The present disclosure generally relates to the field of combustors.
Vapor combustors may be used to destroy vapors and other harmful particles that may be present as a result of drilling and/or mining natural resources. Typically, a combustor is used to burn some of the vapors prior to releasing the drilling byproducts into the atmosphere. Typically, combustors utilize a single burner to burn vapors as they are introduced into the combustor. However, a single burner may not always burn the vapors completely. Therefore the possibility remains that harmful vapors may be released into the atmosphere.
This disclosure will now more fully describe exemplary embodiments with reference to the accompanying drawings, in which specific embodiments are shown. Other aspects may be embodied in many different forms and the inclusion of specific embodiments in the disclosure should not be construed as limiting such aspects to the embodiments set forth herein. Rather, the embodiments depicted in the drawings are included to provide a disclosure that is thorough and complete and which fully conveys the intended scope to those skilled in the art. When referring to the figures, like structures and elements are shown throughout are indicated with like reference numerals.
The terms and phrases as indicated in quotes (“ ”) in this section are intended to have the meaning ascribed to them in this Terminology section applied to them throughout this document including the claims unless clearly indicated otherwise in context. Further, as applicable, the stated definitions are to apply, regardless of the word or phrase's case, to the singular and plural variations of the defined word or phrase.
The term “or” as used in this specification and the appended claims is not meant to be exclusive rather the term is inclusive meaning “either or both”.
References in the specification to “one embodiment”, “an embodiment”, “a preferred embodiment”, “an alternative embodiment” and similar phrases mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least an embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all meant to refer to the same embodiment.
The term “couple” or “coupled” as used in this specification and the appended claims refers to either an indirect or direct connection between the identified elements, components or objects. Often the manner of the coupling will be related specifically to the manner in which the two coupled elements interact.
Directional and/or relationary terms such as, but not limited to, left, right, nadir, apex, top, bottom, vertical, horizontal, back, front and lateral are relative to each other and are dependent on the specific orientation of an applicable element or article, and are used accordingly to aid in the description of the various embodiments and are not necessarily intended to be construed as limiting.
The term “vapor” as used herein means any particle(s), vapors, combustible gas and any byproduct of mining or drilling for natural gas and other naturally occurring resource.
Described herein is a combustor having a first burn chamber and a second burn chamber. The first burn chamber has a first burner and the second burn chamber has a second, separate burner. The first burn chamber is in fluid communication with the second burn chamber which allows vapors to move from the first burn chamber to the second burn chamber. The first burn chamber is configured to perform a primary burn on the vapors that have been introduced into the first chamber and the second burn chamber is configured to perform a secondary burn on the vapors that have not been burned in the first chamber and move to the second burn chamber.
Also described herein is a system for burning vapors. The system includes a primary burn module having a first burning apparatus disposed therein. The first burning apparatus is configured to perform a primary burn on vapors as the vapors are introduced into the system. The system also includes a secondary burn module having a second burning apparatus disposed therein. The second burning apparatus is configured to perform a secondary burn on the vapors after the vapors have moved from the primary burn module into the secondary burn module. A cool down chamber disposed between the first burn module and the second burn module and is configured to cool the vapors as the vapors pass from the primary burn module to the secondary burn module.
Still yet other embodiments provide a method for burning vapors in a combustor. The method includes introducing the vapors into at least one burn chamber of a combustor. Once the vapors have been introduced, a primary burn is performed on the vapors. A secondary burn is also performed on the vapors. When both of the primary burn and the secondary burn have been performed on the vapors, the vapor combustion byproducts are released into the atmosphere.
The dual chamber combustor 100 includes a base portion 105 and a column portion 107 in which the vapors are burned according to embodiments. Vapors are introduced into the dual chamber combustor 100 via a vapor inlet pipe 101. Prior to the vapors entering the combustor 100 via the inlet pipe 101, the vapors pass through a spark arrestor 103. The spark arrestor is coupled to the inlet pipe 101 and is configured to prevent a flame from chasing down the inlet pipe 101 as vapors are introduced into the dual chamber combustor 100. Embodiments provide that the spark arrestor 103 is configured in a vertical position. Other embodiments provide that at least a portion of the vapor inlet pipe 101 is configured to have at least a two percent slope. Therefore, if any vapors condense into a liquid, the liquid is able to drain out of the system. Other embodiments provide that the spark arrestor 103 may be disposed in a horizontal position. When in the horizontal position, at least a portion of the inlet pipe 101 that is coupled to the spark arrestor has at least a two percent drop.
