Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F24—HEATING; RANGES; VENTILATING
  • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
  • F24H3/00—Air heaters
  • F24H3/02—Air heaters with forced circulation
  • F24H3/06—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators
  • F24H3/08—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators by tubes
  • F24H3/087—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators by tubes using fluid fuel
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
  • F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
  • F23C9/00—Combustion apparatus characterised by arrangements for returning combustion products or flue gases to the combustion chamber
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F24—HEATING; RANGES; VENTILATING
  • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
  • F24H9/00—Details
  • F24H9/18—Arrangement or mounting of grates or heating means
  • F24H9/1854—Arrangement or mounting of grates or heating means for air heaters
  • F24H9/1877—Arrangement or mounting of combustion heating means, e.g. grates or burners
  • F24H9/1881—Arrangement or mounting of combustion heating means, e.g. grates or burners using fluid fuel
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
  • F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
  • F23C2202/00—Fluegas recirculation
  • F23C2202/20—Premixing fluegas with fuel
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
  • F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
  • F23C2900/00—Special features of, or arrangements for combustion apparatus using fluid fuels or solid fuels suspended in air; Combustion processes therefor
  • F23C2900/9901—Combustion process using hydrogen, hydrogen peroxide water or brown gas as fuel
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
  • F23D—BURNERS
  • F23D2207/00—Ignition devices associated with burner

Definitions

• the present disclosure relates to heat exchanger systems for generating heat for heating fluids, such as air, by combusting gaseous molecular hydrogen.
• a process for heating ambient air comprising: emplacing a reaction zone material within a reaction zone, wherein the reaction zone material includes gaseous molecular hydrogen and an oxidant; igniting the reaction zone material, with effect that the reaction zone material is converted to reaction products via a reactive process, wherein the reaction products include a post-reactive process gaseous material; wherein: the reactive process generates heat energy, wherein a first portion of the generated heat energy heats the reaction products such that heated reaction products are produced; and emplacing the heated reaction products in heat transfer communication with ambient air, such that the ambient air is heated by the reaction products, such that heated ambient air and cooled reaction products are produced, wherein the cooled reaction products include a cooled post-reactive process gaseous material; emplacing the cooled post-reactive process gaseous material in heat transfer communication with the reaction zone such that, while the heat energy is being generated in response to the conversion of the reaction zone material to the reaction products, the cooled post-reactive process
• a system for producing heat energy comprising: a source of gaseous molecular hydrogen; a manifold, comprising: a gas-receiving chamber disposed in flow communication with the gaseous molecular hydrogen source for receiving the gaseous molecular hydrogen; and a manifold-defined heat exchanger; a nozzle for discharging the gaseous molecular hydrogen that is received by the gas-receiving chamber; an igniter for effecting ignition of reaction zone material within a reaction zone, wherein the manifold-defined heat exchanger and the reaction zone are emplaced in heat transfer communication; a heat exchanger; and wherein: the source of gaseous molecular hydrogen, the gas-receiving chamber, the nozzle, the igniter, and the reaction zone are co-operatively configured such that, while: (i) the gaseous molecular hydrogen is being received by the gas-receiving chamber and discharged via the nozzle to the reaction zone, and (ii) oxidant
• a kit of components for retrofitting a furnace that includes a conventional burner assembly and a heat exchanger, comprising: a source of gaseous molecular hydrogen; a gaseous hydrogen-compatible burner assembly, comprising: a manifold, comprising: a fluid conductor for receiving and conducting a reaction zone supply to a reaction zone such that a reaction zone material, within the reaction zone, is obtained, a manifold-defined heat exchanger, and an igniter for igniting the reaction zone material emplaced within the reaction zone; wherein: the source of gaseous molecular hydrogen, the gaseous hydrogen-compatible burner assembly, and the heat exchanger are co-operatively configured such that while: (i) the gaseous hydrogen-compatible burner assembly is replacing the conventional burner assembly, (ii) the gaseous hydrogen-compatible burner assembly is receiving a reaction zone supply; (iii) the gaseous hydrogen-compatible burner assembly is disposed in flow communication with the source of gaseous molecular hydrogen, such that
• Figure 1 is a schematic illustration of an embodiment of a heat exchanger system of the present disclosure
• FIG 2 is a schematic illustration of an embodiment of a conventional heat exchanger system prior to its modification to obtain the heat exchanger system illustrated in Figure 1;
• FIG. 3 is a schematic illustration of an alternate embodiment of a heat exchanger system
• Figure 4 is a schematic illustration of the manifold of the heat exchanger system of Figure 3.
• FIG. 5 is a schematic illustration of the heat exchanger system of Figure 3, including a separator.
• a heat exchanger system 10 The heat exchanger system 10 is provided and configured to generate heat, from combustion of a gaseous fuel within a reaction zone 8, for heating ambient air for climate control of an interior space.
• a first gaseous material supply source 12 is provided and functions to provide a source of first gaseous material 102.
• the first gaseous material includes a gaseous fuel.
• the source 12 is for supplying the first gaseous material 102 to the reaction zone 8 for combustion of the gaseous fuel.
• the gaseous fuel includes gaseous molecular hydrogen.
• the first gaseous material 102 is combined with second gaseous material 104, such that a combined fluid material 106 is produced and supplied to the reaction zone 8.
• the second gaseous material 104 includes an oxidant, and, in this respect, within the reaction zone 8, combustion of the gaseous fuel of the first gaseous material 102 is effected by the oxidant of the second gaseous material 104.
