WO2017213671A1

WO2017213671A1 - Apparatuses and methods for reducing pollutants in gas streams

Info

Publication number: WO2017213671A1
Application number: PCT/US2016/037869
Authority: WO
Inventors: Edward O. Taylor
Original assignee: Global Solutions Technology, Inc.
Priority date: 2016-06-10
Filing date: 2016-06-16
Publication date: 2017-12-14

Abstract

An apparatus for reducing pollutants in a gas stream, including an inlet for the gas stream, a pre-treatment transfer tube, coupled to the inlet, configured to receive an electrical charge; a first reaction chamber coupled to the pre-treatment transfer tube, having a plurality of helically-arranged probes; at least one condensation chamber coupled to one reaction chamber; at least one reduction chamber coupled to one condensation chamber, the reduction chamber being adapted to absorb pollutants from the gas stream; at least one resonance chamber adapted to ionize the gas stream; a second polishing reactor coupled to one resonance chamber, wherein the apparatus is configured to reduce pollutants in the gas stream; and an outlet for the treated gas stream.

Description

APPARATUSES AND METHODS FOR REDUCING

POLLUTANTS IN GAS STREAMS

REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. Application No. 15/179,932, which is a continuation-in-part of U.S. Application No. 13/460,255, which is a continuation-in-part of U.S. Application No. 13/298,933, now U.S. Patent No. 8,187,362, which is a continuation of U.S. Application No. 12/879,730, now U.S. Pat. No. 8,097,072. The disclosures of the aforementioned documents are each incorporated herein by reference in Iheir entirety.

TECHNICAL FIELD

The present disclosure relates to apparatuses and methods for reducing pollutants in gas streams, and particularly reaction chambers configured to destroy pollutants in gas streams emitted from combustion processes.

BACKGROUND

Emissions continue to pose numerous problems for the global community. Pollutants in gas streams can cause adverse human health effects and affect global climate change. To protect public health and the environment, environmental agencies around the globe regularly monitor levels of numerous pollutants. In particular, the atmospheric presence of sulfur dioxide (SO2), nitrogen dioxide (NO2), particulate matter (PM), carbon monoxide (CO), volatile organic compounds (VOC), and other toxic pollutants are monitored and evaluated to assure continued health and safety. Some of these pollutants are emitted directly or indirectly into the atmosphere from a variety of sources, including, but not limited to, power plants, factories, waste treatment plants, buses, cars, trucks, airplanes, bulldozers, and commercial and industrial processes. Principally, emissions of carbon dioxide (CO3) from coal-fired power plants create various environmental problems that countries, like the United States, are attempting to obviate due to global warming concerns and continued dependence on coat- fired power plants as energy sources.

Coal-fired power plants and other facilities producing electrical power or steam conventionally bum hydrocarbons in a process that produces substantial emissions of greenhouse gases, particulates, and other toxic air pollutants. In conventional systems, power plant emissions are unavoidable, and emission control systems, devices, and methods typically require multiple, expensive, post-combustion treatment systems that capture, SOx, NOx, and other toxic air pollutants. In addition, to date, economical methods for capturing and sequestering CO2 do not exist Accordingly, power plants continue to contribute significantly to greenhouse gases. The few available methods for combustion treatment of gases reduce the fuel efficiency of power plants, by preventing complete combustion, and significantly add to power plant operating costs.

Generally, known devices and methods in the prior art either remove or destroy particles of pollutants before they are emitted into the atmosphere. These devices and methods use mechanical, electrical, and chemical processing means. Examples of such devices include electrostatic precipitators, baghouses, scrubbers, and catalytic converters. While these devices are somewhat effective, each has limitations.

An electrostatic precipitator is a device that removes particles from gas streams using forces associated with induced electrostatic charges. While these devices are known to remove particulate matter, e.g. dust and smoke from gas streams, they generally do not work well in removing carbon particles, such as, for example, carbon particles, resulting from the burning of diesel fuel.

Baghouses are devices used to collect particulates and are generally effective in collecting carbon and fry ash particulates. These devices, however, are prone to moisture, particularly when used in small power plant applications. Excessive moisture can cause the particles to cake within baghouses, preventing proper operation.

Scrubbers are devices that collect particulates and gases. Scrubbers are classified into wet and dry scrubbers. Wet scrubbers either dissolve or absorb particulates using liquids. Polluted particles and gas streams are brought in contact with a scrubbing liquid, e.g. by spraying, such that pollutants are removed. The dissolved pollutants and resulting waste water, however, can form corrosive solutions which thereafter have to be disposed of according to regulatory standards. Dry scrubbers, in contrast, do not saturate gas streams. These devices add absorbent alkaline materials to pollutant gas streams. The alkaline materials react with the gas stream to form a solid byproduct Both types of scrubbers must be designed considering the properties of the pollution. As a result, scrubbers which are designed to remove SOx from pollutant-filled gas streams are typically not as effective at reducing NOx from pollutant-filled gases.

