Patent Application
20130025512
The present disclosure is directed to an apparatus and method for oxygenating fuel oil and may be adapted for use in connection with a wide variety of fuel oils, including both conventional and nonconventional fuel oils. It finds particular application in oxygenating fuel oils and solvent oils to increase the efficiency and burning capabilities of known, existing oil burning systems. The present system has been found to reduce overall usage of oil while maintaining the same heat output. In addition, the present system has been found to greatly reduce the amount of pollution created by conventional oil burning systems. Although the present disclosure will be described herein primarily by way of reference to fuel oil burning systems, it will be recognized that the present system and method may be used with any type or make of fuel oil supply burner or heat generation appliance, including, boilers, turbines, furnaces, and the like. The fuel oil supply burner or heat generation appliance may be forced hot water, steam, high pressure steam, low pressure steam, steam like vessels, and other like types. In a more limited aspect, the fuel oil oxygenation system and method herein may advantageously be used with an oil burning system as shown and described in the aforementioned Ser. No. 12/231,604.
Accordingly, the present invention contemplates a new and improved fuel oxygenation apparatus and method which can reduce energy consumption and harmful emissions.
In one aspect of the present disclosure, a fuel oxygenation apparatus for adding oxygen into a fuel oil source is provided, which includes a fuel tank constructed to contain a supply of fuel and a source of pressurized oxygen gas. A fuel pump has an inlet side and an outlet side, the inlet side including a pump inlet through which fuel is drawn from the fuel tank and the outlet side including a pump outlet. The fuel pump is configured to receive the fuel at a first pressure and discharge the fuel at a second pressure greater than the first pressure. A first fluid line is in communication with the fuel tank and the fuel pump inlet and a second fluid line is in communication with the source of pressurized oxygen and the fuel pump inlet. In certain embodiments, the source of pressurized oxygen can have its own oxygen pump or metering device for proper regulation of the volume and pressure of oxygen in communication with the fuel pump inlet. A check valve in the second fluid line is normally closed to prevent the flow of oxygen gas through the second fluid line when the fuel pump is not operating, and is configured to open when the pump is operating, thereby allowing oxygen to flow through the second fluid line and admix with fuel in the first fluid line.
In a more limited aspect, the fuel pump is of a type which creates a negative pressure on the inlet side during operation, and in a further limited aspect, the fuel pump is a positive displacement pump.
In another more limited aspect, the check valve includes a valve head yieldably biased against a valve seat to a closed position, wherein the valve head is displaceable from the valve seat to an open position to permit oxygen to flow through the second fluid line responsive to the negative pressure.
In yet another more limited aspect, the second fluid line is in communication with the source of pressurized oxygen and the first fluid line upstream of the pump inlet.
In still another more limited aspect, a filter is provided in the first fluid line.
In a further more limited aspect, the second pressure is in the range of about 300 psi to about 3,200 psi.
In another more limited aspect, the fuel is an oil based fuel. In still further aspects, the fuel may be water based glycerin, bio-mass products, or the like.
In still another more limited aspect, the system herein includes an oil burner nozzle communicating with the pump outlet.
In yet another more limiting aspect, the oil burner nozzle is constructed to receive and atomize the fuel, e.g., oil based, water based, etc., prior to delivering the selected fuel to a burner.
In a still further more limited aspect, the burner is a burner of an associated boiler.
In other more limited embodiments, the system herein includes one or both of an accumulator communicating with the pump outlet, the accumulator constructed to absorb pulsations in the fuel when it is discharged by the fuel pump; and a pre-heater communicating with the pump outlet, the pre-heater constructed to heat the fuel to a desired temperature, a desired viscosity, or both.
In yet another more limited aspect, the apparatus herein includes a gas pressure regulation system, such as one or more gas pressure regulators and/or a metering pump in the second fluid line, the regulator system constructed to reduce the pressure of gas received from the source of pressurized oxygen and/or deliver a metered quantity of oxygen to the fuel pump inlet.