• the second gaseous material 104 includes ambient air, such that the oxidant includes molecular oxygen. The oxidant of the second gaseous material 104 is adscititious to any oxidant that is part of the first gaseous material 102.
• the second gaseous material 104 includes return air. In some embodiments, for example, the second gaseous material 104 includes fresh air. In some embodiments, for example, the second gaseous material 104 includes a mixture of return air and fresh air.
• an eductor 14 (also sometimes referred to as a “venturi mixer”) is provided for inducing flow of the first gaseous material 102 with a flow of second gaseous material 104, in response to the venturi effect, with effect that at least the first gaseous material 102 and the second gaseous material 104 are combined such that a combined fluid material flow 106 is obtained, at least a fraction of which is supplied to the reaction zone 8.
• the eductor 14 includes a motive fluid receiver 16, a converging nozzle flow passage 18, a suction fluid receiver 20, a mixing zone 22, a diverging nozzle flow passage 24, and a combined fluid material discharge communicator 26.
• the motive fluid receiver 16 is disposed in flow communication with the mixing zone 22 via the converging nozzle flow passage 18.
• the mixing zone 22 is disposed in flow communication with the combined fluid material discharge communicator 26 via the diverging nozzle flow passage 24.
• the suction fluid receiver 20 is disposed in flow communication with the mixing zone 22.
• the motive fluid receiver 16, the converging nozzle flow passage 18, the suction fluid receiver 20, the mixing zone 22, the diverging nozzle flow passage, and the combined fluid material discharge communicator 26 are co-operatively configured such that, while: (i) the motive fluid receiver 16 is receiving a flow of the second gaseous material 104 at a sufficiently high pressure, and (ii) the suction fluid receiver 20 is disposed in flow communication with the first gaseous material 102 and the first gaseous material 102 is disposed at a sufficiently low pressure: an increase in velocity of the flow of the second gaseous material 104 is effected, as the second gaseous material flow is conducted, via the converging nozzle flow passage 18, from the motive fluid receiver 16 to the mixing zone 22, such that, concomitantly, pressure of the flow of the second gaseous material 104 decreases, with effect that the second gaseous material 104 becomes disposed within the mixing zone 22 at a reduced pressure; flow of the first gaseous material 102 is induced, via the suction fluid receiver 20, into the mixing
• the flow of the combined fluid material 106, including the first gaseous material 102, is discharged from the eductor 14, via the combined fluid material discharge communicator 26, at a pressure that is higher than the pressure of the first gaseous material 102 upstream of the suction fluid receiver 20 of the eductor 14.
• this increase in pressure of the gaseous fuel effected by the venturi effect, enables flow of the gaseous fuel (as part of the combined fluid material flow) through a heat exchanger 28, for effecting heating of ambient air 49, as described below.
• the first gaseous feed material 102 is supplied from an electrolyzer 30, such that the source 12 includes the electrolyzer 30.
• the electrolyzer 30 is configured for effecting electrolysis of water with effect that reaction products are obtained.
• the electrolyzer 30 including an anode, a cathode, an electrolysis chamber containing an aqueous electrolyte solution.
• the anode, the cathode, and the electrolyte are co-operatively configured such that application of an electrical potential difference between the anode and the cathode effects electrolysis of water of the aqueous solution such that the reaction products, including gaseous molecular hydrogen and gaseous molecular hydrogen, are produced.
• the first gaseous feed material 102 is recovered from the reaction products, such that the first gaseous feed material 102 includes the produced gaseous molecular hydrogen and the gaseous molecular hydrogen of the reaction products.
• the gaseous fuel of the first gaseous material 102 includes the produced gaseous molecular hydrogen that is recovered from the reaction product.
• the source 12 of the first gaseous material 102 is fluidly coupled to the suction fluid receiver 20 of the eductor 14 via a first gaseous material conductor 50.
• the first gaseous material conductor 50 includes a flame arrestor 56 (for example, a composite metal foam material flame arrestor, such as a hastelloy flame arrestor) for interfering with potential flashback from the reaction zone 8.
• the first gaseous material conductor 50 includes a check valve 52 for further interfering with potential flashback from the reaction zone.
• the check valve is a floating ball check valve 52.
• the floating ball check valve 52 includes a ball 54 (it is understood that the ball 54 is not necessarily spherically-shaped or otherwise ball-shaped), whose movement is constrained within a chamber 58, and a valve seat 60 configured for receiving the ball 54 for effecting closure of a flow communicator 62 (e.g. a port) that is effecting flow communication between the source 12 and the suction fluid receiver 20 of the eductor 14.
• a flow communicator 62 e.g. a port
• sufficient downstream pressure effects seating of the ball 54 on the valve seat 60, thereby effecting closure of the flow communicator 62, and thereby mitigating potential flashback from the reaction zone 8.
• the first gaseous material conductor 50 includes a sightglass 64 for providing visibility of the ball 54 and, thereby, amongst other things, enabling visual confirmation of flow of the first gaseous material 102.
• the ball 54 is a flame retardant foam ball, such as a flexible polyimide foam body.
• a suitable flexible polyimide foam body is made from SOLVER PI- Flexible Foam manufactured by SOLVER POLYIMIDE of Room 1401, Peninsula International Mansion, Jiande City, 311600 Zhejiang province, China.
• the flow of the second gaseous material 104 is supplied to the eductor 14 at a pressure of between 2 psig and 12 psig and at a velocity of at least 0.021 metres per second.