Catalytic converters are devices incorporated into an automobile's exhaust system. These devices reduce the amount of pollutants found in exhaust gases to environmentally harmless levels. A catalytic converter may be placed anywhere in the exhaust system. For optimum efficiency, however, it is necessary to locate a catalytic converter as close as possible to the combustion chamber in an engine compartment As such, these devices have several limitations.

A pollution control device is also described in U.S. Pat No. 5,366,701, the disclosure of which is incorporated by reference in its entirety. This device relates to the ionization of a gas stream from a source by passing gas streams through a resonance field. In addition, potential ization and dieassociation of molecules that make up the gas stream occurs by passing the stream through a continuous electrical arc. While a significant improvement over the prior art devices described thus far, in practice, this device produces a treated gas released in an excited state at an elevated temperature, such that post-processing of the treated gas is still required.

Due to the limitations described and others known in the art, the pollution control industry is still in need of apparatuses and methods that overcome these and other limitations. In particular, there is still a need for apparatuses, and methods that do not create hazardous pollutant byproducts. There is also a need for cost-effective apparatuses, and methods that do not consume high amounts of energy. There is a further need for apparatuses adaptable for retro-fit with existing sources of pollution, particularly those sources that emit gas streams from combustion processes.

While certain aspects of prior art pollution control devices have been discussed, technical aspects of these devices are in no way disclaimed and it is contemplated that the claimed invention may encompass one or more technical aspects of the prior art devices discussed herein.

SUMMARY

Embodiments of the present invention arc directed toward apparatuses and methods for reducing pollutants in gas streams. Certain embodiments of the apparatuses of the present invention, as well as its method of use, reduce pollutants such as hydrocarbons, nitrous oxides, carbon monoxide, particulates (e.g. carbon particulates in soot), and offensive odors from gas streams.

As used herein, the term "pollutants" is broadly defined to include any undesirable matter in a gas stream. Pollutants within the scope of the invention are therefore not limited to toxk substances and can include, for example, targeted processing byproducts or filtered substances that, when reduced, have a beneficial effect on the gas stream. Whether me effect is beneficial is based upon considerations in the various industries where the apparatuses, systems, and methods of embodiments of the invention are applied. Embodiments of the invention can be used to reduce pollutants from many different sources. Pollutants can be contained in gas streams emitted from internal combustion engines such as, but not limited to, those in cars, trucks, buses, boats and trains. Pollutants can also be emitted from sources other than combustion engines, such as, but not limited to, incinerators; restaurant and bakery stove exhaust; dry cleaning exhaust; automotive and paint shop exhaust; sewage treatment plant exhaust; exhaust from power generating stations; and exhaust from manufacturing facilities.

Embodiments of the invention include systems, apparatuses, and methods variously used to:

o efficiently and effectively reduce pollutants in gas streams;

o efficiently and effectively reduce the amounts of particulates in gas streams, e.g. nitrogen oxide species (NOx), carbon monoxide (COX carbon dioxide (C02), volatile organic compounds (VOC) and sulfur oxide species (SQx); o efficiently and effectively remove and/or destroy particulates, including NOx, CO, CO2, VOC and SOx such that the requirements of environmental agencies including, but not limited to, the Environmental Protection Agency are met or exceeded.

o reduce pollutants in gas streams such that treated gas streams can be recycled for reuse; and

o recycle waste and control emissions of engines, and other effluent gas sources, while meeting energy efficiency requirements and increasing engine efficiency.

It is contemplated that embodiments of the present invention may address limitations in a number of technical areas, as well as the limitations of the prior art discussed above. Therefore, the claimed invention should not necessarily be construed as limited to any of the particular limitations discussed herein.

An apparatus for reducing pollutants in a gas stream includes an inlet for an effluent gas having pollutants, a pre-reaction probed transfer tube, several fluidically coupled chambers, and an outlet for the treated gas. The fluidically coupled chambers include: a condensation chamber adapted to condense the gas stream, a first reaction chamber adapted to dectrochemically alter the gas stream, a reduction chamber adapted to reduce pollutants from the gas stream, a resonance chamber adapted to ionize the gas stream, and a second reaction chamber. A method for reducing pollutants in a gas stream includes the steps of treating the gas stream in a pre-reaction, probed transfer tube, electro chemically altering the gas stream in a plurality of reaction chambers; condensing the gas stream in a condensation chamber, reducing pollutants in the gas stream in a reduction chamber, and ionizing the gas stream in a resonance chamber.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure, and together with the description serve to explain the principles of the present disclosure.

