Patent Application
20190270094
The present invention relates to a boiler.
Aerosol fine particles, i.e. particles floating in a gas, arise in many natural and man-made processes. Examples of natural processes are pollen particles arising from plants, sea aerosols caused by wind and evaporation, and dust lifted by the wind from the surface of the ground. The most common of man-made processes is the use of organic fuels, such as the use of fossil or bio-fuels in energy production. Many of these aerosol fine particles are detrimental to health. Particles arising in natural processes may cause allergic symptoms in people and detrimental organic compounds may also occur in some processes. Particles arising in combustion and industrial processes for their part often contain not only detrimental organic compounds, but also heavy metals. Small particles, less than a micrometre in size, may cause problems in health purely due to their small size, when they induce defence reactions in the body.
Several different methods are known for filtering aerosol particles from gases. The most efficient of these are various fibre filters and electrical filters. In fibre filters, separation is based on the inertia of aerosol particles impacting the material of the filter. In electrical filters, aerosol particles are charged electrically and their movement is influenced with the aid of an electric field, so that they collide with collector surfaces. The advantage of electrical filters is a small pressure drop and easier detachment of the collected solids from the collector surfaces for further treatment.
In traditional electric filters aerosol particles are charged typically with the aid of gas ions arising in a corona discharge. The charged aerosol particles are transferred with the aid of an external electrical field to a collector plate. The electrodes creating a corona discharge are generally located in the flue gas and can also form an electric field used to collect aerosol particles (a so-called one-stage electric filter). Known drawbacks of the method are keeping the electrodes and high-voltage insulators used in a corona discharge clean. The operation of traditional electric filters also limits the geometry of the equipment. Good filtering efficiency is achieved only with cylindrical or flat-plate structures.
Traditional electric filters can be combined with other functions, such as heat recovery. However, it is then necessary to operate within the boundary conditions set by filtering, and the thermal transfer process cannot be optimized.
Aerosol particles can also be collected without the effect of an external electric field. This phenomenon called chamber charging filtering is based on exploiting an electric field created by unipolar charged particles when guiding particles to the collector surfaces. A cloud formed by unipolar charged aerosol particles tends to expand due to the effect of internal electrical repulsive forces and in a delimited chamber some of the particles are driven onto the walls. However, the method is not particularly efficient and in it is theoretically possible to achieve a cleaning effect of only about 40% by using it. The electric field formed by of charged aerosol parts is not as powerful as a field formed by an external voltage source. In addition, the electric field formed by an aerosol particle cloud weakens as filtering progresses.
The invention is intended to create a boiler comprising a flow channel for flue gases having a selected chamber delimited by walls made at least partly of conductive material, the selected chamber being grounded and a device arranged at least partially inside the selected chamber for forming a first electric field to collect the fine particles of flue gases on the walls of the selected chamber, the device comprising
an ion source for creating gas ions with aid of a corona discharge, the ion source comprising a corona electrode for creating the corona discharge, an electrically passive body having an opening for corona discharge, the corona electrode being located inside the electrically passive body and a fan/shielding-gas connection in the electrically passive body for feeding shielding gas inside the electrically passive body in contact with the corona electrode to prevent dirtying of the ion source, the shielding gas exiting the electrically passive body through the opening; and
a high-voltage source for the corona electrode;
in which boiler the walls of the selected chamber form a ground potential for the corona electrode to collect the fine particles of flue gases on the walls of the selected chamber.
In the boiler the number and life of the gas ions created by the corona electrode increases, so that the efficiency of the separation of fine particles can be increased.
According to an embodiment the electrically passive body has side walls and a rear wall, the corona electrode extending through the rear wall. This enables the use of a straight corona electrode.
The shielding gas connection may be formed in the rear wall. Thus the shielding gas is in connection with the corona electrode on the whole length of the exposed surface of the corona electrode keeping it clean.
The device is preferably situated in such chamber, in which the flow velocity of the flue gases past the corona electrode is 0.1-1.5 m/s, preferably 0.1-0.5 m/s. In this way the fine particles are able to be charged properly and collect on the walls of the chamber. At the same time, the flow velocity is sufficiently low for the risk of the fine particles collected detaching from the walls to be small.
The diameter of the body is 10-50%, preferably 15-40% of the diameter of the chamber. Thus the first electric field creating gas ions will be sufficiently strong over the entire area of the selected chamber.