• the first gaseous material 102 which is disposed in flow communication with the suction fluid receiver 20, is disposed at a pressure of atmospheric pressure.
• the second gaseous material 104 which is supplied to the eductor 14, is ambient air that is supplied by an air pump 34 which draws from ambient air.
• the source 34 for example, the air pump of the second gaseous material 104, which is being supplied to the motive fluid receiver 16 of the eductor 14, is fluidly coupled to the motive fluid receiver 16 by a second gaseous material conductor 150.
• the second gaseous material conductor 150 includes a flame arrestor 156 (for example, a composite metal foam material flame arrestor, such as a hastelloy flame arrestor) for interfering with potential flashback from the reaction zone 8.
• the second gaseous material conductor 150 includes a check valve 152 for further interfering with potential flashback from the reaction zone.
• the check valve is a floating ball check valve 152.
• the floating ball check valve 152 includes a ball 154 (it is understood that the ball 154 is not necessarily spherically- shaped or otherwise ball-shaped), whose movement is constrained within a chamber 158, and a valve seat 160 configured for receiving the ball 154 for effecting closure of a flow communicator 162 (e.g. a port) that is effecting flow communication between the source 34 and the motive fluid receiver 16 of the eductor 14.
• a flow communicator 162 e.g. a port
• the second gaseous material conductor 150 includes a sightglass 164 for providing visibility of the ball 154 and, thereby, amongst other things, enabling visual confirmation of flow of the second gaseous material 104.
• the ball 154 is a flame retardant foam ball, such as a flexible polyimide foam body.
• a suitable flexible polyimide foam body is made from SOLVER Pl-Flexible Foam manufactured by SOLVER POLYIMIDE of Room 1401, Peninsula International Mansion, Jiande City, 311600 Zhejiang province, China.
• the combined fluid material discharge communicator 26 of the eductor 14 is fluidly coupled to the burner assembly 36 via a bubbler 68.
• the bubbler 68 includes a combined fluid material receiver 70, for receiving a flow of combined fluid material 106 flow from the venture mixer 14, and conducting the flow of the combined fluid material 106 into a liquid medium 72 that is contained within the bubbler 68, with effect that impurities are separated from the flow of the combined fluid material 106 (such as, for example, by dissolution within the liquid medium), and such that a flow of purified combined fluid material 108 is obtained and discharged via a bubbler discharge communicator 74, of the bubbler 68, at least a fraction of which is supplied to the burner assembly 36.
• the impurities being separated include electrolyte that is carried over from the electrolyzer 30.
• the liquid medium further functions as a flame arrestor for mitigating flashback from the reaction zone 8.
• the combined fluid material receiver 70 includes coiled tubing 76 for conducting the received combined fluid material 104.
• the coiled tubing 76 functions to effect flow resistance to any flashback from the reaction zone, thereby interfering with its propagation to the sources 12, 34 of the first and second gasesous materials, respectively.
• the coiled tubing 76 is manufactured from heat conducting material (such as copper) for facilitating heat transfer from fluid being conducted through the coiled tubing 76 to the liquid medium, and thereby further mitigating potential flashback.
• the flow of the purified combined fluid material 108, being discharged from the bubbler 68 is accelerated in response to a venturi effect that is obtained via conduction of a third gaseous material 110 (e.g. ambient air that is supplied from an air pump 134) via a second venturi meter 114, with effect that at least the flow of the purified combined fluid material 108 and the third gaseous material flow 110 are combined such that a combined fluid material flow 112 is obtained and discharged into the reaction zone 8.
• a third gaseous material 110 e.g. ambient air that is supplied from an air pump 13
• the third gaseous material 110 includes return air. In some embodiments, for example, the third gaseous material 110 includes fresh air. In some embodiments, for example, the third gaseous material 110 includes a mixture of return air and fresh air.
• the second eductor 114 includes a motive fluid receiver 116, a converging nozzle flow passage 118, a suction fluid receiver 120, a mixing zone 122, a diverging nozzle flow passage 124, and a combined fluid material discharge communicator 126.
• the motive fluid receiver 116 is disposed in flow communication with the mixing zone 122 via the converging nozzle flow passage 118.
• the mixing zone 122 is disposed in flow communication with the combined fluid material discharge communicator 126 via the diverging nozzle flow passage 124.
• the suction fluid receiver 120 is disposed in flow communication with the mixing zone 122.
• the motive fluid receiver 116, the converging nozzle flow passage 118, the suction fluid receiver 120, the mixing zone 122, the diverging nozzle flow passage, and the combined fluid material discharge communicator 126 are co-operatively configured such that, while: (i) the motive fluid receiver 116 is receiving a flow of a third gaseous material 110 at a sufficiently high pressure, and (ii) the suction fluid receiver 120 is disposed in flow communication with the purified combined fluid material 108 and the purified combined fluid material 108 is disposed at a sufficiently low pressure: an increase in velocity of the third gaseous material flow 110 is effected, as the flow of the third gaseous material 110 is conducted, via the converging nozzle flow passage 118, from the motive fluid receiver 116 to the mixing zone 122, such that, concomitantly, pressure of the flow of the third gaseous material 110 decreases, with effect that the third gaseous material 110 becomes disposed within the mixing zone 122 at a reduced pressure; flow of the purified combined fluid material 108 is
• the flow of the combined fluid material 112, including the gaseous fuel is discharged from the second eductor 114, via the combined fluid material discharge communicator 126, at a pressure that is higher than the pressure of the flow of the purified combined fluid material 108 at the suction fluid receiver 120 of the second eductor 114.