FIG. 1 is a schematic diagram of an apparatus for reducing pollutants fn a gas stream;

FIG. 2 is a front elevational view of a first configuration of an apparatus for reducing pollutants in a gas stream;

FIG. 3 is a rear elevational view of the apparatus shown in FIG. 2;

FIG. 4 is a left side view of the apparatus shown in FIG. 2;

FIG. 5 is a right side view of the apparatus shown m FIG. 2;

FIG. 6 is a cross-sectional view taken along line 6-6 of a condensation chamber;

FIGS, la and 76 are representations of cross-sectional views of a reaction chamber, schematically illustrating the positioning of collar assemblies;

FIG. 8a is a side view of a probe;

FIG. 86 is a side view of a probe and a probe holder,

FIG. 8c is side view of a probe, a probe holder, and a resistor,

FIG. 8d is a side view of a collar assembly;

FIG. 9a is a left side view of a collar,

FIG. 96 is a front view of a collar;

FIG. 9c is a right side view of a collar;

FIG. 10a is a left side view of a resistor;

FIG. 106 is a front view of a resistor;

FIG. 10c is a right side view of a resistor,

FIG. 1 la is a left side view of a probe holder,

FIG. 116 is a front view of a probe holder;

FIG. 1 lc is a right side view of a probe holder,

FIG. 12 is a cross-sectional view of a reduction chamber taken along line 12-12; FIG. 13 is a cutaway view of a resonance chamber,

FIG. 14 is a schematic diagram a second configuration of an apparatus for reducing pollutants in a gas stream;

FIG. 15 is an upper plan view of another configuration of an apparatus for reducing pollutants in a gas stream;

FIG. 16 is an initial front elevation view of the apparatus shown in FIG. 15;

FIG. 17 is another front elevation view of the apparatus shown in FIG. 15 at a designated section;

FIG. 18 is a front elevation view of the apparatus shown in FIG. 15 at another designated section;

FIG. 19 is a middle plan view of the apparatus shown in FIG. 15;

FIG. 20 is an initial rear elevation view of the apparatus shown in FIG. 15;

FIG. 21 is another rear elevation view of the apparatus shown in FIG. 15 at a designated section;

FIG. 22 is another rear elevation view of the apparatus shown in FIG. 15 at a designated section;

FIG. 23a is an elevation view of the apparatus shown in FIG. 15 taken along line 'A';

FIG. 23b is an elevation view of the apparatus shown in FIG. 19 taken along line 'B';

FIG. 23b is an elevation view of the apparatus shown in FIG. 19 taken along line 'C ; and FIG. 23d is an elevation view of the apparatus shown in FIG. 19 taken along line 'D';

DESCRIPTION

The following description should bo read with reference to the drawings, wherein likc reference numerals indicate like elements throughout the several views. The drawings, which are not necessarily to scale, are not intended to limit the scope of the claimed invention. The detailed description and drawings illustrate exemplary embodiments of the claimed invention. Those skilled in the art will recognize that the various elements described and/or shown may be arranged in various combinations and configurations without departing from the scope of the disclosure. The detailed description and drawings illustrate example embodiments of the invention.

All numerical values herein are assumed to be modified by the term "about." The disclosure of numerical ranges by endpoints includes all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5). As used in this specification and the appended claims, the singular indefinite articles "a", "an," and the definite article "the" should be considered to include or otherwise cover both single and plural referents unless the content clearly dictates otherwise. In other words, these articles arc applicable to one or more referents. As used in mis specification and the appended claims, the term "or" is generally employed to include or otherwise cover "and/or" unless the content clearly dictates otherwise.

References in the specification to "an embodiment," "embodiments," "such embodiments," etc, indicate that the embodiment described may include a particular feature, structure, or characteristic_* but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases do not necessarily refer to the same embodiment Further, any particular feature, structure, or characteristic described in connection with a particular embodiment is intended to be applied, incorporated or substituted into other embodiments, whether or not explicitly described, unless clearly stated to the contrary.

Overview of Scientific Principles

For background purposes, various embodiments of the present invention applies, in part, three principles of physics: plasma physics, resonance, the waveguide concept, and longitudinal wave propagation in probes/rods. Applying these principles in combination with combustion thermodynamics enables the systems, apparatuses and methods disclosed herein to dectrochemically alter pollutant gas streams to produce a purified gas stream. Moreover, the application of these principles employs means of stabilization, dis association, and condensation, such that embodiments of the present invention can electrochemically alter pollutant gas streams.