In still further more limited aspects, the one or more gas pressure regulators includes a first stage regulator for receiving gas from the source of pressurized oxygen at a first pressure and outputting the gas at a second pressure lower than the first pressure; and a second stage regulator for receiving gas from the first stage regulator and outputting the gas at a third pressure lower than the second pressure.
In yet another more limited aspect, the second stage regulator is adjustable to adjust the pressure of the oxygen gas in the second line.
In still a further more limited embodiment, a safety valve is provided in the second fluid line.
In a further more limited embodiment, the safety valve is a solenoid valve moveable between an open position permitting the flow of oxygen when the solenoid valve is energized and closed position preventing the flow of oxygen in the second fluid line when the solenoid valve is de-energized.
In another aspect, a method of oxygenating fuel includes storing fuel in a storage device and operating a fuel pump to withdraw fuel from the storage device. The fuel pump has a pump inlet and a pump outlet, the pump inlet communicating with the storage device via a first fluid line. A volume of oxygen is established in a second fluid line, the second fluid line communicating with the first fluid line and a source of pressurized oxygen. The oxygen may be regulated by a check valve which opens responsive to negative pressure on the inlet side of the fuel pump or by a metering pump fluidically coupled to the inlet side of the fuel pump. A check valve is provided in the second fluid line, the check valve preventing the flow of oxygen in the second fluid line when the check valve is closed. Responsive to operating the fuel pump, a negative pressure is established in the second fluid line and the check valve is opened in response to the established negative pressure, wherein oxygen is admixed with the fuel when the check valve is open.
One advantage of the present development is that it can allow smaller compact combustion areas, which can result in smaller boilers with larger outputs. Smaller boilers for the same British Thermal Unit (BTU) output use less raw materials and save shipping costs.
Another advantage of the present development is that it provides a hotter flame, which concentrates more in the center of the combustion area, resulting in a faster complete burn resulting in less stack heat loss.
Yet another advantage of the present development is a higher BTU output due to a smaller volume of outside air being needed for the combustion process.
Still another advantage of the present development is that it can provide faster combustion, which results in a shorter controlled flame, thereby enabling the BTU output to be increased in a manner that is safer than for existing systems.
Another advantage of the present development is an improved starting of the combustion process with fuel oils having a temperature below 50° F.
Yet another advantage of the present development is lower emissions, e.g., lower emissions of nitrogen oxide, nitrogen dioxide, carbon monoxide, hydrocarbon particles, sulfur monoxide, and sulfur dioxide. The present development produces safer emissions while reducing fuel oil consumption, e.g., by 20-30% or more compared to conventional oil burner systems.
Still another advantage of the present development resides in its reduction of the actual volume of flue gases, e.g., in cubic feet per minute (rate) and total cubic feet/BTU measured in pounds.
Another advantage of the present development is found in the reduction of the acidity of the flue gas emissions, e.g., by twenty to thirty-five percent. Emissions with lower acidity will extend the life of a boiler and the flue gas chimney or stack.
A further advantage of the present development is that better oxygenation and ionization of the fuel oil supply and other hydrocarbon chain chemicals may yield thermo-chemical breakdowns to become less toxic. For example, the safer destruction of hydrocarbon chemical solvent oils can prevent toxic, carcinogenic, or other environmentally harmful materials from entering the environment and negatively affecting people, plants, and animals.
Still another advantage of the present development is that fewer or less frequent boiler and system cleanings may be required.
Yet another advantage of the present development is that it reduces pollution in the emissions, thereby improving air quality and causing less damage to vegetation, water supplies, building structures, and property.
Another advantage of the present development is that it can reduce the consumption of virgin fossil fuels and bio fuels.
Still another advantage of the present development is that it facilitates the increased use and recycling of waste oils and bio mass fluids, including automotive and industrial waste oils. The present system also shows positive results with waste glycerin based liquids.
