclone cooler 120d via cross over pipe
126b. The cooling process continues reducing the volume of the vapor and reducing the
velocity of the vapor. A design configuration of fourth cyclone cooler 120d may allow vapor
to leave this cyclone and enter into a forced air heat exchanger 400 (see, FIGS. 1 and 4). In an
exemplary design, forced air heat exchanger (air cooled condenser) 400 has a total cross
sectional area of about 1600 square inches inside the oval flatten tubes. This high surface area
increases the on time and slows the velocity of the remaining gas stream to about 150
feet per minute and reduces the heat dramatically from approximately 100 degrees Celsius to
70 degrees Celsius due to the ambient air temperature. This creates a large amount of
condensation that is collected inside oval flatten tubes 157 and allowed to drip back into
fourth cyclone cooler 120d disposed located directly below. This returning liquid fuel, in
turn, further cools the vapor leaving third cyclone cooler 120c. The vapor travels through
forced air heat ger 400 and is pushed into chilled cooling coils of coil condenser 300
(FIGS. 1 and 3) via pipe 141.
Turning to an internal configuration 302 and exploded view 304 of coil
condenser 300 is rated. Coil condenser 300 serves as a short carbon chain condensing
unit. In an exemplary embodiment, coil condenser 300 is a cooler that is constructed with six
internally coiled 1 inch tubes 167 that are submerged h a tank of d glycol 169.
The six l inch diameter stainless steel round tubes are in the form of a spiral. The spiral
reduces the overall length of the 1 inch tubing from sixty feet where it is contained in an
tus that is about five feet in height. The six coils are generally arranged evenly around
each other in a circular pattern. This creates an even distribution of the flowing gases inside
the coils. The spiral shape s in the slowing of the incoming vapors by the use of turning
static pressure. These coils are attached through a top and bottom flange plate 170. This
assembly is inserted into a drum housing 169 with ng s 168 and 169. The drum
housing 169 is filled with a glycol product that acts as the media for the heat exchange. The
glycol remains present inside this drum. A cooling coil 167 is introduced into the drum which
cools the glycol. In turn the glycol cools the 1 inch tubing that is ng the vapors inside.
11733982_1 (GHMatters) P110127.NZ
Cooling coil 167 is attached to a standard refrigeration system 144 ( and
remains closed loop through the glycol drum 169. The vapors pass h cooling coil 167,
allowing condensation to drip into the collection chamber 171. The vapor that does not turn
into condensation exits the coil condenser at 174 after the vapor circles the glycol drum. The
flange connection 170 at the bottom of the glycol drum allows the liquid to go in one
direction and gas to go in another. The chamber 173 between the glycol drum and the
housing is the location of where the vapors travel to the gas outlet at 174. This zone also sees
the glycol temperature on the outside of the glycol drum 169 to further cool the vapor. The
condensed vapor that exits coil condenser 300 as a liquid is collected in a smaller or
secondary tank 129 ( and pumped to storage.
Coil condenser 300 is designed with bolted flange connections for access and
service to all components of this equipment. Each e cooler and the coil chiller has a
tank or collection hopper below them (at 151a, 15lb, 15lc, and 15ld). In the case of the
cyclone coolers, the collection discharge hopper (at 151a, 15lb, 151c, and 151d) has a
drain port, level indicator (at 153) ng connection and a fuel outlet port (spill
over) (at 151p). The spillover 151p allows for the build-up of collected fuel to be
discharged into a respected holding tank.
The first three cyclones coolers 120a, 120b, and 120c discharge into a first hold
tank also regarded as the main holding tank 136 via control ball valves 139 (FIGS. 1 and 6).
The fourth cyclone 120d discharges in r or second holding tank also regarded as
secondary tank 129 that is located beneath the chilling coil of coil condenser 300. ing
to the disclosed subject matter, smaller or secondary tank 129 receives the lighter, cooler
ted fuels. The lighter or cooler collected fuels may include r or shorter carbon
chains (i.e., gasoline, naptha) as d to diesel which has longer carbon chains. Main
holding tank 136 ts heavier heated fuels (i.e., those fuels having a higher boiler point).