• this increase in pressure of the gaseous fuel effected by the venturi effect, enables flow of the gaseous fuel (as part of the combined fluid material flow) through the heat exchanger 28, for combustion for effecting heating of ambient air.
• the flow of the combined fluid material 112 is supplied to a burner assembly 36 for effecting the combustion of the gaseous fuel of the first gaseous material 102 within the reaction zone 8.
• the combined fluid material 112 is a reaction zone material.
• a burner assembly 36 is provided, and the burner assembly 36 includes a manifold 38 and a plurality of nozzles 40.
• the manifold 38 defines a flow passage, for example, a manifold fluid passage network 42 for receiving the flow of the combined fluid material 112 and distributing the received combined fluid material flow amongst the plurality of nozzles 40.
• Each one of the nozzles 40 is configured for receiving the flow of the combined fluid material 112 and discharging a portion of the flow of the combined fluid material 112 to a respective reaction zone 8, such that the combined fluid material flow, including the first gaseous material and the second gaseous material, becomes disposed, for example, emplaced, within the reaction zone 8.
• the emplacing of the combined fluid material 112 within the reaction zone 8 is effectuated by the flowing of the combined fluid material 112 via the manifold fluid passage network 42.
• the manifold fluid passage network 42 defines a minimum cross-sectional flow area of at least 7.66 X 10' 4 square inches. In some embodiments, for example, the manifold fluid passage network 42 defines a minimum cross-sectional flow area of between, inclusively, 7.66 X 10' 4 square inches and 1.23 X 10' 2 square inches.
• the nozzle 40 defines a maximum cross-sectional flow area of less than 3.14 X 10' 6 square inches. In some embodiments, for example, the nozzle 40 defines a maximum cross-sectional flow area of between, inclusively, 7.85 X 10' 7 square inches and 3.14 X 10' 6 square inches. In some embodiments, for example, such sizing of the maximum cross-sectional flow area of the nozzle 40 mitigates potential flashback from the reaction zone 8.
• the burner assembly 36 further includes, for each one of the nozzles 40, independently, an igniter 44 (such as, for example, a surface igniter), for effecting ignition of the combined fluid material 112 within the respective reaction zone 8. While the combined fluid material 112 is disposed within the respective reaction zone 8, in response to ignition by the igniter 44 (such as, for example, a surface igniter), combustion of the gaseous fuel, of the first gaseous material 102, is effected such that reaction products, for example, combustion products 41, are produced, and with effect that a gaseous flame 400 is obtained.
• an igniter 44 such as, for example, a surface igniter
• gaseous fuel present within the combined fluid material 112 which is continuing to be supplied to the reaction zone 8, becomes combusted, to thereby provide continuing production of combustion products.
• the combustion products 41 include a post-reactive process gaseous material 341.
• the combustion also generates heat energy.
• the combustion is with effect that at least 25,000 BTUs, for example, 30,000 BTUs, of heat energy is generated.
• the generated heat energy heats the combustion products, and any unreacted gaseous material, such that heated combustion products 41 are produced.
• the heated combustion products 41 are conducted through the heat exchanger 28, such that the heated combustion products 41 becomes disposed in heat transfer communication with the heat exchanger 28.
• the heated combustion products 41 become disposed in heat transfer communication with the ambient air 49, via the heat exchanger 28, and, thus, heats the ambient air, such that heated ambient air 490 and cooled reaction products 342 are produced.
• the disposition, of the heated reaction products 41 in heat transfer communication with the ambient air 49 is a disposition of the heated reaction products 41 in indirect heat transfer communication with ambient air 49, such that the heating of the ambient air 49 by the heated reaction products 41 is effectuated by indirect heat transfer.
• At least 75%, for example, 80%, of the heat generated from the combustion of the combined fluid material 112 is transferred to the ambient air 49 to produce the heated ambient air 490.
• the amount of heat energy that is received by the ambient air 49, to produce the heated ambient air 490 is based on the heat transfer efficiency of the heat exchanger 28.
• the ambient air 49 includes return air. In some embodiments, for example, the ambient air 49 includes fresh air. In some embodiments, for example, the ambient air 49 includes a mixture of return air and fresh air.
• the heat exchanger 28 includes a plurality of tubes 48, for example, longitudinally extending tubes 48, and each one of the longitudinally extending tubes 48, independently, is aligned with a respective one of the nozzles 40.
• the heated combustion products 41 is conducted through the tubes 48 of the heat exchanger 28, and the ambient air 49, which is drawn across the heat exchanger 28 by the circulating air fan 46, is flowed as flow 49 across the outermost surface of the tubes 48.
• the tubes 48 are coiled tubes 48, and each one of the coiled tubes 48, independently, includes a longitudinally extending portion that is aligned with a respective one of the nozzles 40.
• the heat exchanger 28 is defined by a furnace.
• the produced heated ambient air 490 is then conducted to a space, for example, a space within a building, by a fluid communicator 364, for example, a duct 364, for heating the space.
• a fluid communicator 364 for example, a duct 364
• the heated ambient air 490 is urged to flow through the fluid communicator 364 to the space via a fan.
• the combustion of the combined fluid material 112 is with effect that water vapour is produced, such that the combustion products 41 include water vapour.