Yet another advantage of the present development is that the reduction of the volume inlet air (which comprises about 76% nitrogen and 20% oxygen) needed to support combustion reduces nitrogen oxide emissions significantly. The reduction of nitrogen oxide emissions, in turn, helps reduce smog and acid rain.
In a more limited aspect, when used in conjunction with an optional carbon monoxide (CO) sensor for sensing a level of CO in the boiler flue stack, the emission quality can be regulated by regulating the amount of oxygen that is admixed with the fuel to allow optimization of a more complete burn that results in better air quality emissions and more optimized heat
Another advantage of the present development is that it provides a system and method for the injection of oxygen gas into a fuel oil supply that is safe and economical. In a more limited aspect, the fuel oxygenation system and method herein may be used in conjunction with the inventor's oil burning system described in commonly owned U.S. Pat. No. 8,052,418, and does not require the addition of motorized equipment or special pumps.
It has been found to be especially advantageous when the oxygenation system of the present disclosure is used in conjunction with the oil burning system disclosed in commonly owned U.S. Pat. No. 8,052,418, which uses uniquely high fluid pressure (e.g., 200-800 psi) or ultra-high fluid pressure (e.g., 800-3,200 psi) and, while under said pressures, the heated oils are controlled of heat up to and in excess of 390 degrees F., depending on the viscosity of the oil.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the general description, serve to explain the principles of the invention.
The invention may take form in various components and arrangements of components and in various steps and arrangements of steps.
The accompanying drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention.
With reference to the drawings, wherein like reference numerals are used to indicate like or analogous components throughout the several views,
The fuel oil supply 102 includes but is not limited to a hydrocarbon chain liquid gel or paste that may be preheated to be used with the fuel oil or any mixture of fuel oils. Fuel oil mixtures known in the art include: No. 1 through No. 6 fuel oils, especially ASTM D396 oil (No. 2 heating oil); gasolines, diesel fuels, solvents, hydraulic oils, spent waste oils, including auto and industrial waste oils; biofuels of all types including biodiesel fuel of all strengths, virgin, used or recycled cooking oil; and industrial gear grease, oils, and lubricants; kerosene and hydraulic oils, waste and virgin paint solvents, waste and virgin cleaning solvents, and light grease.
The system 100 also includes filter 104 in fluid communication with the storage tank 102. The fuel is delivered from the fuel oil supply 102 via a fuel supply line through the filter 104 using a positive displacement pump 108. The filter 104 removes particles or solid impurities in the fuel or any sludge that has built up in the fuel supply line. The positive displacement pump 108 may be a high pressure, variable pressure pump with, for example, a 300 to 3,200 psi output in the preferred embodiment.
A source of pressurized oxygen gas 116 is in fluid communication with the inlet side of the pump 108 via a fluid line. The source of pressurized oxygen gas may be a conventional oxygen tank, and may include a manual shut off valve 118 and a main pressure regulator 114 for reducing the pressure of the oxygen gas from the high pressure of the tank 116 to a workable level. A fine adjust regulator 110 and a check valve 106 are disposed in the line between the main pressure regulator 114 and the inlet side of the pump 108. Although the system has been illustrated showing an oxygen regulation system comprising two gas pressure regulator stages, it will be recognized that the system could also employ other numbers of regulators including as a single stage regulator, or, may employ a gas metering system, such as a metering pump, in addition to or in place of the one or more regulators.
In operation, the positive displacement pump 108 creates a momentary vacuum on the pump inlet side. This momentary vacuum or negative pressure allows the air check valve 106 to open and the oxygen gas to admix with the fuel oil entering the positive displacement pump 108. The pump 108 may be for example, a rotary type positive displacement pump, such as a gear pump, screw pump, shuttle block, flexible vane or sliding vane, helical twisted roots, liquid ring vacuum pump, piston pump, diaphragm pump, peristaltic pump, and the like. The oxygenated fuel is delivered to a high-efficiency oil burning system for combustion.
