US20190368729A1 - Post-combustion device and method - Google Patents

Post-combustion device and method Download PDF

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Publication number
US20190368729A1
US20190368729A1 US16/478,178 US201816478178A US2019368729A1 US 20190368729 A1 US20190368729 A1 US 20190368729A1 US 201816478178 A US201816478178 A US 201816478178A US 2019368729 A1 US2019368729 A1 US 2019368729A1
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Prior art keywords
combustion
post
gas
furnace
chamber
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US16/478,178
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Danny VOYKA
John VOYKA
Michael Kidd
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Energy2cleanair Holdings Pty Ltd As Trustee For Energy2cleanair Unit Trust
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Energy2cleanair Holdings Pty Ltd As Trustee For Energy2cleanair Unit Trust
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Assigned to ENERGY2CLEANAIR HOLDINGS PTY LTD AS TRUSTEE FOR ENERGY2CLEANAIR UNIT TRUST reassignment ENERGY2CLEANAIR HOLDINGS PTY LTD AS TRUSTEE FOR ENERGY2CLEANAIR UNIT TRUST ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: VOYKA, Danny, VOYKA, John, KIDD, MICHAEL
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J15/00—Arrangements of devices for treating smoke or fumes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G7/00—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals
    • F23G7/06—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G7/00—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals
    • F23G7/06—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases
    • F23G7/061—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases with supplementary heating
    • F23G7/065—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals of waste gases or noxious gases, e.g. exhaust gases with supplementary heating using gaseous or liquid fuel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J15/00—Arrangements of devices for treating smoke or fumes
    • F23J15/006—Layout of treatment plant
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J15/00—Arrangements of devices for treating smoke or fumes
    • F23J15/08—Arrangements of devices for treating smoke or fumes of heaters
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2209/00—Specific waste
    • F23G2209/14—Gaseous waste or fumes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00—Combustion technologies with mitigation potential
    • Y02E20/12—Heat utilisation in combustion or incineration of waste

Definitions

  • the present invention relates to post-combustion processing and more particularly to post-combustion processing using a combustible gas mixture.
  • WO2015/015447 by Futurenergy Pty Ltd (Futurenergy) (incorporated in its entirety herein by reference), describes a combustion system using Magnegas, as described in U.S. Pat. No. 6,663,752.
  • Futurenergy is not suitable for long-term continuous usage, as would be required in any continuous furnace operation. Anything beyond short-term usage of the device described in the Futurenergy specification results in intermittent failure of post-combustion and decreasing efficiency that shuts down the combustion process. This can be explosively dangerous and damaging to the equipment. Intermittent failure also results in the undesirable release of unprocessed combustion gases into the environment.
  • the present invention provides a post combustion apparatus comprising:
  • the present invention provides a process of post combustion comprising the steps of:
  • the ratio of the mode of cross-sectional area of the combustion expansion chamber is greater than that of the mode of cross-sectional area of the mixing chamber, more preferably at least double that of the mode of cross-sectional area of the mixing chamber.
  • the mode of a cross-sectional combustion exhaust chamber area is also preferred for the mode of a cross-sectional combustion exhaust chamber area to be at least double that of the mode of the mixing chamber area.
  • the combustion exhaust chamber outlet can be connected to an exhaust flue stack.
  • the combustion exhaust chamber is connected to an inlet for the furnace such that, in use, at least some processed furnace exhaust gas is recycled into the furnace.
  • the amount of processed furnace exhaust gas entering the furnace is controlled by way of a valve.
  • the minimum cross-sectional area anywhere along the combustion expansion chamber through to the outlet of the apparatus is greater than the mean cross-sectional area of the mixing chamber.
  • Oxygen levels in the mixing chamber should be below atmospheric levels.
  • the inventors have found that high levels of oxygen in the mixing chamber often cause the post-combustion gas fuel to undesirably react preferentially with oxygen. It is preferred that the post-combustion gas fuel be allowed to react with the furnace emissions.
  • the exhaust path between the furnace and the exhaust stack should preferably be sealed from the air and no additional oxygen should be introduced into the system.
  • the exhaust path should preferably be at least the same cross-sectional area as the expansion chamber to minimise back-pressure. Back pressure has been found to degrade the performance of the post-combustion apparatus and process.