According to one embodiment, the boiler includes a fan for feeding a shielding gas in connection with the feed-through between the body and the wall. With the aid of the feed of a shielding gas the chamber between the body and the wall is kept clean, so that a surface layer causing leak flows is not able to arise.
According to one embodiment, the device can be aligned relative to the chamber in the case of the corona electrode. In other words the corona electrode is perpendicular to the wall of the chamber. Thus the ions creates can be directed more effectively to achieve a better cleaning ability and at the same time also to increase the charge received by the particles to increase the collection efficiency.
In the solution according to the invention, the average strength of the first electric field used to collect the particles can be increased to be as large as the field created by an external voltage source in traditional electric filters.
Because the ions used both for charging the aerosol particles and for creating the collection field are created in a shielding airflow outside the actual gas being cleaned, the problem of the dirtying of the corona electrode and the insulation is avoided.
The ions required to charge the aerosol particles and to collect the particles can be produced either at the same time (one-stage filtering) or separately (two-stage filtering).
Preferably corona electrode is located at a distance from the walls acting as a collector surface the distance being calculated by diving the operating voltage of the corona electrode by the voltage of the corona electrode that is 50-95% of a breakdown voltage of 7 kV/cm. This enables the ions to have a sufficiently long lifetime to reach the collecting surfaces.
According to one embodiment, the charging and collection of the particles can be performed in any partly delimited chamber containing the gas to be cleaned. An example of such a chamber is the heat exchanger of a pellet burner, in which the necessary equipment for cleaning collected solids already exists. A second example is the part of a flue duct to be connected with the ash pan of a fireplace, into which the collected solids can be emptied in connection with the emptying of the ash pan. The filter can also be implemented in a partly delimited chamber designed particularly for the filter.
According to one embodiment, the shielding gas is used to keep both the ion source and the corona electrode clean. In this way leak flows and breakdowns on both the inner and outer surfaces of the body are avoided.
The boiler according to the invention is best suited for diesel and wood-burning processes and processes of the glass industry. The size of fine particles from wood burning is on average less than 0.3 micrometers and from the combustion of diesel slightly less than this and in glass-industry processes less than 0.7 micrometers. In the boiler the recovery of fine particles can be performed without a separate collector, using the walls of a closed chamber for collection.
The operating voltage of the corona electrode of the device is preferably 50-95%, preferably 80-90% of the breakdown voltage. In this way it is possible to ensure the formation of a corona discharge under all conditions.
The electrically passive body is preferably manufactured from a ceramic material, the volume resistivity of which is at least 4*106 ohm-cm, preferably at least 4*107 ohm-cm, most preferably 4*108 ohm-cm at a temperature of 500° C. Such a ceramic material retains its electrical insularity even at high temperatures, and does not cause leak flows.
The boiler may be used with a method for collecting fine particles from flue gases on selected collector surfaces, in which the flue gases containing fine particles exiting the combustion chamber are led to a selected chamber delimited by walls, which is part of the flue gas flow channel. With the aid of a corona discharge of a corona electrode which is in high-voltage relative to the collector surfaces of the ion source, gas ions are formed in a separate body relative to the chamber. Gas ions formed are led to a selected chamber in order to charge the fine particles contained in the flue gas with the aid of gas ions. The charged fine particles are collected on the collector surfaces. The fine particles can be collected without a separate collection area, as the walls of the selected chamber act as such as the collection area.
Preferably a second electric field is formed with the aid of gas ions, which is at least over a specific length of the selected flow channel more powerful than a third electric field formed by the corona electrode against the ground potential. In other words the electrically charged aerosol particles are collected by exploiting the second electric field formed by the gas ions. In this way, the collection efficiency of the fine particles can be raised to as much as more than 90% of the total amount of fine particles contained in the flue gases.
The corona discharge can be created with the aid of a corona electrode and a surface in the ground potential relative to the corona electrode.
Preferably the electrical field created with the aid of the gas ions is stronger than the electric field formed by the corona electrode against the ground potential of the selected flow channel over a length of 3-30 cm, preferably 10-25 cm.
Preferably fine particles of a size of less than 10 μm, preferably less than 2 μm are collected. It is extremely difficult to collect these fine particles with the aid of conventional fibre filters.