A user may easily and accurately regulate the oxygenation or volume of oxygen going into the fuel oil supply either mechanically or electromechanically by using the assistance of a carbon monoxide (CO) sensor 244 to support the regulated injection of oxygen gas into the fuel oil before it passes through the positive displacement pump 108. For example, the carbon monoxide sensor 244 may be used to monitor the amount of CO in the flue gas or exhaust exiting the boiler, furnace or other oil burning system. If the sensor 244 detects a level of CO which exceeds a predetermined threshold, the regulator 110 is adjusted to increase the volume of oxygen delivered to the fuel pump inlet, or, in the case of a metering pump being used to deliver the oxygen to the fuel at the fuel pump inlet, the metering pump is used to increase the metered quantity of oxygen delivered to the fuel at the fuel pump inlet.
Current burner systems can automatically adjust combustion air (which is often room air comprising roughly 76% nitrogen+20% oxygen) and fuel-oil input levels to between 1 and 1.8 times the normal ranges to sustain proper combustion. The presently disclosed fuel oxygenation system 100 will properly and automatically adjust on similar systems from one to three times the input of the fuel oil supply while maintaining and maximizing proper and safe combustion. This could enhance a boiler's BTU output rating by causing it to be more adaptable to have a wider firing range to help save on fuel oil when supply or demand changes. Similarly, the heat BTU output can more closely match that of the BTU input rating without causing impinging, damage, or unsafe conditions in the combustion chamber. It is also commonly known that current combustion processes of fuel oils have an efficiency on average of between 75% and 83% when the ASHRE formula to calculate fuel volume is used. The present disclosure has been shown to improve the efficiency of combustion to over 94% when used in its preferred embodiment.
The fine adjust regulator 110 (or other regulator system such as a precise metering device, e.g., a gas metering pump) is provided to fine tune the pressure of the oxygen gas supplied to the fuel oil entering the pump 108. The oxygen tank 116 may be attached to an oil burning system or component thereof, or may be located near or remote to the oil burning system, depending on its size. The shut off valve 118 enables the user to manually shut off the oxygen gas supply.
In the depicted preferred embodiment, a safety solenoid valve 112 is provided between the main pressure regulator 114 and the fine adjust regulator system 110. The safety solenoid valve 112 acts as an extra preventative measure to prevent oxygen gas or oil from traveling, if the air-check valve 106 should fail, or when the fuel oxygenation system 100 is off. In addition, the fuel oxygenation system 100 could have a manual or automatic control on/off switch (not shown) on a control panel which would allow a user to control when the oxygen gas travels. For example, turning off the control switch could de-energize the safety solenoid valve 112, causing the valve 112 to close automatically and shut-off the oxygen supply 116.
Oxygen gas passes from the safety solenoid valve 112 and on to the fine adjust regulator system 110 where the oxygen gas pressure is further reduced before mixing with the fuel oil supply. The fine adjust regulator system 110 regulates the oxygen gas pressure and volume to ensure it is a proper or optimal pressure to mix with the fuel supply. As described above, the positive displacement pump 108 creates a momentary vacuum at the pump inlet side (e.g., during the suction cycle) allowing the air check valve 106 to open and the oxygen gas to enter the positive displacement pump 108 to mix with the fuel oil supply. In the absence of the momentary vacuum (e.g., during the discharge cycle), the valve 106 closes to prevent pressure of oxygen and/or fuel oil in the reverse direction. The amount of oxygen gas passing into the fuel oil supply line is regulated by regulator system 110, e.g., by adjusting the output pressure in the case of a fine adjust regulator or by operation of the metering device in the case of a metering pump. In certain embodiments, the delivery of oxygen to the fuel pump inlet is based on the pressure changes created by the positive displacement pump 108. In alternative embodiments, the optional carbon monoxide sensor 244 may be used to support optimization and safe combustion and to improve emissions by monitoring CO levels in the exhaust gas and controlling the volume of oxygen delivered to the fuel at the fuel pump inlet responsive to the CO level detected.