  • At least some processed furnace exhaust gas is used as a heat source for generators, preferably by way of a steam-line heat exchanger.
  • furnace exhaust gas is preferably cooled to between 360 K and 395 K by the cooler.
  • the cooler comprises a pre-combustion water jacket, preferably supplied by a compressor pump with water as a cooling medium.
  • water heated during the cooling process is fed to a steam generator. More preferably, the steam is cooled to liquid water and recycled.
  • the mixing chamber is between 0.3 m and 1.5 m in length, more preferably 0.8 m to 1.5 m in length.
  • the post-combustion gas fuel injection port has at least one nozzle within the chamber, more preferably angled to swirl post-combustion gas fuel at least partially radially perpendicular to the flow direction of the furnace exhaust gas.
  • there are three post-combustion gas fuel injection ports preferably spaced 0.1-0.3 m apart, more preferably 0.2 m apart and extending in the direction of propagation of the furnace exhaust gas.
  • the distance from the nozzle closest to the combustion furnace is to be located sufficiently far from the cooler to ensure that all of the furnace exhaust gas has been cooled and mixed sufficiently that no furnace exhaust gas in proximity to the nozzle is above the post-combustion gas ignition temperature, more preferably no greater than 395 K.
  • the distance from the nozzle nearest to the combustion expansion chamber should be sufficient distance away from it to efficiently mix the post-combustion gas fuel and cooled furnace exhaust gas prior to combustion taking place.
  • Further nozzles can be supplied to optimise the inflow of post-combustion gas fuel and to maximise the mixing of the gases.
  • the nozzles are preferably angled to swirl the post-combustion gas fuel in the general downstream direction.
  • a minority of the nozzles (it could be a single nozzle) is directed in a direction oblique to the other nozzles to impart turbulence.
  • the angle of the nozzles is capable of being varied depending on the volume, density and composition of the cooled furnace exhaust gas being mixed with the Post-combustion gas. It is currently preferred that the optimum burning be judged by an increasing roaring sound emanating from the post combustion reaction and the nozzles manually adjusted to achieve optimum burning.
  • a suitable post-combustion gas fuel will largely depend on the nature of the emissions from the fuel being burned in the furnace. That is a function of the furnace itself and the type of fuel being burned in the furnace.
  • the post-combustion gas fuel is a gas capable of combustion in air with an air flame temperature of at least 1,950° C. at STP.
  • gases in this low temperature group include propane, butane, methane and propane-butane mixtures.
  • the post-combustion gas fuel is a gas capable of combustion in air with an air flame temperature at STP of at least 2,000° C. for a better reaction.
  • Non-limiting examples are a CO/H 2 mixture (Hydrogen 55-65% and carbon monoxide 30-35%), hydrogen, acetylene, propane, cyanogen and dicyanoacetylene.
  • the inventors have found that the post-combustion process is most efficient when the furnace exhaust gas is rich in TVOC, particulates and carbon monoxide emissions. It is therefore strongly preferred to have only a single post-combustion chamber in series with the furnace instead of a series of multiple combustion chambers. However, parallel configurations served by a manifold with multiple outlets for larger furnaces are contemplated.
  • the post-combustion gas fuel should preferably have an ignition temperature in air at STP greater than 480° C.
  • the post-combustion gas fuel is a CO/H 2 mixture (Hydrogen 55-65% and carbon monoxide 30-35%) or hydrogen.
  • the non-return valve is preferably a swing gate check valve, but other valves are known in the industry that are suitable. Any valve chosen should have minimal resistance to opening and should be highly sensitive to backpressure, causing it to close as quickly as possible.
  • a main flow control valve is interposed between the furnace flue inlet and the cooler or between the cooler and the mixing chamber to control the flow rate of the furnace exhaust gas through the gas post combustion apparatus.
  • this is a manually-operated valve.
  • the combustion expansion chamber needs to withstand high temperatures. It is therefore preferably internally ceramic lined, more preferably cast ceramic lined. In a currently preferred embodiment, a Kaolin ceramic clay is employed.