• the heating of the ambient air 49 by the heated combustion products 41 is with effect that the water vapour of the heated combustion products 41 is condensed, such that liquid water 346 is produced, and such that the cooled reaction products 342 includes the liquid water 346.
• the cooled reaction products 342 are conducted to a separator 348 that is disposed in flow communication with the heat exchanger 28.
• the liquid water 346 is separated from the cooled reaction products 342 by the separator 348 and collected, and the collected liquid water 346 is conducted to a container 32, which functions as a source of water for the electrolyzer 30.
• the gaseous molecular hydrogen of the combined fluid material 112, which is received by the manifold 38 includes the produced gaseous molecular hydrogen.
• the collected liquid water 346 is conducted to the container 32 via an inducer motor or blower, such as the inducer motor or blower 355.
• a conventional heat exchanger system 200 uses gaseous hydrocarbon material (such as, for example, natural gas) as the gaseous fuel.
• the gaseous fuel supply source 212 includes a source of pressurized gaseous fuel (such as, for example, a gaseous hydrocarbon material).
• the gaseous material-supplying conductor 214 supplies the gaseous fuel from the gaseous fuel supply source 212 to a burner assembly 236 for effecting combustion of the gaseous fuel within a reaction zone 238.
• the burner assembly 236 includes a manifold 237, and the manifold includes a plurality of nozzles 240.
• Each one of the nozzles 240 is configured to discharge a portion of the gaseous fuel into the reaction zone 238 for effecting combustion of the gaseous fuel, via the burner assembly 236.
• the burner assembly 236 includes, for each one of the nozzles 240, independently, a respective flow mixer 234 (such as, for example, a Venturi-type burner) igniter 244 (such as, for example, a surface igniter). For each one of the igniters 244, independently, there is associated a respective reaction zone 238.
• the discharged gaseous fuel, and ambient air, whose flow is induced by the combustion air fan 218, are communicated from the manifold 237 to the reaction zone 238 via, and mixed within, the flow mixer 234 to generate a gaseous fuel / air mixture. While the gaseous fuel / air mixture is disposed within the reaction zone 238, in response to ignition by the igniter 244, combustion of the gaseous fuel is effected such combustion products are produced. The combustion also generates heat energy, which heats the combustion products, and any unreacted gaseous material, such that a heated post-combustion gaseous material 241 is produced.
• the heated post-combustion gaseous material whose flow is being induced by the combustion air fan 218, is flowed through the heat exchanger 28, such that the heated postcombustion gaseous material 241 becomes disposed in indirect heat transfer communication with ambient air 249 that is drawn across the heat exchanger 28 by the circulating air fan 46, and, thus, heating the ambient air.
• the heat exchanger 28 includes a plurality of longitudinally extending tubes 48 and each one of the longitudinally extending tubes 48, independently, is aligned with a respective one of the nozzles 240.
• the heated post-combustion gaseous material whose flow is being induced by the combustion air fan 218, is flowed through the tubes 48 of the heat exchanger 28, and the ambient air 249, which is drawn across the heat exchanger 28 by the circulating air fan 46, is flowed across the outermost surface of the tubes 48, and then conducted to a predetermined space for heating the predetermined space.
• the conventional heat exchanger system 200 is modified to enable use of gaseous molecular hydrogen as the gaseous fuel.
• the conventional heat exchanger system 200 is modified to obtain the heat exchanger system 10 is provided for generating heat, via combustion of gaseous molecular hydrogen, for heating ambient air.
• the burner assembly 236 of the conventional heat exchanger system is replaced by the burner assembly 36, such that gaseous fuel, in the form of gaseous molecular hydrogen, can be supplied for combustion within the modified heat exchanger system 10.
• a kit is provided for retrofitting a conventional heat exchanger system and includes the burner assembly 36 and the electrolyzer 30.
• the kit further includes the separator 348. In some embodiments, for example, the kit further includes the eductor 14. In some embodiments, for example, the kit includes the burner assembly 36, the eductor 14, as well as the bubbler 68 and the second eductor 114. In some embodiments, for example, the kit further includes the separator 348. In some embodiments, for example, the kit further includes the electrolyzer 30. In some embodiments, for example, the kit includes the burner assembly 36 and the eductor 14, as well as the first gaseous material conductor 50 and the second gaseous material conductor 52, and, in some of these embodiments, further includes the bubbler 68 and the second eductor 114. In some embodiments, for example, the kit further includes the separator 348. In some embodiments, for example, the kit further includes the electrolyzer 30.
• the electrolyzer 30 is disposed in heat transfer communication with a heat sink, such that, while the electrolysis is being effected, heat is transferred from the electrolyte to the heat sink.
• the heat sink includes a chiller 31.
• the temperature within the electrolyte is sufficiently low such that vaporization of water, of the aqueous electrolyte, is mitigated, such that the presence of water within the first gaseous material 102 is mitigated.
• the sufficiently low temperature from 27 degrees Celsius to 32 degrees Celsius.
• temperature of the electrolyte is maintained at the sufficiently low temperature by controlling the rate of heat transfer from the electrolyte to the heat sink.
• Water that is present within the first gaseous material 102 (and, therefore, the combined fluid material 112) may, undesirably, interrupt combustion, with effect that the gaseous flame within the furnace becomes extinguished.