The life of gas ions formed with the aid of a corona discharge can be 30-150 ms, preferably 50-80 ms. Thus they are able to charge a considerable number of fine particles.
The operating voltage of the corona electrode of the ion source is preferably 50-95%, preferably 80-90% of the breakdown voltage. The voltage is tried to be maximized without breakdowns that weaken filtering.
The gas ions can be mixed with flue gases, the temperature of which is less than 700° C., preferably less than 500° C. At these temperatures, the collection of fine particles takes place efficiently.
According to one embodiment the gas ions are mixed with the flue gases at a point that is out of reach of the combustion flame. The ions arising in connection with combustion will then not disturb the charging of the fine particles.
The excess pressure used can be 50-2000 Pa, preferably 100-500 Pa relative to the chamber. Thus a sufficient shielding-gas flow is created, so that the entry of flue gases to the ion-source body can be prevented.
According to one embodiment, the fine particles are collected inside the combustion boiler. The collection of the fine particles can then be implemented, for example, in the chimney without a separate process stage.
Preferably the operating voltage is proportional to the distance between the corona electrode and the walls of the selected chamber.
The device can be located in such chamber, in which the flow velocity of the flue gases in the area of influence of the corona electrode is 0.1-1.5 m/s, preferably 0.1-0.5 m/s. Thus the fine particles contained in the flue gases can be charged properly and collect efficiently on the walls of the boiler. In this connection, the term area of influence refers to an area around the corona electrode which is a maximum of 30 cm long.
The diameter of the body of the ion source can 20-50%, preferably 15-40% of the diameter of the chamber. The electric field formed by the gas ions will then be formed sufficiently effectively over the whole area of the selected chamber.
An electrically passive body is preferably formed from ceramic material, which retains its insulating capacity at the operating temperature. Thus the formation of leak flows is effectively prevented.
The electrically passive body may comprise a gas guide for accelerating the flow of the shielding gas exiting the electrically passive body and obstructing entry of flue gases inside the electrically passive body. The use of gas guide facilitates the generation of sufficient excess pressure inside the electrically passive body.
Preferably the gas guide includes a narrowing part and a diffusor part. This facilitates the functions of the gas guide.
The narrowing part and the diffusor part may be at an angle of 30-40° to longitudinal direction of the electrically passive body.
According to an embodiment the electrically passive body comprising a gas guide for accelerating the flow of the shielding gas exiting the electrically passive body and obstructing entry of flue gases inside the electrically passive body and the boiler comprising a second fan for feeding a shielding gas inside the electrically passive body through the fan/shielding gas connection wherein the gas guide and the second fan are designed to create an excess pressure of 50-2000 Pa, preferably 100-500 Pa inside the electrically passive body relative to the selected chamber.
According to an embodiment the electrically passive body comprising a gas guide for accelerating the flow of the shielding gas exiting the electrically passive body and obstructing entry of flue gases inside the electrically passive body and the boiler comprising a second fan for feeding a shielding gas inside the electrically passive through the fan/shielding gas connection wherein the gas guide and the second fan are designed to create an excess pressure of 50-2000 Pa inside the electrically passive body relative to the selected chamber and the ion source is arranged to create gas ions having a life of 30-150 ms, preferably 50-80 ms with aid of the corona electrode.
Preferably the electrically passive body is fed through a feed-through of the walls of the chamber, the electrical passive body being arranged at least partially inside the selected chamber.
In the following, the invention is described in detail with reference to the accompanying drawings depicting some applications of the invention, in which
For reasons of clarity, the figures only show the details necessary in terms of the invention. Structures and details that are unnecessary in terms of the invention, but which will be obvious to one skilled in the art, have been omitted from the figures, in order to emphasize the specific features of the invention. Such unnecessary details are, among others, the firebox and the more detailed structures of the heat exchanger.
The boiler according to the invention may be utilized using a method wherein a flue gas containing fine particles, which can come from, for example, a boiler, is cleaned of fine particles by collecting the fine particles on collector surfaces. The flue gases containing fine particles exiting the combustion chamber are led to a selected chamber acting as a flow channel delimited by walls, such as, for example, a flow channel flowing downwards from the boiler. An ion source separate form the selected chamber delimited by walls is situated in the flow channel and contains a high-voltage corona electrode and an electrically passive body, in which the corona electrode is located. The ion source can also include a fan, by means of which a shielding gas is blown around the corona electrode to prevent dirtying. The high voltage of the corona electrode discharges as a corona discharge between the corona electrode and the walls of the delimited chamber in a ground potential relative to the corona electrode, which forms together with the shielding gas charged gas ions. In other words, in the method according to the invention, the body of the ion source is electrically passive.