  • the present invention is not limited to this embodiment as other methods and materials able to protect the chamber are available and known to art-skilled workers, especially those in the aerospace and furnace industries. Particularly preferred are ceramics employed in high-voltage ceramic power pole insulators that can withstand very high temperatures.
  • the igniter can be anything that raises the temperature of the mixture of gases to ignition point.
  • a pilot light a spark plug, a series of spark plugs or combinations of these.
  • the igniter is preferably located proximal the inlet of the combustion expansion chamber.
  • it is a sparkplug, more preferably a platinum spark plug connected to a 12 V transformer though an ignition coil generating continuous sparks.
  • an ignition coil generating continuous sparks.
  • Art-skilled workers will be aware of this technology from the automotive industry.
  • multiple igniters can be used, preferably multiple spark plugs, most preferably 3 spark plugs.
  • multiple ignition types can be used, such as spark plugs in conjunction with pilot lights.
  • the gas power system is preferably connected between the cooler and the mixing chamber. This permits the use of materials that do not need to tolerate the high temperatures of furnace exhaust gas prior to being cooled. Even so, the chosen materials need to realistically survive temperatures in excess of 580 K, so art-skilled workers will generally choose materials typically used in the gas turbine industry.
  • the gas power system is an electric motor connected by belt to a centrifugal compressor incorporating an impeller.
  • a matter collection chamber is installed between the combustion expansion chamber and the post combustion exhaust chamber, which matter collection chamber comprises a gas passage and a matter collection vessel. More preferably, the matter collection vessel has at least one magnet in close association with it that, in use, draws magnetised material out of the gas flowing through the gas passage into the matter collection vessel.
  • the at least one magnet is preferably at least one electromagnet, more preferably a series of electromagnets.
  • the series of electromagnets are preferably mounted on brackets located beneath mild steel plate. A series of electromagnets are powered by 240 V A/C mains power.
  • the matter collection vessel is located, in use, beneath the gas passage.
  • the matter collection vessel preferably collects solid matter, more preferably activated carbon.
  • the magnet should be kept relatively cool or it can stop working efficiently or become inoperative. The use of the combination of the water tray assists in keeping the magnets cool enough to function.
  • matter collection vessel in a currently preferred embodiment also comprises a water tray between the exhaust flow and the electromagnets that retains particulates, such as activated carbon, in the water even after the electromagnets are turned off. This permits harvesting of particulates and the water also serves to cool the electromagnets.
  • particulates such as activated carbon
  • a U-bend pipe is installed into the apparatus to change direction of flow, more preferably located before the matter collection chamber.
  • the change of direction of flow increases the turbulence of the gas.
  • An alternative option is to install vanes to induce turbulence prior to the matter collection chamber.
  • Water jackets are preferably installed between the combustion expansion chamber and the extreme downstream location such that the combusted cooled furnace exhaust gas and post-combustion gas fuel mixture is cooled within 2 seconds so that the gas exits the outlet of the apparatus at a temperature lower than 500° C. This assists in preventing the formation of noxious compounds of the dioxin and furan families.
  • FIG. 1 is a perspective view of a post-combustion apparatus of the invention
  • FIG. 2 is a perspective view of a post-combustion apparatus of the invention in conjunction with a furnace;
  • FIG. 3 is a sectional side view of a portion of the post combustion apparatus of FIG. 1 ;
  • FIG. 4 is a sectional side view of a mixing chamber in the post-combustion apparatus shown in FIG. 1 ;
  • FIG. 5 is a blown-up view of a nozzle identified as A-A in FIG. 4 ;
  • FIG. 6 is a sectional side view through valves located between a mixing chamber and impeller as shown in FIG. 3 ;
  • FIG. 7 is a perspective view of a non-return valve in the post-combustion apparatus shown in FIG. 1 with part of the supply pipe removed to expose the elements of the valve;
  • FIG. 8 is a perspective view of a matter collection chamber in the post-combustion apparatus shown in FIG. 1 ;
  • FIG. 9 is a sectional side view of a matter collection chamber as shown in FIG. 7 .
  • FIG. 10 is a graph of baseline measurements for various emissions from a furnace without being put through a post-combustion process.
  • FIG. 11 is a graph of measurements for various emissions from a furnace coupled with a post-combustion process.