• the combustion of the gaseous fuel continues to be supplied to the reaction zone 8 via the combined fluid material 112, is suspended, such that the uncombusted gaseous fuel may accumulate within the furnace and potentially cause a backfire upon re-ignition of the igniter 44. Accordingly, the mitigation of the presence of water within the first gaseous material 102 (and, therefore, the combined fluid material 112), mitigates extinguishment of the gaseous flame and conditions conducive for backfiring.
• the system further includes a sensor for sensing extinguishment of the gas flame.
• the sensor is a photocell sensor.
• the sensor co-operates with the power supply, that is establishing the electrical potential difference between the anode and the cathode of the electrolyzer 30, such that, in response to sensing of an absence of the gaseous flame by the sensor, power being supplied to the electrolyzer 30 is suspended, with effect that the electrolysis is suspended.
• the combustion of the gaseous fuel (e.g. hydrogen) of the first gaseous material 102 is effected via ambient air.
• the combustion of the gaseous fuel of the first gaseous material 102 is effected by return air, for improving the efficiency of the combustion of the gaseous fuel of the first gaseous material 102.
• return air is combined with the combined fluid material 108 or the combined fluid material 112 to change the stoichiometric combustion ratio of the combined fluid material 108 or the combined fluid material 112, to improve the efficiency of the combustion of the gaseous fuel (e.g. hydrogen) of the first gaseous material 102.
• FIG. 3 depicts a heat exchanger system 300 that is an alternate embodiment of the heat exchanger system 10.
• the flow of the combined fluid material 112 is supplied to a burner assembly 336 of the heat exchanger system 300.
• the burner assembly 336 which is an alternate embodiment of the burner assembly 36, is configured to effect the combustion of the gaseous fuel of the first gaseous material 102 within the reaction zone 8 to heat ambient air 49, and to admix re-heated combustion products with the heated ambient air 490 to obtain a heated gaseous mixture 362.
• a burner assembly 336 is provided, and the burner assembly 336 includes a manifold 338, which comprises a gasreceiving chamber 3382 and a manifold-defined heat exchanger 3384, and a plurality of nozzles 40 as described with respect to the burner assembly 36.
• the gas-receiving chamber 3382 of the manifold 338 defines a flow passage, for example, a fluid passage network 339, similar to the fluid passage network 42, for receiving the flow of the combined fluid material 112 and distributing the received combined fluid material flow amongst the plurality of nozzles 40, as described with respect to the burner assembly 36.
• a fluid passage network 339 similar to the fluid passage network 42, for receiving the flow of the combined fluid material 112 and distributing the received combined fluid material flow amongst the plurality of nozzles 40, as described with respect to the burner assembly 36.
• the disposition of the combined fluid material 112 within the reaction zone 8 is effectuated by flowing the combined fluid material 112 via the fluid passage network 339.
• Each one of the nozzles 40 is configured for receiving the flow of the combined fluid material 112 and discharging a portion of the flow of the combined fluid material 112 to a respective reaction zone 8, such that the combined fluid material flow 112, including the first gaseous material and the second gaseous material, becomes disposed within the reaction zone 8.
• the emplacing of the combined fluid material 112 within the reaction zone 8 is effectuated by the flowing of the combined fluid material 112 via the fluid passage network 339.
• the fluid passage network 339 defines a minimum cross-sectional flow area of at least 7.66 X 10' 4 square inches. In some embodiments, for example, the fluid passage network 339 defines a minimum cross-sectional flow area of between, inclusively, 7.66 X 10' 4 square inches and 1.23 X 10' 2 square inches.
• the manifold-defined heat exchanger 3384 and the reaction zone 8 are disposed in heat transfer communication.
• the manifold-defined heat exchanger 3384 defines a flow passage, for example, a fluid passage network 356, for receiving a flow of the cooled post-reactive process gaseous material 344, to heat the cooled post-reactive process gaseous material 344 by the heat energy generated from the combustion of the combined fluid material 112, such that a re-heated post-reactive process gaseous material 360 is produced.
• the emplacement of the cooled post-reactive process gaseous material 344 in heat transfer communication with the reaction zone 8 is effectuated by flowing the cooled post-reactive process gaseous material 344 through the fluid passage network 356.
• the heating of the cooled post-reactive process gaseous material 344 includes heating effectuated in response to heat conduction via the manifold 338.
• the fluid passage network 356 is further configured to distribute the re-heated post-reactive process gaseous material 360 amongst a plurality of discharge communicators 358 defined by the manifold-defined heat exchanger 3384.
• Each one of the discharge communicators 358 is configured for receiving the flow of the re-heated post-reactive process gaseous material 360 and discharging a portion of the flow of the re-heated post-reactive process gaseous material 360 out of the manifold- defined heat exchanger 3384, for admixing the portion of the flow of the re-heated post-reactive process gaseous material 360 with heated ambient air 490 to obtain a heated gaseous mixture 362.
• the fluid passage network 356 defines a minimum cross-sectional flow area of at least 0.14 square inches. In some embodiments, for example, the fluid passage network 356 defines a minimum cross-sectional flow area of between, inclusively, 0.14 square inches and 0.25 square inches.
• the discharge communicator 358 defines a minimum cross-sectional flow area of at least 0.60 square inches. In some embodiments, for example, the discharge communicator 358 defines a minimum cross-sectional flow area of between, inclusively, 0.60 square inches and 1.2 square inches.
• the discharge communicator 358 is a vent port.
• the burner assembly 336 further includes, for each one of the nozzles 40, independently, an igniter 44 (such as, for example, a surface igniter), for effecting ignition of the combined fluid material 112 within the respective reaction zone 8, as described with respect to the burner assembly 36.