Plasma Physics

Plasma physics is a field of physics which relates to the study of highly ionized gases. Plasma is a gaseous state of matter, composed of a nearly equal number of positive and negative free charges (positive ions and electrons), where atoms or molecules are broken apart such that ions are formed. Because plasma is composed of charged particles, it exhibits many phenomena not encountered in ordinary gases.

The charged particles of plasma are each surrounded by a Coulomb's field; and it is through mis field that the particles interact with each other. Microscopically, these electrostatic fields give rise to localized attractive or repulsive forces between the particles as they pass near each other, resulting in mutual neutralization. Plasma also reacts as a conducting fluid to the total electromagnetic field in which it is immersed. A plasma field will break the bonds of a gas in an orderly and manageable equilibrium, enabling usage of the energy potential in a target gas by recombination.

Pollutants, as well, can be clipped from the gas exhaust of engines, turbines, boilers, machines, etc., and recombincd to make other products, destroyed or released as harmless natural elements to the environment. In one application of these principles, non-thermal plasma, also referred to as cold plasma, can be used to generate gas phase free radicals which are used to destroy pollutants in gas streams.

Resonance

The principle of resonance is applicable to the resonance chambers and subsystems herein described. In one application, a particle moving along a horizontal axis is said to exhibit simple harmonic motion when the displacement for equilibrium, X, varies in time according to the following relationship: X- A COS(wt+ δ), where A, w and 6 are constants, and t is time. In order to give physical significance to these constants, it is convenient to plot X, where A=amplitude of motion, i.e. the maximum displacement of the particle in either positive or negative X direction; W=an angular frequency; δ (the constant angle)=a phase constant or phase angle, where δ, along with A, is determined by the initial displacement and velocity of the particle. Resonance fields can be created applying these principles by various means, including, exposing pollutant gas streams to alternating currents, physical vibration, sound, light, or other means of oscillation.

Wave Guide Concept

A discussion of the concept and science of the use of waveguides, large circuits and random wave output is also useful in understanding the principles employed by embodiments of the present invention.

The sinusoidal wave is a time-varying current associated with circuits as a modern integration with a number of closed loop filaments (ideally resistanccless conductors) connecting various combinations of generated or induced voltage with the passive elements— resistors, capacitors, and inductors. There are two classes of time varying sinusoidal currents, repetitive and non-repetitive. Repetitive sinusoidal current can be defined as having a cyclic function mat has a time of reoccurrence (f= l/Τχ the frequency in which a sinusoidal wave completes one hold cycle in the period f 1/T.

By mixing homogeneous waves, harmonic frequencies are achieved. These frequencies are then used to disassociate hydrocarbon chemicals. Further, harmonic non- homogeneous current propagates random wave output. To assure maximum coverage and minimum collection attraction potential, one of the effects, bipolarization, is achieved in polarizing orientation of the non-homogeneous environment of non-specific wave generation. The automatic release of both negative and positive species of an airborne mass will experience bipolarization in a piezoelectric field, specifically a crystalline dielectrical waveguide. The electric circuit employed within the scope of embodiments of the present invention is largely associated with the production of waves that are generally boundary less. Applying the aforementioned principles, and in particular the wave guide concept, allows for the electrochemical alteration of pollutant gas streams.

Longitudinal Wave Propogation in Thin Rods

An assessment of wave propagation in probes formed as thin rods can be determined by referencing d'Alembert's method, which provides a solution to the one-dimensional wave equation and investigating Hooke's law in stress evaluation, Poisson's ratio with respect to vibration of the rod, and Hertz's theory of impact.

The d'Alembert method provides:

that models vibrations of a string.

The general solution can be obtained by introducing new variables

and applying the chain rule to obtain

(2)

(3)

(4)

(5)

Using (4) and (5) to compute the left and right sides of 3) then gives

(6)

(7)

(8)

(9)

respectively, so plugging in and expanding then gives

Variables considered in determining operational parameters for the reaction chambers disclosed herein include stress applied to the probes/thin tods, velocity of particles flowing through the apparatuses described herein, and energy. These and other variables may be used to assess electromagnetic and/or acoustic disturbances in the apparatuses described herein. Apparatus

Turning to the drawings, FIG. 1 illustrates schematically an apparatus 10 for reducing pollutants in a gas stream. FIGs. 2-13 show one configuration of the apparatus 10 and FIGs.

14 schematically shows an alternative configuration of an apparatus 100, and FIGs. 15-24d show another alternative configuration of an apparatus 200. The arrows shown in FIGs. 1 and

15 illustrate the direction of the flow of the gas stream 12. The direction shown and the position of the elements of the apparatus, however, are not to be construed as limiting.

Elements of the apparatus may be arranged in any way that allows for a desired level of reduction of pollutants in the gas stream.