  • a post combustion apparatus generally indicated as 100 has a furnace flue inlet 110 connected to a furnace flue (not shown in FIG. 1 ) by way of a furnace flue flange 120 .
  • Furnace flue inlet 110 is an extreme upstream location of furnace exhaust gas entering the post combustion apparatus 100 .
  • post combustion exhaust chamber 130 On the opposite side of post combustion apparatus 100 is a post combustion exhaust chamber 130 that has an inlet 140 and an outlet 150 , the outlet 150 being the extreme downstream location of processed furnace exhaust gas exiting the apparatus. Gas flows (in use) from furnace flue inlet 110 to outlet 150 .
  • Three generating connections 160 , 170 , 180 in use connect to generators (not shown).
  • furnace return 190 that in use, returns hot gas to a supplying furnace to aid in furnace efficiency.
  • This connection is affected by way of a flange 200 and controlled by an interposed manual control valve 195 .
  • a cooler 210 has an inlet, which is the furnace flue inlet 110 , and an outlet 220 .
  • a water jacket 230 acts in use as a cooling element by pumping water via a water inlet 240 into the water jacket 230 and out of a water outlet 250 to a water compressor pump 260 .
  • the compressor pump 260 is connected by a water line 270 to a water supply inlet 280 .
  • An electrical water pump 290 is connected between the water line 270 and water supply inlet 280 .
  • a manually operated valve 300 is interposed between the electrical water pump 290 and the water supply line 270 .
  • a gas power system is a centrifugal impeller compressor pump that is connected to the cooler 210 via the outlet 220 .
  • An outlet 320 connects to a non-return valve, generally indicated as 325 , that is, in turn connected to a mixing chamber 330 .
  • the mixing chamber 330 has three post-combustion gas fuel injection ports 340 and an outlet 350 .
  • the mixing chamber 330 is 1.3 m in length.
  • the outlet 350 is connected to a combustion expansion chamber 360 , in turn connected to a tubular heat exchanger 370 through an exhaust gas inlet 380 .
  • the heat exchanger 370 has an exhaust gas outlet 390 , a steam line inlet 400 and a steam line outlet 410 connected to an exhaust steam line 411 .
  • Steam generator connection flanges 412 , 415 and 417 permit connection of the exhaust steam line 411 to steam driven electrical generators (not shown).
  • the steam line inlet 400 is connected via a steam supply line 420 to the water compressor pump 260 .
  • the steam line inlet 400 is also connected via a water supply line 430 to a manually operated valve 440 connected to the water supply 280 via the electrical water pump 290 .
  • a U-bend pipe 450 is connected to the exhaust gas outlet 390 at one end and a matter collection chamber 460 at the other end.
  • connections between elements are typically achieved by way of complementary flanges that are connected together by nuts, bolts and washers in the usual way. These flanged connections are depicted in the drawings but are not necessarily numbered herein in the interests of decluttering the drawings.
  • the post-combustion apparatus 100 as shown in FIG. 1 is shown connected to a furnace, generally indicated as 500 .
  • a furnace generally indicated as 500 .
  • the reader is directed to the explanation of the reference numerals in relation to the post combustion apparatus 100 in FIG. 1 , which have the same meanings in FIG. 2 .
  • Not all reference numerals shown in FIG. 1 are shown in FIG. 2 in the interests of decluttering FIG. 2 .
  • the furnace 500 is a commercial incineration chamber furnace, model: Midi Waste Incinerator by Proburn Waste Incinerators. It has a conveyor 510 connected to a door 520 , that permits entry of waste material for combustion (not shown) from the conveyor 510 into a furnace combustion chamber 530 , in turn connected to a furnace exhaust chamber 540 , in turn connected to a furnace flue 550 .
  • the furnace flue 550 is connected to the furnace flue flange 120 .
  • Furnace return pipes 560 and 570 are connected at one end thereof to the lower end of furnace combustion chamber 530 .
  • the furnace return pipes 560 and 570 are connected at the other end thereof to the furnace return 190 at the flange 200 .
  • FIG. 3 a portion of the post combustion apparatus 100 is shown. Elements of the same numbers as appear in earlier figures are identical and are not re-described here. The reader is directed to the earlier description for these reference numerals.