When the gas ions are led out of the body of the ion source, they mix with the flue gases and at the same time the gas ions charge the fine particles contained in the flue gases. The gas ions form an ion cloud, which creates through a chamber charging phenomenon in the chamber delimited by walls an electric field E, which drives the charged fine particles VH to the collector surfaces formed by the collector area KA of the selected chamber, i.e. to the walls of the selected chamber. A second electric field formed by the gas ions is preferably over a specific distance of the flow channel formed by the selected chamber stronger than a first electric field formed by the corona electrode against the ground potential. Preferably this distance is 3-30 cm, most preferably 10-25 cm, so that the life of the gas ions is up to tens that of solutions according to the prior art. The counter-potential of the corona electrode and the collector surface of the charged fine particles is formed of the walls of the selected chamber.
The shielding gas SK prevents dirty flue gas from entering the body 110 of the ion source 100. The properties of the shielding gas, such as composition and temperature, can be adjusted to optimize the operation of the filter. The output of the filtering can be improves by using several single-phase filter units SU1.
The ionized gas IK1 and IK2 fed by the ion sources 100 to the chamber 20 can be mixed with the flue gas PK through the turbulence effect caused by the channels 110. Because the unipolar gas ions of the ionized gases IK1 and IK2 reject each other, the gas ions I1 and I2 can be mixed with the flue gas to be cleaned with the aid of electrostatic forces. The gas ions I1 contained in the ionized gas IK1 produced by the ion source 100 charge the fine particles H in the gas, which collect on the collector surfaces according to
The shielding gas SK prevents dirty gas from entering the ion sources 100. The properties of the shielding gas, such as composition and temperature, can be adjusted to optimize the operation of the filter. The effectiveness of the filtering can be improved by using several chargers VA and collectors KE in different combinations.
In this connection, the term electrically passive refers to the fact that the body of the ion source should have a sufficient electrical isolation capacity for the corona discharge to take place between the corona electrode 303 and the wall 200 of the chamber 20, and that electrons cannot travel in the body. More specifically, resistivity can be used as a gauge of separation ability, which should be at least 4*106 ohm-cm, preferably at least 4*107 ohm-cm, most preferably 4*108 at a temperature of 500° C., measured according to the ASTM-D1829 standard. This is possible in among other ways by selecting a substance with a sufficiently good insulation ability as the material for the body 301 of the ion source 100. A sufficient insulation ability can be achieved, for example, by many ceramic materials, such as aluminium oxide which is as pure as possible and which has the resistivity referred to above, or some other corresponding ceramic material. Sufficient electrical passivity can also be achieved by coating the body with an electrically passive substance and keeping the part inside the coating sufficiently cool, so that leak flows do not occur. As an alternative, it is also possible to use a catalytic coating in order to maintain insulation ability, for example, according to the principles known from diesel vehicles.
The electric insulation ability of the body 301 of the ion source 100 can be improved by shaping the outer surface of the body 301 in such a way that the distance of a surface discharge increases. In
With the aid of an electrically passive body of the ion source all the gas ions formed with the aid of the corona discharge are brought from the ion source to the chamber delimited by the surrounding walls. The electrically passive ion-source body does not act as a ground destroying the gas ions unlike in solutions according to the prior art, in which only about a tenth of the gas ions formed exit the ion-source body to the selected chamber. With an electrically passive ion-source body, a greater gas ion density is achieved at least over part of the distance to the selected chamber, when the first electric field formed by the gas ions is stronger than a second electric field formed by the corona electrode. The first electric field driving gas ions to the walls is, on average, less than in solutions according to the prior art. For this reason, the life of the gas ions is many times that in solutions according to the prior art. Based on this, the boiler is possible to achieve a cleaning effect of more than 90%, in relation to fine particles.
With the aid of the gas guide 302, it is possible also to influence the flow of the shielding gas SK after the ion source 100, to promote mixing. The shielding gas SK is led to the ion source 100 through the shielding-gas connection 304. The shielding gas SK can be a gas substantially free of particles, which means that the particle content is so small that the particles collected inside the ion source do not cause significant dirtying of the internal parts of the ion source 100. The shielding gas SK can be, for example, air, water vapour, carbon dioxide, nitrogen, or a mixture of several gases. The pressure, flow quantity, and temperature of the shielding gas can adjusted to optimize the operation of the filter.