Referring to FIGs. 1-13, the apparatus 10 includes an inlet 14 for a gas stream, several fluidically coupled chambers, as described below, and an outlet 54 for the treated gas. The transport of the gas stream through the apparatus is preferably achieved by negative pressure suction.

In certain configurations of the apparatus, the gas stream travels from a source S (FIG. 1) through the apparatus at a rate of approximately 8.6 feet/second such that the approximate travel time for the gas stream is approximately 27.4 seconds. Alternatively, the outlet gas stream may be fluidically coupled to recirculate the gas stream back into the apparatus, providing for a closed-looped system that will run in excess of 30 hours. Equipment or sources appropriate for use with the apparatus include: steel industry processing equipment, plating system equipment, soil remediation equipment, battery backup systems, vehicles systems, maintenance facilities exhaust systems, landfill processing equipment, and waste removal systems. Each apparatus configuration includes an inlet 14 for the gas stream 12. The inlet 14 may be piping, tubing, funnels, or other types of openings proving for fluid communication. Also, the apparatus may include an inlet port (not shown) which allows the gas stream to flow without significant resistance. The inlet port may optionally use electronic valves actuated by logic circuitry, e.g. a programmable logic controller ("PLC"). These types of valves allow portions of the gas stream to flow to other apparatuses, if required for a particular application.

Each chamber of the apparatus is fluidically coupled using piping 16. The piping 16 preferably is made from Polyvinyl Chloride (PVC), however, any suitable material may be employed. The material, however, should provide for sufficient sulfur exchange with the gas stream 12. The piping may optionally be adapted as heat exchangers.

In one embodiment, the inlet 14 is fluidically coupled to a plurality of condensation chambers 18 which are adapted to condense the gas stream and gradually decrease its temperature, pressure, and velocity. In various configurations, as shown particularly in FIGS.2-4 and FIGS. 14, 17, and 18, one or more condensation chambers may be positioned before or after the first reaction chamber discussed below.

Each condensation chamber 18 includes a housing 20 that is thermally conductive, chemically resistant, lightweight, and easily fabricated. In addition, the chamber material is suitable for of high inlet gas temperatures of 500° F. or higher. Examples of such housing materials include high temperature aluminum alloys. These types of materials are suitable for any of the respective chambers discussed herein. Contained within the housing is cooling coil 22. The coil may be any type of corrosion resistant tubing, including plastics, stainless steel, copper tubing, etc. A coolant from a coolant source (not shown) is transported through the coib to condense the gas stream 12. Various types of coolants may be used, as long as they arc not corrosive to the cooling coil.

Coupled to me condensation chambers 18 is tubing 23 that transports condensate from the chambers to receptacles 24. The receptacles 24 collect condensate formed in the condensation chambers 18. In some configurations, the tubing 23 is vertically connected to a plurality of condensation chambers and the receptacles are positioned near the base of the apparatus.

Optionally, the apparatus is fluidically coupled to an expansion chamber (not shown) that includes baffle plates (not shown) with drilled holes for allowing the gas to flow through the baffle. Baffles can reduce the flow of the gas stream and provide for additional flow control. These baffles may also be controlled by the PLC. The reduction in temperature of the gas stream accomplished by an expansion chamber will help to stabilize the gas stream. Exemplary baffles may be formed from stainless steel and/or may be lined with a nonmagnetic material. The removal of pollutants in the expansion chamber can further enable other chambers within the apparatus to target pollutants like NOx and SOx that could make up the gas stream.

Where the expansion chambers are not utilized, the gas stream 12 flows from at least one condensation chamber 18 to a first reaction chamber 26. This reaction chamber 26 comprises a reaction chamber body 28 preferably made from a material that is conductive, highly resistant to chemicals, and capable of withstanding high temperature environments. The body has openings 29 that are adapted to receive novel collar assemblies, as described below.

The reaction chamber 26 electrochemicaUy changes the state of matter from a gas stream to plasma, thereby destroying undesirable pollutants. Plasma may be generated by a number of methods, including electrical fields, electron beams, and irradiation with electromagnetic energy of appropriate intensity and wavelength such as those disclosed in "Recent Development of Plasma Pollution Control technology: A Critical Review," authored by Jcn-Shih Change, the entirety of which is incorporated herein by reference. When plasma is generated with strong electromagnetic fields of high voltage, negatively and positively charged tons, disassociation of molecular bonds occurs. When the plasma is enclosed with a magnetic field caused by high voltage, structures are formed, e.g. filaments, beams, and double layers. Electromagnetic spectnims of light can exist and can range from subatomic to hundreds of yards of visible light.