  • the gas power system 310 has an impeller 600 driven by a pulley (not shown) connected via a belt 610 to an electric motor 620
  • the impeller is rated to at least 580 K.
  • the impeller 600 is an Aerotech branded, Model HP 184 steel housed 500 mm impeller with a 120 mm diameter outlet and a 150 mm diameter inlet connected by a direct drive connected to a 415 volt 4 kW electric motor 620 .
  • the outlet 320 connects to a reducer 630 that reduces the inner pipe diameter to 100 mm and is connected to the non-return valve 325 .
  • the non-return valve 325 consists of a swing gate check valve 640 in conjunction with a manually operated ball valve 650 for emergency cut-off.
  • the ball valve 650 is connected to the mixing chamber 330 .
  • the mixing chamber 330 is made from 100 mm NB SCH10 welded pipe T304L.
  • the injection ports, generally indicated by 340 consist of 3 injectors 660 , 670 and 680 .
  • a reducer 690 that expands the inner diameter from 100 mm to 200 mm.
  • a platinum spark plug 700 igniter connected to a 12 V transformer though an ignition coil generating continuous sparks (not shown).
  • the reducer 690 opens into the combustion expansion chamber 360 , which has a ceramic lining 710 of refractory ceramic.
  • the ceramic lining 710 has a 200 mm NB and a lining thickness of between 40 to 48 mm.
  • the ceramic lining 710 is housed within 300 mm NB SCH10 T304L welded pipe 720 , connected to 300 ⁇ 200 mm NB SCH10 T304L reducers 730 , 740 at each end of the combustion expansion chamber 360 .
  • the ceramic lining 710 is created by forming a mould by inserting a plastic pipe (not shown) with an outer diameter of 200 mm into the welded pipe 720 , thereby forming a mould filling cavity.
  • a pumping hole is formed in the one end of the plastic pipe (not shown).
  • a castable high alumina low cement refractory powder (by weight: Al 2 O 3 84%, SiO 2 7.5%, CaO 3.3%, Fe 2 O 3 1.3%, alkalies 0.23% and TiO 2 1.5%) is mixed with water using an electric mixer to make up to 4.4-5.5% by weight water. This forms a pumpable slurry that is pumped through the pumping hole (not shown) to fill the mould (not shown). The pumping hole is sealed once the mould is filled.
  • the mould is agitated until the ceramic is set. Once dry, the plastic pipe (not shown) is removed and gaps and cracks in the ceramic lining 710 are filled in using an air-setting refractory wet mortar (not separately shown) comprising by weight: Al 2 O 3 42%, Fe 2 O 3 0.7%, CaO(+MgO) 0.4%, SiO 2 45%, alkalies 3.5% and TiO 2 1.5%.
  • the ceramic lining 710 is permitted to dry and is gradually heated to operational temperature and maintained there for a few hours prior to operational use.
  • the combustion expansion chamber 360 is connected to the heat exchanger 370 via the exhaust gas inlet 380 .
  • the heat exchanger 370 has an exhaust gas passage 750 surrounded by 200 mm NB SCH10 welded pipe T304L.
  • a water jacket 760 of tapered 300 mm NB SCH10 welded pipe T304L surrounds the exhaust gas passage 750 .
  • the water jacket 760 houses the steam line inlet 400 and the steam line outlet 410 , in turn connected to the steam supply line 420 and the exhaust steam line 411 , respectively.
  • the various parts of the post-combustion apparatus are supported on pipe supports 780 , 790 , 800 , 810 and 820 that, in use, maintain the exhaust gas flow in a substantially horizontal plane. While these are shown in other drawings, they are not necessarily numbered in the interests of reducing clutter.
  • the mixing chamber 330 is shown flanked by the ball valve 650 and the reducer 690 in FIG. 4 (both of which are only partially shown in this cut-away view).
  • the injection ports consist of the injectors 660 , 670 and 680 , each of which has angled nozzles 900 , 910 and 920 , respectively.
  • the angled nozzles 900 , 910 and 920 terminate into the mixing chamber 330 and can be swiveled within the mixing chamber 330 by the use of each of adjustment nuts 930 , 940 and 950 (respectively) about gas-proof fittings 960 , 970 and 980 (respectively).