Disclosed embodiments provide that main g tank 136 collects the heavier heated fuels
as being filled from the cyclone s 120a, 120b, and 120c. Higher temperature fuels are
regarded as those fuels having higher boiling points and higher flash point e.g., above 40
degrees Celsius. Although the first three cyclone coolers 120a, 120b, and 120c collect higher
temperature fuels, some amount of light fuel (like benzene) may also be collected. The lighter
fuels will vaporize from the heat of the holding fuels inside main holding tank 136 and drift
up the tank column 121. A pump 122 located at the top of the expansion column 121 will pull
11733982_1 ters) P110127.NZ
these vapors from main holding tank 136 before they can re-condense and force them into
coil condenser 300. This allows for the collection of fuel of higher quality in main holding
tank 136 by rising the flash point on the collected fuel. Disclosed cyclones coolers A, B, C, D
all work together to collect fuels having a range of carbon to carbon chain structure. In
accordance with disclosed ments, the configuration of cyclonic condensing and
cooling system 100 allows heavier heated fuels to be collected by cyclone s A, B, C,
and D while the lighter fuel is capable of being collected in coil condenser 300.
The chilled gases leave coil condenser 300 and travel to two bubbler tanks 500 that
are connected in sequence h pipe connection 141. These tanks have an extended pipe
from the inlet port that is submerged under the liquid water line at 181. This
submerged pipe 181 causes back pressure to the system by the ance of the liquid in the
bubbler tank. This is referred to as water column pressure. By using two tanks to achieve the
water column pressure, the height can be divided. These bubbler tanks can contain different
liquid ents as needed to remove any contaminants in the remaining vapors. As
illustrated in the first tank is designed to hold water and is equipped with a level
indicator 186 and a PH meter 187 to monitor the condition of the water. Water is used to
remove sulfur and the buildup of sulfur will indicate a change in the PH. The second r
contains caustic soda. This will capture any chlorine gas in the vapors. This tank also has a
PH meter 187 and is also equipped with a level indicator 186 and level sensor.
[0057] The last tank on cyclonic condensing and cooling system 100 is a standard
expansion tank 142. Expansion tank 142 is also designed to catch any liquid droplets that
may travel through cyclonic condensing and cooling system 100. Pressure sensors and
indicators r the reactor pressure from this point in the system.
In operation, the as gases are received within the disclosed cyclonic condensing
and cooling system 100, embodiments of the disclosed subject matter force rotations of the
gases through the system. Throughout on, the hot gases will lose heat from thermo
contact loss with the outside body wall 145. In accordance with the design of the disclosed
subject matter, the ng gasses are channeled down first channel 206 in a direction
commensurate with a first onal direction enabled by turning fins 149 and up second
channel 208 commensurate with a second rotational direction mandated by the placement of
turning fins 147. In an exemplary embodiment, the second rotational ion may include a
e rotational direction from the first rotational direction. Prior to sing up second
11733982_1 (GHMatters) P110127.NZ
channel 208, embodiments of the disclosed subject matter allow the gases to pack generally
at the bottom of cone 150 like a standard cyclone whereupon they are forced to reverse
rotational ion before entering the internal tube (i.e., outer tube structure 210 and inner
tube structure 212). This adds to the le separation, e the ga ses come to a
complete stop before reversing direction, allowing the particles to fall out of the gas stream.
The design then uses the cyclone as a separator and a cooler/condenser. As hot gases lose
heat, condensation is ted in the cooler area. By controlling the gas resident time inside
the cyclone, a fixed condensing temperature can be achieved. By controlling this temperature,
fuel can be distilled into c-chain groups between a group of cyclones.
[0059] Embodiments of the disclosed cyclonic sing and cooling system provide
four cyclone coolers in series (at 120a, 120b, 120c, and 120d). The first cyclone cooler
120a collects the larger particles and higher carbon chain fuels only. The next three cyclone
coolers 120b, 120c, and 120d separate the fuel grades (e.g., gasoline, petroleum, derived
liquid for fuel) based on condensing temperatures. Separated fuels have temperatures which
cause vaporization of the fuels to ignite when exposed to an open flame. This process is
referred to as a flash point. The lower the carbon chain number in the fuel, the lower the
temperature of the liquid fuel, that will cause the fuel to ignite. This temperature will be
referred to as the "yield flash indicator" (YFI). In order to increase the YFI, the removal of
the r carbon chains by use of heat is required.
[0060] Each cyclone collects vapor at a lower temperature than the one before it in the gas
stream creating its own YFI value. Inside the internal tube at 154 is a reversed set of
fins 147 connected to a filler drum 148 inside the tube. The rge of each cyclone cooler
has a hopper, or discharge tank 151 to store condensed fuels. Each hopper can be ed to
a holding tank by selected ball valves. A level indicator 153 is used to start the discharge of
the collected fuels. The tion hopper also has a drain valve (at 139) for cleanout
use.