In embodiments, the base portion 105 and the column portion 107 are coupled together to form a single unit. When coupled together, the height of the dual chamber combustor 100 is approximately 18 feet. However, it is anticipated that the height may be adjusted based on the location and/or volume of vapor that will be burned in the combustor.
Although the dual chamber combustor 100 functions as a single unit, various components of the dual chamber combustor 100 may be removed, separated and operated independently. For example, the column portion 107 may be removed from the base portion 105 for repair and replacement of components. Furthermore, the column 107 itself, as well as various components of the column 107 may be separated and removed. Such a configuration may enable a user of the dual chamber combustor 100 to more easily repair and replace various components of the dual chamber combustor 100. It is also contemplated that although each of the various components of the dual chamber combustor are configured to work simultaneously, or substantially simultaneously, with the other, each component of the dual chamber combustor 100 may function independently from each of the other components.
According to embodiments the base portion 105 of the dual chamber combustor 100 is constructed of standard sheet metal. However other materials or combination of materials may be used in the construction of the base portion 105 and/or the column portion 107. The dimensions of the base portion 105 are approximately 6′×4′×3′ although it is contemplated that the base portion 105 may be constructed having various other dimensions than those explicitly stated herein.
The base portion 105 includes at least one air intake mechanism 109 disposed therein. According to embodiments, the air intake mechanism may also function as a flame arrestor. Although one air intake mechanism 109 is shown in
The dual chamber combustor 100 also includes a column portion 107. In embodiments, a flange 102 may be disposed on a lower portion of the column portion 107. The flange 102 may be used to secure and separate the column portion 107 of the combustor 100 from the base portion 105 of the combustor 100.
Embodiments provide that the column portion 107 includes a primary burn chamber 115, a cool down chamber 116, and a secondary burn chamber 117. The primary burn chamber 115 is in fluid communication with, via the cool down chamber 116, the secondary burn chamber 117. A flange 118 couples the primary burn chamber 115, portions of the cool down chamber 116, and the secondary burn chamber 117 together. The coupling of each section allows the vapors to flow from the primary burn chamber 115 to the secondary burn chamber 117.
Embodiments provide that the primary burn chamber 115 is constructed of ten inch diameter schedule-twenty pipe. However, it is also contemplated that various other pipe sizes and schedules may be used. According to embodiments, at least a portion of the primary burn chamber 115 is contained within the base portion 105 of the dual burn combustor 100. Such embodiments may permit a user access to various components that are contained within the primary burn chamber, such as for example, a primary burner, and/or pilot light, for maintenance and repair purposes.
In embodiments, a pilot light 120 and burner 122 are contained within a lower portion of the primary burn chamber 115. The pilot light 120 and burner 122 is supplied with natural gas, or other combustible material or vapor, through a standard natural gas line. The natural gas may be supplied from an on-site source, such as for example, a source that is currently being mined or drilled. Alternatively, the natural gas may be supplied from a tank or other portable source. According to embodiments, the pilot light and burner is a 750,000 BTU burner although other types and strengths of burners may be used. The pilot light 120 and burner 122 are configured to perform a primary burn on vapors as the vapors are introduced into the primary burn chamber 115 of the dual burn combustor 100 by the inlet pipe 101 and the spark arrestor 103 combination. It is contemplated that an electronic ignition switch may be used in lieu of, or in combination with the pilot light.
The dual chamber combustor 100 also includes a sight glass 125 disposed on the primary burn chamber 115 according to embodiments. The sight glass 125 is positioned near the pilot light 120 and provides means by which a user may safely look into the primary burn chamber 115 to determine whether the pilot light 120 is burning. A thermostat and/or thermometer (not shown) may also be disposed on a portion of the primary burn chamber 115 to track and control the temperature within the primary burn chamber 115. The thermostat may be powered by power source, such as, but not limited to a generator, a battery, such as a twelve volt battery, solar power, wind power or a combination thereof.