  • Angled nozzles 900 and 910 are drawn facing away from the point of view whereas nozzle 1000 is drawn facing laterally.
  • Angled nozzles 900 and 910 are configured, in use to concentrically swirl the gas in the mixing chamber 330 , whereas nozzle 1000 is configured to introduce turbulence to the gas in the mixing chamber 330 .
  • the injectors 660 , 670 and 680 are constructed from 25 mm NB SCH10 welded pipe T304L.
  • the injectors 660 , 670 and 680 are spaced 200 mm apart and are angled at 45° to the centreline of the chamber 330 .
  • a mixing length 990 is defined between the angled nozzle 900 and the end of the mixing chamber 330 , which is about 0.48 m in length.
  • Nozzles 900 , 910 and 920 are composed of metal, each having a reduced inner diameter of 10 mm at its terminus (only terminus 1000 is shown for nozzle 920 , but the others are similarly configured).
  • the non-return valve generally indicated as 325 , is shown, including the swing gate check valve 640 and the ball valve 650 connected between the gas power system outlet 320 and the mixing chamber 330 . Swing gate check valve 640 and the ball valve 650 are independently operable.
  • the ball valve 650 has a handle 1100 connected to a ball 1110 in a seat 1125 that has a through bore 1120 that is shown in an open configuration that permits gas to pass through the ball valve 650 . If the handle 1100 is rotated 90 degrees from that as shown, then the through bore 1120 will be occluded by the seat 1125 and the ball valve 650 will be in its closed configuration (not shown).
  • the swing gate check valve 640 has a hinge 1130 that hinges a sealing flap 1140 with a sealing plate 1150 .
  • the sealing plate 1150 has an orifice 1160 .
  • a connecting pipe 1170 (only partially shown in FIG. 7 ) connects the swing gate check valve 640 to the ball valve 650 .
  • the sealing flap 1140 is substantially circular with a diameter of 91 mm whereas the orifice 1160 has a diameter of 92 mm. in use, the sealing flap 1140 is not able to swing back to a position upstream of the normal direction of the flow of emissions as it has been designed to seal against the sealing plate 1150 .
  • the hinge 1130 is cut at a very slight diagonal which in a situation where there is no movement of gas causes the flap 1140 to close under its own weight. This is the same principle as described in US284084 to HICKEY, which is incorporated into this specification in its entirety by reference.
  • the flap 1140 will open as soon as the flow begins and will be held open by the flow. In the case of back pressure, the flap 1140 will close. Because the flap 1140 is sealing against the sealing plate 1150 (acting as a flange with a lesser diameter than the orifice 1160 ), the flap 140 is slightly smaller than the diameter of the connecting pipe 1170 .
  • the matter collection chamber 460 is installed between the U-bend pipe 450 and the combustion exhaust chamber inlet 140 .
  • a gas passage 1200 permits passage of gas between the U-bend pipe 450 and the combustion exhaust chamber inlet 140 .
  • Three electromagnets 1210 , 1220 , 1230 that are 240V A/C Commercial Electro-Magnetic Base Power 13500 N Magnetic Force from Techstyle group are located in a 6 mm material thickness stainless steel sealed enclosure 1240 .
  • a water tray 1250 is located beneath the gas passage 1200 that is supplied with a constant supply of water to replace water that is evaporated during operation.
  • the furnace 500 is fed by the conveyor 510 with waste material to be incinerated (not shown).
  • the waste material enters the furnace combustion chamber 530 via the door 520 , where it is combusted.
  • Furnace exhaust gas (not shown) and particulates produced by the combustion pass up through the furnace exhaust chamber 540 and into the furnace flue 550 .
  • Furnace exhaust gas (not shown) passes into the post-combustion apparatus 100 via furnace flue inlet 110 .
  • Furnace flue inlet 110 is an extreme upstream location of furnace exhaust gas (not shown) entering the apparatus post combustion apparatus 100 .
  • the furnace exhaust gas passes into the cooler 210 , where it is cooled by the cooling jacket 230 by water pumped by water compressor pump 260 into the water inlet 240 , which exchanges heat with the furnace exhaust gas and exits the cooling jacket 230 via the water outlet 250 .