In at least one configuration, however, the first reaction chamber 26 is configured as an arc plasma reactor where the creation of a plasma arc is created using, in part, novel collar assemblies 30. In this configuration, the first reaction chamber 26 is fitted with eight collar assemblies. Each collar assembly 30 is disposed through openings 31 radially positioned in the body 27 of the reaction chamber 26. Further, each collar assembly comprises a probe 32, a probe holder 34, a resistor 36, and a collar 38. The collar 30 is made from a non-conductive material and is alternatively referred to a probe attenuator. Suitable materials for the collar include Electrical Grade Virgin Poyltetrafluorethylene (PTFE). The collar material must be highly electrically resistant such that the collar assembly can withstand 60,000 volts or more. In one configuration, eight collar assemblies are used although a lesser or greater number of collar assemblies may be used, depending on the application and the concentration of pollutants contained in the gas stream. The collars 38 are preferably threaded for attachment within the chamber, however, any other means of attachment may be used.

Attached to the collars 38 are probes 32 and probe holders 34 which can both act as electrodes. Preferably, these components are made from conductive materials like steel, and more preferably chemically resistant conductive materials like stainless steel. The probes are disposed within a through-hole 33 in the probe holder and coupled to the holder with a set screw. For the first reaction chamber, a portion of the probe, approximately 0.625 inches is bent to form a probe tip 37, angled at 45°. To generate a suitable arc, the paired probe tips have a space between the tips of about 0.50 to 0.75 inches. The probe holders 34 are optionally threaded to facilitate attachment to the collars 38; however, other means of attachment are possible. The collar assemblies 30 are preferably placed equidistant around the reaction chamber body 28 at specific angles, 45° apart for example.

The probes 32, each preferably having a diametrical cross-section ranging from about 0.5 millimeters (mm) to 5 mm, are used to produce an electromagnetic field through the generation of a plasma arc 35. The orientation of the probe holders and distance between the probes can also affect the effectiveness of the each reaction chamber in electrochemically altering the gas stream. These and other types of adjustments to probe positioning, distance between probes, and probe orientation are essentially a tuning of the probe, which can yield added effectiveness in each reaction chamber. Such adjustments may be further configured to affect operational frequencies of the chemical makeup of the gas stream on a molecular level.

The orientation of the collar assemblies with respect to the chamber body may be angularly positioned around a central axis 37 of the body, using a plurality of collar assemblies. In one embodiment, eight collar assemblies are utilized with four of the assemblies being mounted in through-holes in the reaction chamber body. The collar assemblies may be located, for example, at 12 o'clock, 3 o'clock, 6 o'clock, and 9 o'clock positions. Another set of four collar assemblies are positioned in the reaction chamber body at a specified distance and angularly offset from the first set of assemblies by about 45 degrees. In an alternative version of the reaction chamber, the plurality of collar assemblies may have a helical configuration, as shown particularly in FIGS. 16, 20 and 22. However, depending on the composition of the gas stream, and specifically the energy to mass density ratio within the first reaction chamber, additional probe holders may be utilized and/or all the utilized probe holdem may be placed in any suitable angular, clock-baeed, or spiral shape orientation. Also, suitable resistors 36 are capable of withstanding temperatures up to 500° F. Preferably, the resistors are made from a nonconductive material such as PVC.

The first reaction chamber 26 is electrically coupled to an AC or DC pulsed electrical power source for generation of plasma within the chamber, using high voltage wiring. The power source is preferably coupled to a high frequency gapped inductor, having a current range from about 1 ampere to about 200 amperes and an inductance value ranging from 1 uH (microhenries), to 1 mH (millihenries). Power and frequency requirements may, however, depend upon the quantity and/or density of the pollutants in the gas stream. Ako for safety reasons, it is preferable to attach an insulator coupled to each probe mat extends from the reaction chamber body. Suitable insulator materials include latex. All components requiring electrical coupling are connected to a control box 56.

From the first reaction chamber 26, the gas stream 12 flows into a reduction chamber 40 and then to a resonance chamber 44. The reduction chamber 40, shown in FIG. 12, is adapted to absorb particulates in the gas stream 12. The reduction chamber has an outer body 42 that is preferably made from steel; however, any material mat can withstand the temperature of the gas stream 12 at this stage in the apparatus is suitable. Contained within the reduction chamber is a cellulose material 43, preferably an absorbent wood, containing natural lubricants. Pine is most preferable. The cellulose material is positioned within the outer body 42 such that flow of the gas stream 12 is optimized. In one configuration, boards of pine are attached to the top and bottom of the outer body 42, using high temperature adhesives or mechanical methods of attachment

From the reduction chamber, the gas stream 12 flows through a resonance chamber 44, shown in FIG. 13. The chamber comprises a body 49 and a wire grid 48. Alternatively the chamber 44 can house one or more resonating coils (not shown). Within the resonance chamber 44, the gas stream 12 is ionized by an established resonance field before flowing to a second reaction chamber 46 discussed below. Extreme ionization potential allows for dis association of the respective molecules of the gas stream. The resonance chamber 44 is optionally configured to collect heavy oxides, hydrocarbons, ash, and dust, among other contaminants. In certain embodiments, the gas stream 12 passes through a wire grid 48. The wire grid is taken from a Honeywell F50 Electric Air Cleaner Cell, using 136434AA coil, or other comparable systems. The gas stream 12 is subjected to an electric field mat is generated by alternating current that passes through the grid. The current is supplied from a power source (not shown). Adjustments to the grid type and resonance adjustments can further initiate control capabilities for the gas stream.