A cool down chamber 116 is disposed between the primary burn chamber 115 and the secondary burn chamber 117. According to embodiments, the cool down chamber 116 has a smaller diameter than the primary burn chamber 115 and the secondary burn chamber 117. Embodiments provide that the cool down chamber is comprised of six inch diameter schedule twenty pipe and measures approximately twelve inches from A-A′ and approximately 18 inches from B-B′. Although specific dimensions of the height and width of pipe used for the cool down chamber 116 are mentioned, it is contemplated that the cool down chamber 116 may have differing heights and be constructed of pipe having various diameters and thickness. For example, the cool down chamber may be twelve inches in height and be constructed of 9 inch diameter pipe.
The purpose of the cool down chamber 116 is to assist in cooling vapors as the vapors pass from the primary burn chamber 115, where a primary burn on the vapors was performed, to the secondary burn chamber 117, where a secondary burn on the vapors is performed. Because the cool down chamber 116 is narrower than the primary burn chamber 115, as vapors attempt to enter the cool down chamber the cooler vapors are forced back down the side and into the center of the primary burn chamber 115 and burned again in the primary burn chamber. Additionally, as the vapors enter the narrower cool down chamber, the hotter, inner vapors are combined with the cooler outer vapors cooler vapors of the vapor stream thereby cooling the overall temperature of the vapors.
The dual chamber combustor 100 also includes a secondary burn chamber 117. According to embodiments, the secondary burn chamber 117 comprises ten inch diameter schedule-twenty pipe and measures approximately 18 inches from section C to C′. Although specific dimensions have been disclosed, it is contemplated that other dimensions may be used for the secondary burn chamber 117.
The secondary burn chamber 117 includes a secondary pilot light and secondary burner 130. The secondary pilot light 130 and secondary burner 133 are fed natural gas that is provided either on site or provided by other means, such as for example a refillable tank, container and the like. According to embodiments, the pilot 130 and secondary burner 133 is a 125,000 BTU burner, although it is contemplated that other burners may be used. Alternative embodiments provide that an electronic ignition switch may be used, in lieu of, or in combination with a standard pilot light.
The secondary burner 133 is disposed within the secondary burn chamber 117 in such a position that as vapors pass from the cool down chamber 116 to the secondary burn chamber 117, that the vapors come into contact with the flame of the burner where a secondary burn is performed. According to embodiments, the secondary burner may be positioned at approximately a forty-five degree angle with respect to the vertical positioning of the secondary burn chamber. Alternatively, the secondary burner may be horizontally disposed within the secondary burn chamber 117. A flame shield 135 and a heat deflector 137 may also be disposed within the secondary burn chamber 117. The flame shield 135 is positioned within the secondary burn chamber 117 so as to prevent the flame from the secondary burner 130 from coming into contact with an outer wall of the secondary burn chamber 117. When heated, the flame shield 135 may also be used to burn vapors as the vapors come into contact with the flame shield 135. For example, if the burn shield has been heated as a result of coming into contact with the secondary burner 133, vapors may be burned as the vapor comes into contact with the flame shield 135.
According to embodiments, the flame shield 135 is positioned at a forty-five degree angle with respect to the vertical positioning of secondary burn chamber 117. The angle of the flame shield 135 causes the vapors to circulate within the secondary burn chamber 117 prior to being released into the atmosphere via the exhaust pipe 160. Circulation of the vapors within the secondary burn chamber 117 may cause the vapors to come into contact with the secondary burner 133 and/or a heated flame shield 135 multiple times which may increases the probability that undesirable vapors will be substantially completely burned. Other embodiments provide that the flame shield is placed at other varying angles. Still yet other embodiments provide that the flame shield 135 is adjustable and may be moved between desired angles using an adjustment mechanism (not shown). The flame shield 135 is also removable and replaceable. Such a configuration may allow for easier maintenance and repair.
The secondary burn chamber 117 also includes a secondary flame arrestor 140 disposed thereon. The secondary flame arrestor 140 comprises a 125,000 BTU intake according to embodiments. However it is contemplated that various flame arrestors having varying strengths may be used. A secondary air intake (not shown) can also be included on the secondary burn chamber 117.
A temperature controller 150 and a high temperature shutdown mechanism 155 are disposed on the secondary burn chamber to control the temperature of the secondary burn chamber. The temperature controller 150 may be powered by a power source. Examples include, but are not limited to “green” power sources such as a twelve volt power source, solar power, wind energy or a combination thereof. A thermometer (not shown) may also be disposed on the secondary burn chamber 117 and configured to track the temperature within secondary burn chamber 117.