The last cyclone cooler, the fourth, in the series (at 120d) will have an air
contact heat exchanger 400 to insure full ambient cooling. This heat exchanger 400
condenses the last of the ambient temperature fuels and drips it back through the cyclone,
acting as a reflux and cooling for the cyclone. The remaining vapors then pass through a coil
type chiller 300 via a connecting pipe 141. This is a set of five coils (at 167) ing
65 feet in straight length each and wrapped around each other in an even g. The coils
11733982_1 (GHMatters) P110127.NZ
167 are set inside a tube filled with glycol 169 for chilling. This glycol is chilled with
refrigerated coils 175 from an air conditioner compressor and controlled to in the set
point temperature. The incoming vapors entering the coil condenser 300 at entrance 164 will
condense and drip out of the chiller housing 171. The vapors then turn up from the bottom of
the coils and travel to the gas outlet 174. On the way to this outlet port, the gases are again
exposed to the cold wall (at 173) of the glycol chamber (at 169). This creates
an effectiveness of 100% use of the ng chamber. The remaining gases are considered
non-condensable at room temperature. This gas is referred to as syn-gas.
The syn-gas is then passed h two sets or bubbler/scrubbers 500. The first is
filled to a fixed point with water. This water acts as a back pressure device, a flame arrester
device and a scrubber. Along with the C4, hydrogen and other gases that make up the syngas
, some unwanted gases also travel with the syn-gas from time to time. Without good
control of the plastics entering in the reactor, chorine and sulfur can be introduced. The first
bubbler will catch the sulfur in the water producing a weak dibasic acid, S02 + H20=H2S03.
[0063] The next bubbler also acts as a back pressure device, flame arrester and scrubber.
This time it is filled with caustic soda to scrub chorine. H=NaClO or salt and water.
The bubblers 500 are also equipped with a level l 186 so the level of the bubbling
liquids is monitored as well as a PH meter 500 at 187 to indicate the condensing on the
bubbling/ scrubbing liquids.
[0064] At this point the syn-gas is ready to be used. Thus, embodiments of the disclosed
subject matter provide an improved means for ing and processing excess gas for use on
any device capable of running on gaseous fuel, i.e., non-condensable petroleum fuels.
Accordingly, the burners for r-type systems are e of utilizing the fuel of the
disclosed t matter. The syn-gas may also be used to power a generator that could power
the electrical system of the reactor. The last item in the cooling system is a finish tank. This
tanks act a drip collection if any liquids travel past the rs. It also serves as an
expansion tank for the syn-gas. When the re inside this tank is at set point, the gas is
allowed to be used.
Turning to an example design construction of cyclonic condensing and cooling
system 100, disclosed embodiments may consist of four cyclones, two fuel tanks, an air
cooled radiator, one glycol chilled coil condenser, two rs, and one expansion tank all
attached to a structural steel frame. The cyclone coolers may be constructed from 10 gauge
11733982_1 (GHMatters) P110127.NZ
stainless steel material. This material is selected due to its ability to withstand the internal
pressure of the reactor while allowing heat to pass through the metal, cooling the incoming
gas. The cyclone coolers t of a scrolled inlet, flanged body section, internal tube with
fixed rotation fins, an interior baffle with reversed rotation fins, a bolted cone with support
pads, and a discharge hopper with an outlet port.
The internal rotation fins are welded to one side of the cyclone tube ng for
the condensed liquid to run h the fins to the discharge hopper. The internal tube also
has a cone bottom to continue the vapor to pressurize inside the cyclone. Inside the internal
tube is a cone drum that acts as a baffle. This baffle also has rotation fins welded to one side.
The cone drum baffle has a sloped top to allow for drainage of any condensation that may
occur inside. The gas inlet and outlet discharge ports have a flange connection. The cone
bottom is equipped with a coupling that acts as a level indicator. The cone bottom has a
discharge part with a stub in flange for rotation and tion to the discharge hopper. The
discharge hopper has a drain port, two outlet ports and the level indicator coupling.
[0067] The cyclone coolers (A, B, C, and D) are piped in a daisy chain configuration. The
piping used between cyclone coolers is a thin wall schedule 10 stainless steel pipe with ANSI
150 flanges. This pipe is sloped from one cyclone coolers to the next and downhill to drain
any condensation vapors. The last cyclone cooler in the daisy chain configuration has an air
cooled heat exchanger connected to the top discharge flange. This air cooled heat ger
reduces the remaining vapor temperature and allows for liquid to condense and return to the
last e where it enters the discharge . This air cooled heat exchanger is
constructed from oval-shaped tubing. The oval-shaped tubing is welded to the top and bottom
seal plate, openings in the seal plate are welded to the oval-shaped tubing to allow vapors to
pass h the inside of the tubing. Housing surrounds the tubing section and connects to
an inlet chamber and gas discharge chamber. The fan is ted to the tube section
housing. This part of the system uses ambient air and forces it across the e of the tubing
to reduce the inside vapor temperature.