Preferably, as an alternative to the wire grid, one or more modified Honeywell FC37A1130 Electronic Air Cleaner Cells are disposed within the resonance chamber. The access door of the cell is removed and replaced with an aluminum paneL The aluminum panel is configured to increase ionic distribution within the resonance chamber. The aluminum plate is preferably disposed over the circuit plate of the air cleaner cell.

The power source of the resonance chamber 44 may alternatively be an AC or a DC power supply. The power source can be pulsed on a three phase system for canceling grounds, allowing the air cleaner cells to run wet or dry without sparking or arcing.

Optionally, an AC or DC pulsed supply may also be used to generate plasma in the reaction chambers to facilitate disassociation and destruction of pollutants within the gas stream.

Additionally, other high powered, high frequency components may be used to target pollutants, including heavy metak and VOCs. Moreover, lower power, lower frequency components may be used to target pollutants, including N Ox and SOx. Both collection and dissociation may be further accomplished where multi-chambered resonance chambers and/or a plurality of resonance chambers are included within the apparatus.

From the resonance chamber 44 the gas stream flows to the second reaction chamber 46 through piping 16. Operatively, the second reaction chamber 46 is substantially similar to the first reaction chamber. The configuration of this second resonance chamber, however, may be the same as or different than the first reaction chamber. In one embodiment, for example, probe tips are straight rather than angled and two collar assemblies are positioned at 3 o'clock and 9 o'clock.

The apparatus 10 may also include cooling unit (not shown) which utilizes a refrigerant such as ammonia, carbon dioxide, ethane, ethylene, glycol, methane, nitrogen, propane, or propylene. In addition, depending on the makeup of the gas stream, one or more heating elements may be integrated in the apparatus to raise temperatures of the gas stream at various points in the apparatus. Use of these heating elements has been shown to boost NOa levels in some gas stream without affecting other substances and an increase in flow velocity of the gas stream without use of a fan, e.g., to facilitate air flow.

Additionally, a blower unit 50 may be used for controlling the gaseous flow of the gas stream through the apparatus. The blower unit SO may be, for example, an enclosed variable speed fan assembly or a damper, or other means for regulating gaseous flow. The flow of the gas stream 12 may also be regulated by the blower unit SO relative to the measured the level of pollutants in the polluted gas stream. If the percentage of undesired pollutants is relatively high, then the dwell time of the gas stream within the apparatus may be increased.

Conversely, if the percentage of undesired pollutants is relatively low, then the flow velocity of the gas stream may be increased, reducing the dwell time of the gas stream.

Preferably, this feature may be utilized to control the residence time of the gas stream in the reaction chambers of the apparatus. The blower unit is preferably controlled by logic circuitry that is responsive to pollutant levels in the gas stream.

Other exemplary embodiments may include further components which help condition the gas stream 12 and reduce pollutants in the gas stream before flow into either the first reaction chamber or the second reaction chamber.

After the gas stream 12 flows through the components described above, a treated gas stream 52 is produced. The gas stream 52 can either enter into the atmosphere through an outlet 54 or optionally be directed for recirculation into the apparatus. By re-circulating the treated gas stream 52 emissions are substantially limited.