  • the compressor pump 260 equalises the pressure and level between the water lines. Water is driven via hot water outlet 250 by compressor pump 260 through a steam supply line 420 to the heat exchanger 370 steam line inlet 400 .
  • the furnace exhaust gas is cooled to between 340 K and 395 K by the cooler 210 .
  • the cooled furnace exhaust gas is drawn into the gas power system 310 via the outlet 220 .
  • the electric motor 620 drives the impeller 600 to draw cooled furnace exhaust gas through the gas power system from the cooler 210 and propel it onward via outlet 320 .
  • the propelled cooled furnace exhaust gas passes through the reducer 630 and through the non-return valve 325 .
  • the swing gate check valve 640 closes by the upstream force of the blow-back causing sealing flap 1140 to hinge closed and seal against sealing plate 1150 , preventing the return of the furnace exhaust gas back to the furnace via orifice 1160 .
  • sealing flap 1140 hinges open again by the pressure exerted by upstream furnace exhaust gas. Sealing flap 1140 is designed to be as light as possible while still allowing sufficient protection against blowback.
  • An emergency cut-off can also be effected by rotating the handle 1100 90° from its open position as depicted in FIG. 6 to its closed position, thereby isolating the post combustion apparatus downstream of the non-return valve 325 .
  • the propelled cooled furnace exhaust gas enters the mixing chamber 330 and is mixed with a Post-combustion gas via the injection ports 340 supplied via the three injectors 660 , 670 and 680 out of nozzles 900 , 910 , and 920 (respectively).
  • the nozzles are angled to impart a swirling motion to the Post-combustion gas that assists in its mixing with the furnace exhaust gas.
  • the post-combustion gas used for the purposes of this example was either hydrogen or a CO/H 2 mixture that has the following percentage by weight: Hydrogen 55-65% and carbon monoxide 30-35%.
  • the nozzles 900 , 910 , and 920 are angled prior to use within the mixing chamber 330 by use of adjustment nuts 930 , 940 and 950 , depending on the volume, density and composition of the cooled furnace exhaust gas being mixed with the Post-combustion gas.
  • the optimum burning is judged by the intensity of the roaring sound emanating from the post combustion reaction.
  • the efficiency of the combustion process improves as the intensity of the roaring sound increases.
  • the mixture ratio and flow rates of Post-combustion gas and furnace exhaust gas into the mixing chamber is not fixed and depends on the type of waste product being burned. The ratios and flow rates would be increased or decreased to achieve the most intense audible ‘roar’.
  • the platinum spark plug 700 is continuously sparking and provides an ignition source for the mixed gases.
  • the mixed gases ignite and expand into the combustion expansion chamber 360 . This ignition reaction is exothermic and produces considerable heat.
  • the ceramic lining 710 acts as a thermal barrier, preventing critical damage to the 300 mm NB SCH10 T304L welded pipe 720 .
  • the combusted mixed gases become exhaust gas.
  • the exhaust gas is driven to the tubular heat exchanger 370 and enters via the exhaust gas inlet 380 into the exhaust gas passage 750 .
  • Water is introduced into the water jacket 760 via steam line inlet 400 from the steam supply line 420 and the water supply line 430 , driven by water compressor pump 260 and electrical water pump 290 , respectively.
  • the exhaust gas in the gas passage 750 is cooled by the water in the water jacket 760 .
  • the water in the water jacket 760 is heated to steam through this cooling process.
  • the steam generator connection flanges 412 , 415 and 417 connected to the exhaust steam line 411 supply steam to connected steam driven electrical generators (not shown) that generate electricity.
  • Cooled exhaust gas leaves the heat exchanger 370 via exhaust gas outlet 390 and passes through U-bend pipe 450 to enter the matter collection chamber 460 and flows along the gas passage 1200 towards the combustion exhaust chamber inlet 140 .
  • Ionised and/or magnetised materials in the exhaust gas in the gas passage 1200 are magnetically attracted to the three electromagnets 1210 , 1220 , 1230 that have a 240V A/C supply applied.
  • the ionised and/or magnetised material enters the water tray 1250 that has water in it and this prevents escape of the ionised and/or magnetised material once the 240V A/C supply is switched off.
  • the exhaust gas leaves the matter collection chamber 460 via the combustion exhaust chamber inlet 140 into the combustion exhaust chamber 130 .