The fuel tanks may be ucted from heavy wall schedule 40 stainless steel pipe
with pipe ends and connecting ports as needed to fill and discharge the incoming fuels. The
top of the main tank 136 has an expansion column to allow light vapors to be removed from
the collected liquids below. The second tank 129 is a standard g tank with inlet and
outlet connections plus a coupling for level indication. The large tank 136 is constructed to
11733982_1 (GHMatters) P110127.NZ
allow for high temperature fuel storage and collects from the first three cyclones. The r
tank 129 will see low temperature fuels and is used to collect fuel from the last cyclone and
the coil ser.
After the vapors leave the air cooled heat exchanger 400 it enters into a chilled coil
condenser 300. The coil condenser is d above the small fuel tank 129. The condenser
consists of six l inch diameter ess steel round tubes that have been rolled into a spiral.
The spiral reduces the l length of the 1 inch tubing to one tenth the . The spiral
shape also assists in the g of the incoming vapors by use of the turning static pressure.
The coils are attached through a top and bottom flange plate. This assembly is inserted into a
drum g with matching flanges. The drum housing is filled with a glycol product that
acts as the media for the heat exchange. The glycol remains resident inside this drum. A
cooling coil is introduced into the drum which cools the glycol. In tum the glycol cools the 1
inch tubing that cools the vapors inside. The cooling coil is attached to a standard
refrigeration system and remains closed loop through the glycol drum. The vapors passing
h the 1 inch coils, cool, so the coil condenser allows the produced condensation to drip
to the bottom in the collection chamber, exiting the device. The special flange connection at
the bottom of the glycol drum allows for liquid to go in one direction and gas to go in
another. The chamber between the glycol drum and the outside is where the remaining vapors
travel. This zone also is cooled by the glycol thus it benefits from double cooling. The coil
condenser is designed with bolted flange connections for access and service to all
components of this equipment.
The chilled gases leave the coil condenser then travel through two bubbler tanks
500. These tanks have an extended pipe from the inlet port that is ged under the liquid
water line. This submerged pipe causes back pressure to the system by resistance of the liquid
in the bubbler tank. This is referred to as water column pressure and by using two tanks the
height can be divided between each one. An example is if total water column back pressure is
60 inches in one bubbler and 50 inches in the second bubbler, a total of 110 inches of water
column back pressure is created. These bubbler tanks can contain different liquid components
as needed to remove any inants in the remaining vapors. The first tank is designed to
hold water and is equipped with a level indicator and a PH meter to monitor the condition of
the water. Water is used to remove sulfur and the buildup of sulfur will be indicated by a
change in the PH. The second bubbler contains caustic soda which will capture any chlorine
11733982_1 (GHMatters) P110127.NZ
gas in the vapors. This is also red with a PH meter and this second bubbler is also
equipped with a level indicator and level sensor.
The last tank on the e cooling system is a standard expansion tank 142 that
is designed to catch any liquid droplets that may travel through the piping. Pressure sensors
and tors mounted on this expansion tank keep track of the reactor pressure. Throughout
the cyclonic condensing and cooling system 100 are differential pressure gauges. These
gauges are used to identify any buildup or clog edge in the pipe or in any component of
cyclonic sing and cooling system 100. The entire process is mounted on a bolted steel
frame system. The frame system may utilize a standard A36 carbon steel frame, d and
equipped with matching connection clips for all corresponding equipment. The size and
shape of the equipment is designed for quick breakdown and transport in a standard sea
ner.
Accordingly, the sed cyclonic condensing and cooling system 100 improves
on heat exchanged logy as it does not require the bolting of the heat exchangers from
end to end; takes up much less space than if the current technology was used; increases the
surface area inside of the condensers that make up a heat exchanger; es much lower
velocity of the vapor when entering the condenser; allows for the continued release of the
condensed liquid after the heat exchange and on, allowing the non-condensed vapors to
move to the next condenser, and; prevents the build-up of char that could plug the tubes
within the condensers.
It should be noted and understood that while the above and other advantages and
results of the present invention will become apparent to those skilled in the art from the
following detailed description and accompanying drawings, showing the contemplated novel
construction, combinations, and elements herein described, and more particularly defined by
the appended claims, it should be clearly understood that changes in the precise embodiments
of the herein described invention are meant to be included within the scope of the claims,
except insofar as they may be precluded by the prior art.
For e, while a select number of cyclonic s are described throughout
the application, it is readily appreciated that more or less of the disclosed apparatus may be
employed by the disclosed subject matter, for example, to accommodate alternate systems,
parameters and results. This includes disclosed temperature , velocities, fuels,
pressures and volumes.