According to embodiments, an exhaust pipe 160 is disposed on an upper portion of the secondary burn chamber 117. The exhaust pipe 160 is typically comprised of eight inch pipe and measures approximately 8 feet in height. However, it is contemplated the height, width and thickness of pipe used for the exhaust pipe 160 may vary. A flange 165 may be disposed on the exhaust pipe 160 which enables the exhaust pipe 160 to be removed from the secondary burn chamber 117. Such embodiments may provide means whereby a user may inspect the secondary burn chamber 117 and its components as well as repair and/or replace the components therein.
Prior to entering the secondary burn chamber 117, the vapors pass through a cool down chamber, such as cool down chamber 116 (
As the vapors 210 continue to travel in an upward direction into the secondary burn chamber 117, a secondary burn is performed on the remaining vapors 210 by the secondary burner 130 (
After circulation, the vapors 210, are released into the atmosphere via an exhaust pipe, such as exhaust pipe 160 (
Vapors are introduced into the combustor 300 via a vapor inlet pipe 301. Prior to entering the combustor 300, the vapors pass through a spark arrestor 303. According to embodiments, the spark arrestor 303 is configured vertically. It is also contemplated that at least a portion of the vapor inlet pipe 301, is configured to have at least a two percent drop prior to being coupled to the spark arrestor 303. The drop allows draining of any liquids that have formed due to the condensing of vapors.
As the vapors are introduced into the lower portion 315 of the column portion 307 of the combustor 300, the vapors are burned by a first burner 323. The first burner is situated near a pilot light 320 and both the first burner 323 and the pilot light 320 are configured to burn natural gas. However, it is contemplated that other combustible fluids may be used.
Embodiments provide that a thermometer 321 is disposed on a lower portion 315 of the column portion 307 for use in monitoring the temperature within the lower portion 315 of the column portion 307. A sight glass 325 may also be positioned on the lower portion 315 of the column portion 307. The sight glass 325 may be used to view the flame and/or the pilot light 320.
Once the vapors have been burned by the first burner 323, the vapors travel in an upward direction toward the second burner 333 that is positioned at the base of the upper portion 317 of the column portion 307 of the combustor 300. According to embodiments, a flame arrestor 335 is positioned near the second burner and pilot light 330 for increased safety. As the vapors enter the upper portion 317, the second burner 333 performs a second burn on the vapors. The remaining vapors and the residual from the first burn and the second burn travels in an upward direction, with increased velocity due to the narrowing of the upper portion, and are released into the atmosphere.
The combustor 300 also includes a twelve volt thermostat 350 positioned on the upper portion 317 of the column portion 307 as well as a thermometer 355 to control and monitor the temperature in the upper portion 317 of the column portion 307 of the combustor 300.
When the vapors have been introduced into the combustor, flow proceeds to step 420 in which a primary burn is performed on the vapors. According to embodiments, the primary burn on the vapors is performed by a primary burner disposed in a primary burn chamber, such as for example, primary burn chamber 115 (
Step 430 provides that the vapors are cooled. According to embodiments, the vapors are cooled by combining cooler vapors outer vapors of a vapor stream with hotter inner vapors of the vapor stream. This is accomplished by introducing the vapors into a cool down chamber, such as, for example, cool down chamber 116 (
Step 440 provides that a secondary burn is performed on the vapors. According to embodiments, the secondary burn is performed by a secondary burner in a secondary burn chamber, such as, for example, secondary burn chamber 117 (
After the secondary burn and circulation, the remaining vapors, and the byproduct of the burned vapors, are released into the atmosphere in step 450. According to embodiments, the vapors are funneled through an exhaust pipe that is coupled to a top portion of the secondary burn chamber.
Although illustrative embodiments of the invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments. As such, many modifications and variations will be apparent to practitioners skilled in this art. Accordingly, it is intended that the scope of the invention be defined by the following claims and their equivalents. Furthermore, it is contemplated that a particular feature described either individually or as part of an embodiment can be combined with other individually described features, or parts of other embodiments, even if the other features and embodiments make no mentioned of the particular feature. Thus, the absence of describing combinations should not preclude the inventor from claiming rights to such combinations.
This application is related to U.S. Provisional patent application Ser. No. ______, entitled “Environmental Condensing Apparatus”, filed on ______. The aforementioned application is hereby incorporated by reference in its entirety.