Referring to FIG. 14, the apparatus 100 includes an inlet 114 for a gas stream, several fluidically coupled chambers, as described below, and an outlet 154 for the treated gas. The transport of the gas stream through the apparatus is also preferably achieved by negative pressure suction. The gas stream travels from a source S through the apparatus 100 to an inlet 114, which may be piping, tubing, funnels, or other types of openings providing for fluid communication. Also, the apparatus 100 preferably includes a probed transfer tube 115 configured such that a current may run through the tube 115. The transfer tube 115 may be actuated by logic circuitry, e.g. a programmable logic controller ("PLC"). As with the first embodiment of the apparatus, other chambers may be fluidically coupled using piping 116. In thb embodiment, me transfer tube 115 is fluidically coupled to the first reaction chamber 126 and then to a plurality of cooling condensation chambers 18 which are adapted to condense the gas stream and gradually decrease its temperature, pressure, and velocity. Each condensation chamber 118 includes a housing 120 that preferably has a non-destructive reactive liner that includes a copper-based material. From here, the gas stream travels to the first reaction chamber 126. The reaction chamber 126 electrochemically changes the state of matter from a gas stream to plasma, thereby destroying undesirable pollutants. The first reaction chamber 126 is preferably configured as an arc plasma reactor where the creation of a plasma arc is created using, in part, collar assemblies 30. In this configuration, the first reaction chamber 126 is fitted with a plurality collar assemblies arranged in a helical pattern as shown with respect to the third embodiment of the apparatus 200. The probes are preferably made from titanium, and more preferably chemically resistant conductive materials like stainless steel. The probes are disposed within a through-hole 133 in the probe holder and coupled to the holder with a set screw. For the first reaction chamber, a portion of the probe, approximately 0.62S inches is not bent, but forms a probe tip 137, angled at 45°. To generate a suitable arc, the paired probe tips have a space between the tips of about 0.50 to 0.7S inches. The probe holders 134 are optionally threaded to facilitate attachment to the collars 138; however, other means of attachment are possible. The collar assemblies 30 are preferably placed equidistant around the reaction chamber body 28 at specific angles, ranging from about 22-45° apart for example.

As with the first embodiment, the first reaction chamber 26 is preferably electrically coupled to an AC or DC pulsed electrical power source for generation of plasma within the chamber, using high voltage wiring. From the first reaction chamber 26, the gas stream 12 flows into a condensation chamber 118 to a plurality of reduction chambers 140 and then to a resonance chamber 144.

From the resonance chamber 144 the gas stream flows to the second reaction chamber 46 through piping 16. Opcrativcly, the second reaction chamber 46 is substantially similar to the first reaction chamber, however with a different probe arrangement The apparatus 100 may also include cooling unit (not shown) which utilizes a refrigerant such as ammonia, carbon dioxide, ethane, ethylene, glycol, methane, nitrogen, propane, or propylene. In addition, depending on the makeup of the gas stream, one or more heating dements may be integrated in the apparatus to raise temperatures of the gas stream at various points in the apparatus. Additionally, a blower unit 150 may be used for controlling the gaseous flow of the gas stream through the apparatus. Other exemplary embodiments may include further components which help condition the gas stream 112 and reduce pollutants in the gas stream before flow into cither the first reaction chamber or the second reaction chamber.

After the gas stream 112 flows through the components described above, a treated gas stream 152 is produced. The gas stream 52 can either enter into the atmosphere A through an outlet 154 or optionally be directed for recirculation into the apparatus 100.

Referring to FIGs. 15-24d, the apparatus 200 includes components, which are referenced in the drawings as follows:

A - cooling condensers, including non-deslructive, reactive coopering liners B - first reaction chamber, including probes and probe assemblies, preferably including titanium based materials that provide high electronic affinity to carbon

C - filtering expansion chambers, including aluminum based baffles

D - a blower unit capable of attaining 15 horsepower such that an associated pressure drop is provided during operation of the apparatus

E - cellulosod based baffle chambers/dryers

F - electrostatic precipitators

G - ion exchangers, including a propriety non-destructive catalyst material

H - baffled expansion chamber

I - a polishing reaction chamber

J - a flexible mechanism that acts as a conduit

The apparatus 200 may include other components described with respect to the additional embodiments disclosed herein. Accordingly, apparatuses and methods for reducing pollutants in gas streams, particularly gas streams emitted from combustion processes are disclosed. Although embodiments and applications of this invention have been shown, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the appended claims.

Claims

1. An apparatus for reducing pollutants in a gas stream that travels through the apparatus, comprising:

an mlet for the gas stream;

a pro-treatment transfer tube, coupled to the inlet, configured to receive an electrical charge,

a first reaction chamber coupled to the pre-treatment transfer tube, comprising a plurality of helically-arranged probes;

at least one condensation chamber coupled to the at least one reaction chamber. at least one reduction chamber coupled to one condensation chamber, the reduction chamber being adapted to absorb pollutants from the gas stream;

at least one resonance chamber adapted to ionize the gas stream;

a second polishing reactor coupled to one resonance chamber, and

an outlet for the gas stream, wherein the gas stream contains a reduced number of pollutants after traveling through the apparatus from the inlet to the outlet to produce a treated gas stream.

2. The apparatus of claim 1, wherein the pie-treatment transfer tube comprises one or more probes disposed therein.

3. The apparatus of claims 1 or 2, wherein the helically-arranged probes comprise titanium.

4. The apparatus of claims 1 or 2, wherein the resonance chamber comprises a nondestructive catalyst material.