11733982_1 (GHMatters) P110127.NZ
Having described the many embodiments of the t invention in detail, it will
be apparent that modifications and variations are le without departing from the scope
of the invention defined in the appended claims. Furthermore, it should be appreciated that all
examples in the present disclosure, while illustrating many embodiments of the invention, are
provided as non-limiting examples and are, therefore, not to be taken as ng the various
aspects so illustrated.
All nts, patents, journal articles and other materials cited in the present
application are incorporated herein by reference.
While the t invention has been disclosed with references to certain
embodiments, us modification, alterations, and changes to the described embodiments
are possible without departing from the sphere and scope of the present invention, as defined
in the appended claims. Accordingly, it is intended that the present ion not be limited to
the described embodiments, but that it has the full scope defined by the language of the
following claims, and equivalents thereof.
11733982_1 (GHMatters) P110127.NZ
Claims (20)
1. An apparatus for processing le fuel comprising: a first-type cyclone cooler having a first configuration; one or more second-type cyclone s, wherein each one or more second-type 5 cyclone coolers has a substantially identical second configuration to respective other one or more second-type cyclone coolers, wherein the second configuration is different than the first configuration; an air cooled heat exchanger; a coil condenser; and 10 one or more bubblers, wherein the first-type cyclone cooler and the one or more second-type e coolers are connected, wherein one of the one or more second-type cyclone coolers is connected to the air cooled heat exchanger, 15 wherein the air cooled heat exchanger is connected to the coil ser, and wherein the coil condenser is connected to the one or more bubblers.
2. The apparatus of claim 1, n the first-type cyclone cooler is connected in a daisy chain configuration with the one or more second-type cyclone coolers.
3. The apparatus of claim 1, wherein the one or more second-type cyclone coolers 20 comprise a first set of turning fins.
4. The apparatus of claim 3, wherein the one or more second-type cyclone s se a second set of turning fins.
5. The tus of claim 4, wherein the first set of turning fins is arranged in a first direction and the second set of turning fins is arranged in a second direction from the 25 first direction.
6. The apparatus of claim 5, wherein the second direction is a reverse direction of the first direction.
7. The apparatus of claim 1, wherein the first-type cyclone cooler and one or more second-type cyclone coolers are arranged as cascading cyclones. 11733982_1 (GHMatters) P110127.NZ
8. The apparatus of claim 7, wherein the one or more second-type cyclone coolers comprises three second-type e coolers.
9. The tus of claim 1, wherein the one or more second-type cyclone coolers comprises three second-type cyclone coolers. 5
10. The apparatus of claim 9, wherein the first-type cyclone cooler and the three secondtype cyclone coolers are arranged in series beginning with the first-type cyclone
11. The apparatus of claim 10, wherein a last of the three second-type e coolers is connected to the air cooled heat exchanger. 10
12. The apparatus of claim 11, wherein the first-type cyclone cooler and two of the second-type cyclone coolers are connected to a first holding tank.
13. The apparatus of claim 10, wherein the air cooled heat exchanger is connected to the coil condenser.
14. The apparatus of claim 13, the coil ser is ted to a second holding tank.
15 15. The apparatus of claim 1, n the one or more bubblers comprise a plurality of bubblers that are connected in sequence.
16. The apparatus of claim 15, wherein the plurality of bubblers are ted together.
17. The apparatus of claim 16, further comprising: an expansion tank, wherein the expansion tank is connected to one of the bubblers. 20
18. The apparatus of claim 1 wherein: the one or more second-type cyclone s comprise a first set of turning fins arranged in a first direction, the one or more second-type cyclone coolers comprise a second set of turning fins arranged in a second direction from the first direction. 25
19. The apparatus of claim 18, wherein the second direction is in an opposite direction to the first direction. 11733982_1 (GHMatters) P110127.NZ
20. The apparatus of claim 18, wherein the first direction is a ic rotation direction and the second direction is a cyclonic rotational direction.
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/054,903 US10436525B2 (en) | 2016-05-12 | 2016-05-12 | Cyclonic cooling system |
US15/054,903 | 2016-05-12 | ||
US15/593,579 | 2017-05-12 | ||
PCT/IB2017/052811 WO2017195169A1 (en) | 2016-05-12 | 2017-05-12 | Cyclonic condensing and cooling system |
US15/593,579 US10345048B2 (en) | 2016-05-12 | 2017-05-12 | Cyclonic condensing and cooling system |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ748509A NZ748509A (en) | 2020-09-25 |
NZ748509B2 true NZ748509B2 (en) | 2021-01-06 |
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