In the solution according to the invention, the pressure of the shielding gas can be kept considerably lower than that of solutions according to the prior art, because its task is to prevent dirtying of the ion source. However, the pressure of the shielding gas should be high enough to prevent the entry of the flue gases to the body of the ion source.
The corona discharge is created by raising the potential of the corona electrode 303 above the threshold voltage of the corona discharge, with the aid of a high-voltage source 306. The high-voltage source is connected to the corona electrode through a high-voltage conductor 305. The other terminal of the high-voltage source is grounded. The number of ions I created can be adjusted by adjusting the potential of the corona electrode. The value of the high voltage used by the ion source is proportional to the dimensions of the chamber of the application. In order for a corona discharge to take place in the corona electrode, a high voltage is required, which is at a maximum in the order of 7 kV/cm. Thus, the available voltage is determined according to the dimensions of the chamber used 10-200 kV, preferably 10-100 kV, the dimensions of the chamber being less than half a metre. This means that a single ion source can be used at a maximum in a radius of half a metre. In larger chambers, the chamber can divided into several smaller flow channels, in each of which its own ion source is used, so that the method can be used even in large chambers.
According to
The intention of the gas guide 302 is to accelerate the flow of the shielding gas in the final part of the body 110 and at the same time to be an obstacle to the entry of flue gases to the body 110. Gas guides can be, for example, pieces, which include a narrowing part 310 and a diffusor part 311. Both parts can be, for example, at an angle of 30-40° to the longitudinal direction of the body 110. Preferably there is a neck 312 between the narrowing part 310 and the diffusion part 311. The body part 313 of the corona electrode 303 preferably ends at the junction of the diffusion part 311 and the neck 312, and a separate corona needle 314, at the end of which the corona discharge takes place, is attached to the body part. In other words, the corona needle 314 is in the length of the diffusion part 311.
The technology of the ion source used in the device according to the invention to charge the aerosol particles of the flue gas is partly disclosed in patent FI 119468.
E=Ei+Eii+Eiii
In the solution according to the invention, the first and third electric fields Eiii and Eii are stronger in the collection area than Ei. The second electric field Ei can be regarded as the collection voltage used in an electrical filter of the prior art. The third electric field Eii is related to the electric field caused by the collection of particles in a chamber-charging filter of the prior art. The first electric field Eiii caused by the ions is the field boosting the collection specific to the present invention. The first electric field Eiii also appears in electric filters of the prior art, but in these solutions it is detrimental in terms of the filtering.
The particles collected on the walls 734 of the heat exchanger 730 can be detached with the aid of the cleaning element 732, when they fall into a collection tray 750. The shielding gas SK prevents the dirty gas from entering the ion source 100. The properties of the shielding gas, such as composition and temperature, can be adjusted to optimize the operation of the filter. The cleaning element 732 can be, for example, some kind of sweeping element, for example, a continuously operating or periodically operating spiral or a so-called flutterer. Cleaning can be performed also during operation.
In the boiler flue-gas fine particles can be cleaned directly in the boiler. The invention can be applied to 0.01-5.0 MW boilers, preferably 20-100 kW boilers.
According to one embodiment, the boiler shown in
To clean and prevent dirtying of the joint between the body and the boiler wall it is also possible to use mechanical cleaning of the outer surface of the body of the ion source by sweeping, by a self-cleaning photo- and thermo-catalytic surfacing, and/or by raising the surface temperature to be sufficiently high, when impurities on the surface burn off or become electrically non-conducting.
With the aid of the embodiment of
| Number | Date | Country | Kind |
|---|---|---|---|
| 20125919 | Sep 2012 | FI | national |
This application is a Continuation-in-Part of U.S. application Ser. No. 14/426,714 filed Mar. 6, 2015, which was a U.S. National Stage Application of International Application No. PCT/FI2013/050851 filed Sep. 4, 2013 and claiming priority to Finland Application No. 20125919, filed Sep. 6, 2012, the disclosures of all of which are incorporated herein by reference in their entireties.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14426714 | Mar 2015 | US |
| Child | 16367096 | US |