  • Some gas is supplied to generators via generator connections 160 , 170 and 180 .
  • a further quantity of remaining exhaust gas entering the combustion exhaust chamber 130 via inlet 140 passes through the furnace return 190 and furnace return pipes 560 and 570 and into the lower end of furnace combustion chamber 530 and acts as a heated combustion gas to aid in furnace efficiency.
  • the post-combustion apparatus started most easily if not exposed to furnace emissions when starting up from cold. Emissions added after the post-combustion apparatus had already started running helped to prevent fouling of the spark plug 700 .
  • An oxyacetylene pilot can be used to initiate the post-combustion apparatus if the spark plug 700 becomes fouled. The spark plug 700 is defouled by the post-combustion process when at temperature.
  • the mixed waste materials in the upstream furnace 500 during testing were: tyres and other rubber materials, plastics, a small lead battery, polystyrene/packaging foam, coal, rags soaked in sump oil and other general waste items.
  • Removal efficiency was calculated by comparing untreated baseline emissions freely flowing through the post-combustion apparatus with the post-combustion gases and to those obtained when the post-combustion apparatus was used with a post-combustion gas, being a CO/H 2 mixture of: Hydrogen 55-65% and carbon monoxide 30-35% gases. Results of the testing are set out in Table 2.
  • the impeller 600 was driven at 50 Hz for this testing.
  • FIG. 10 shows the baseline emissions for some of the parameters in Table 2 over a period of time.
  • FIG. 11 shows the post-combustion emissions for some of the parameters in Table 2 over a period of time.
  • Table 3 shows the results from this testing. Results were taken when the results stabilised.
  • the impeller 600 was driven at 60 Hz for this testing resulting in a higher flow rate than the CO/H 2 testing in Table 2. At this higher flow rate, combustion correctly took place in the combustion expansion chamber 360 .
  • the flow rate of the exhaust at the stack was 3.36 Nm 3 /min, slightly higher than that in the testing results in Table 2 as a result of the increase in the impeller speed 600 . 0.54 Nm 3 /min of hydrogen gas was being introduced into the mixing chamber 330 in the final test in Table 3.
  • the post-combustion process has been run using an oxy-acetylene pilot light instead of the spark plug 700 without significant change to the results obtained.
  • the present invention is applicable to industry, and particularly to industries that produce gaseous emissions that need to be processed into less harmful forms prior to release into the environment. There are many industries that produce such gases and there are often regulatory requirements for the reduction of toxic or environmentally damaging gaseous emissions. Additionally, industrial processes produce gases suitable for a post-combustion gas fuel, such as hydrogen or carbon monoxide and hydrogen, potentially permitting synergies between industries. This invention assists in meeting at least some regulatory requirements for the release of gaseous emissions into the environment.

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  • Engineering & Computer Science (AREA)
  • Environmental & Geological Engineering (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Incineration Of Waste (AREA)
  • Portable Nailing Machines And Staplers (AREA)
US16/478,178 2017-01-16 2018-01-16 Post-combustion device and method Abandoned US20190368729A1 (en)

Applications Claiming Priority (3)

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NZ72835117 2017-01-16
NZ728351 2017-01-16
PCT/AU2018/050024 WO2018129596A1 (en) 2017-01-16 2018-01-16 Post-combustion device and method

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JP (1) JP2020505580A (zh)
KR (1) KR102507768B1 (zh)
CN (1) CN110418919A (zh)
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IL268091B1 (en) 2024-08-01
ZA201905384B (en) 2020-07-29
CA3056328A1 (en) 2018-07-19
AU2018207583A1 (en) 2019-09-05
KR102507768B1 (ko) 2023-03-07
EP3568636A4 (en) 2020-09-09
WO2018129596A1 (en) 2018-07-19
AU2018207583B2 (en) 2023-11-02
EP3568636B1 (en) 2023-10-18
EP3568636A1 (en) 2019-11-20
IL268091A (en) 2019-09-26
CN110418919A (zh) 2019-11-05
EP3568636C0 (en) 2023-10-18
KR20190108596A (ko) 2019-09-24
JP2020505580A (ja) 2020-02-20

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