• the combined fluid material 112, the gas receiving chamber 3382, the nozzles 40, the igniter 44, and the reaction zone 8 are co-operatively configured such that, while the combined fluid material 112 is disposed within the respective reaction zone 8, in response to ignition by the igniter 44, combustion of the gaseous fuel, of the first gaseous material 102, is effected such that reaction products, for example, combustion products 41, are produced, and with effect that a gaseous flame 400 is obtained.
• gaseous fuel present within the combined fluid material 112, which is continuing to be supplied to the reaction zone 8, becomes combusted, to thereby provide continuing production of combustion products.
• the combustion products 41 include the post-reactive process gaseous material 341.
• the combustion also generates heat energy, for example, 30,000 BTUs of heat energy.
• a first portion of the generated heat energy heats the combustion products 41, and any unreacted gaseous material, such that heated combustion products 41 are produced.
• the first portion of the generated heat energy, for heating the combustion products 41 and producing the heated combustion products 41 is defined by at least 80% of the heat energy generated by combustion of the combined fluid material 112.
• the heated combustion products 41 are discharged through the nozzles 40 and conducted through the heat exchanger 28, for example, through the tubes 48, such that the heated combustion products 41 becomes disposed in heat transfer communication with the heat exchanger 28.
• the reaction zone 8 and the heat exchanger 28 are co-operatively configured such that, while the heated reaction products 41 are produced, and while ambient air 49 is emplaced in heat transfer communication with the heat exchanger 28, for example, while the ambient air 49 is drawn across the heat exchanger 28 by a circulating air fan 46, the heated combustion products 41 become disposed in heat transfer communication, for example, indirect heat transfer communication, with the ambient air 49, via the heat exchanger 28, and, thus, heats the ambient air 49.
• at least 75% of the generated heat energy for example, 80% of the generated heat energy via combustion of the combined fluid material 112, is received by the ambient air 49 to produce the heated ambient air 490.
• the heating of the ambient air 49 by the heated combustion products 41 is such that heated ambient air 490 and the cooled reaction products 342 are produced.
• the cooled reaction products 342 include a cooled post-reactive process gaseous material 344.
• the reaction zone 8, the heat exchanger 28, and the manifold-defined heat exchanger 3384 are co-operatively configured such that, while the cooled reaction products 342 are produced, the cooled reaction products 342, including the cooled post-reactive process gaseous material 344, is conducted to the manifold-defined heat exchanger 3384, such that the cooled reaction products 342 becomes disposed in heat transfer communication with the manifold-defined heat exchanger 3384, which is with effect that the cooled reaction products 342 is disposed in heat transfer communication with the reaction zone 8 via the manifold-defined heat exchanger 3384.
• the cooled reaction products 342, including the cooled post-reactive process gaseous material 344 is heated by a second portion of the generated heat energy, such that a re-heated reaction product 359, including a re-heated post-reactive process gaseous material 360, is produced, and is discharged through the discharge communicators 358 and admixed with the heated ambient air 490 such that a heated gaseous mixture 362 is obtained.
• the ambient air 49 is heated at least two times by the heat exchanger system 300, in particular, by heat transfer via the heat exchanger 28 to produce heated ambient air 490, and then by admixing re-heated post-reactive process gaseous material 360 with the heated ambient air 490 to produce the heated gaseous mixture 362.
• the heated gaseous mixture 362 is then conducted to a space, for example, a space within a building, by a fluid communicator 364, for example, a duct 364, for heating the space.
• the heated gaseous mixture 362 is urged to flow through the fluid communicator 364 to the space via a fan.
• the second portion of the generated heat energy, for heating the cooled reaction products 342, including the cooled post-reactive process gaseous material 344, and producing the re-heated reaction product 359, including the re-heated post- reactive process gaseous material 360 is defined by at least 5% of the heat energy generated by combustion of the combined fluid material 112.
• the cooled combustion products 342, including the cooled post-reactive process gaseous material 344 is urged to flow to the manifold-defined heat exchanger 3384 via an inducer motor or blower 355.
• the blower 355 is powered by 110 V Ac / 0.46 Amps, and has an output of at least 90 cubic feet per minute. In some embodiments, for example, the blower 355 has an output of 100 to 150 cubic feet per minute.
• the manifold 338 further comprises a blowout resister 3383 interposed between the gas-receiving chamber 3382 and the manifold-defined heat exchanger 3384.
• the blowout resister 3383 is configured to resist blowout of the gaseous flame 400, which is generated via combustion of the combined fluid material 112, by the cooled post-reactive process gaseous material 344. While the cooled post-reactive process gaseous material 344 is conducted to the manifold-defined heat exchanger 3384 for emplacement in heat transfer communication with the reaction zone 8, an absence of flow communication, between the emplaced post-reactive process gaseous material 344 and the reaction zone 8, that is effective for stimulating blowout of the gaseous flame 400 by the cooled post-reactive process gaseous material 344, is effected by the blowout resister 3383.
• the blowout resister 3383 is a plate.
• a mixture zone 80 is provided by the heat exchanger system 300 for admixture of the heated ambient air 490 and the re-heated post-reactive process gaseous material 360 to obtain the heated gaseous mixture 362.
• the heated ambient air 490 is flowed to the mixture zone 80 from the heat exchanger 48.
• the heated ambient air 490 is urged to flow to the mixture zone 80 from the heat exchanger 48 via convection.
• the heated ambient air 490 is urged to flow to the mixture zone 80 from the heat exchanger 48 via the fan 46.
• the re-heated post-reactive process gaseous material 360 is discharged from the manifold-defined heat exchanger 3384, through the discharge communicators 358, and into the mixture zone 80, for admixing with the heated ambient air 490 to obtain the heated gaseous mixture 362.
• the mixture zone 80 is disposed above the heat exchanger 48.
• the mixture zone 80 is disposed in flow communication with the duct 364, such that the heated gaseous mixture 362 is flowable from the mixture zone 80 to the duct 364, to be conducted to the space of the building for heating the space.
• the separator 348 is disposed in flow communication with the heat exchanger 28, and further disposed in flow communication with the manifold-defined heat exchanger 3384. While the cooled reaction products 342 are being produced via heating of the ambient air 49, the cooled reaction products 342 are conducted to the separator 348 to effect separation of the cooled reaction products 342 into the liquid water 346 and a post-separation gaseous material 352. In some embodiments, for example, the post-separation gaseous material 352 is conducted to the manifold-defined heat exchanger 3384, such that the postseparation gaseous material 352 becomes disposed in heat transfer communication with the manifold-defined heat exchanger 3384.
• the disposition of the post-separation gaseous material 352 in heat transfer communication with the manifold-defined heat exchanger 3384 is with effect that the post-separation gaseous material 352 is disposed in heat transfer communication with the reaction zone 8 via the manifold-defined heat exchanger 3384. While the heat energy is being generated in response to the conversion of the combined fluid material 112 to the combustion products 41, the post-separation gaseous material 352 is heated by a second portion of the generated heat energy, for example, at least 5% of the generated heat energy, such that the reheated post-reactive process gaseous material 360 is produced.
• the re-heated post-reactive process gaseous material 360 is discharged through the discharge communicators 358 and admixed with the heated ambient air 490 such that a heated gaseous mixture 362 is obtained.
• the heated gaseous mixture 362 is then conducted to a space, for example, a space within a building, by the duct 364, for heating the space.
• the cooled post-reactive gaseous material 344 is defined by the postseparation gaseous material 352.
• the liquid water 346 that is separated from the cooled reaction products 342 by the separator 348 is collected and conducted to the container 32 for supplying water to the electrolyzer 30.
• the gaseous molecular hydrogen of the combined fluid material 112, which is received by the manifold 338 includes the produced gaseous molecular hydrogen.
• the collected liquid water 346 is conducted to the container 32 via an inducer motor or blower, such as the inducer motor or blower 355.
• the flow communication between the separator 348 and the manifold-defined heat exchanger 3384 is established by a flow communicator 354.
• the post-separation gaseous material 352 is urged to flow to the manifold-defined heat exchanger 3384 via the blower 355.
• the post-separation gaseous material 352 includes water vapour, such that, while the post- separation gaseous material 352 is flowing through the flow communicator 354, the water vapour of the post-separation gaseous material 352 is condensed, such that liquid water is produced.
• the collected liquid water is conducted to the container 32, which functions as a source of water for the electrolyzer 30 for producing gaseous molecular hydrogen.
• the flow communicator 354 functions as a condenser.
• the collected liquid water 346 from the flow communicator 354 is conducted to the container 32 via an inducer motor or blower, such as the inducer motor or blower 355.
• the conventional heat exchanger system 200 is modified to enable use of gaseous molecular hydrogen as the gaseous fuel and to enable admixing of re-heated combustion products with heated ambient air.
• the conventional heat exchanger system 200 is modified to obtain the heat exchanger system 300 for generating heat, via combustion of gaseous molecular hydrogen, for heating ambient air, and for re-heating combustion products and admixing the re-heated combustion products with the heated ambient air.
• the burner assembly 236 of the conventional heat exchanger system is replaced by the burner assembly 336, such that gaseous fuel, in the form of gaseous molecular hydrogen, can be supplied for combustion, and that combustion products can be re-heated and admixed with heated ambient air, within the modified heat exchanger system 300.
• a kit is provided for retrofitting a conventional heat exchanger system and includes the burner assembly 336 and the electrolyzer 30.
• the kit further includes the separator 348.
• the kit further includes the eductor 14.
• the kit includes the burner assembly 336, the eductor 14, as well as the bubbler 68 and the second eductor 114. In some embodiments, for example, the kit further includes the separator 348. In some embodiments, for example, the kit further includes the electrolyzer 30. In some embodiments, for example, the kit includes the burner assembly 336 and the eductor 14, as well as the first gaseous material conductor 50 and the second gaseous material conductor 52, and, in some of these embodiments, further includes the bubbler 68 and the second eductor 114. In some embodiments, for example, the kit further includes the separator 348. In some embodiments, for example, the kit further includes the electrolyzer 30.

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• 2023
  • 2023-05-03 US US18/862,841 patent/US20250297774A1/en active Pending
  • 2023-05-03 CA CA3257322A patent/CA3257322A1/en active Pending
  • 2023-05-03 AU AU2023264113A patent/AU2023264113A1/en active Pending
  • 2023-05-03 EP EP23799074.2A patent/EP4519614A4/en active Pending
  • 2023-05-03 JP JP2024565051A patent/JP2025516051A/ja active Pending
  • 2023-05-03 WO PCT/CA2023/050604 patent/WO2023212816A1/en not_active Ceased

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