Referring now to
The combination of the fuel oxygenation system 100 and the high-efficiency oil burning system 202 is disposed to increase the oil burning capabilities of existing systems, by oxygenating the fuel prior to entering the oil burning system 202. The oil burning system 202 is preferred for its ability to increase oil burning capabilities by maintaining high-pressure (300-800 psi) or ultra-high fluid oil pressure, (800-3,200 psi) throughout the system 202 and allowing for more effective fuel flow, among other things. In the preferred embodiment, the oil burning system 202 utilizes number two heating oil, however, in alternative embodiments the oil burning system 202 allows for the burning of a combination of number two heating oil with various other waste oil, including but not limited to biofuels and light grease, waste and virgin paint solvents, waste and virgin cleaning solvents, and diesel, kerosene and hydraulic oils. More preferably, the oil burning system 202 allows for up to seventy percent waste oil in combination with the burning of number two heating oil or Bio-Diesel, wherein the waste oil may be a single composition itself, or a combination of the waste oils listed above, given that they do not comprise more than seventy percent of the overall liquid within the oil burning system 202.
The positive displacement pump 108 also maintains ultra-high pressure throughout oil burning system 202, thereby creating a more efficient fuel flow throughout the oil burning system 202, while also preventing the build-up of any sludge during the heating in the oil burning system 202. In the preferred embodiment, the displacement pump 108 is operable to supply the oxygenated fuel oil in a range of 300-3,200 pounds per square inch, and more preferably, the displacement pump 108 is operable to supply the oxygenated fuel oil in a range of 800-2200 pounds per square inch, e.g., when using conventional No. 2 fuel oil. The displacement pump 108 may include a variable pressure control (not shown), wherein the control regulates the exhaust temperature or stack temperature of the overall oil burning system 202 for more efficient fuel usage, preferably around 410 degrees Fahrenheit; it is known in the art that a stack temperature above this range creates waste and inefficiency within a system once the boiler is heated up to eighty percent of capacity. Furthermore, the oil burning system 202 can be automatically controlled by setting the overall stack temperature. Alternatively, an individual may manually control the system and set the pressure of the system for each desired fuel and burn usage.
The oil burning system 202 includes an even pressure accumulator 210 as known in the art, wherein the accumulator 210 maintains and ensures steady pressure distribution throughout the oil burning system 202. The accumulator 210 is located between the displacement pump 108 and a heater 220, such that the accumulator 210 is in fluid communication with the displacement pump 108 and the heater 220 via one or more fuel lines. The heater 220 operates under high pressure or ultra-high pressure to maintain efficient fuel viscosity throughout the oil burning system 202 and this unique application prevents the formulation of any sludge or impurities within the liquid. In the preferred embodiment, the heater 220 operates between 800-3,200 pounds per square inch, and heats the fuel oils in a range from 100-390 degrees F., wherein the pressure and/or temperature are adjustable depending on the desired viscosity of the liquid. Therefore, the heater 220 serves the purpose of heating the liquid to the desired temperature and viscosity for use in the oil burning system 202. Moreover, in the preferred embodiment, the heater 220 may be operated at a temperature range between 70-190 degrees Fahrenheit when used specifically for No. 2 heating oils, wherein the individual utilizing the oil burning system 202 may determine the specific temperature setting.
The oil burning system 202 also includes a filter 230 located after the heater 220 which is in fluid communication with the displacement pump 108 and the heater 220 via a fuel line. The filter 230 is for the removal of any particles in the fuel or any sludge that has built up prior to distribution through the nozzle 242. Additional filters within the oil burning system 202 are also contemplated. Such filters may comprise two stage high-pressure micron filters with mesh that allows for the removal of any liquid in a semi-solid state, thereby creating an extremely liquefied material for introduction into a boiler or furnace 250. The filters more preferably operate at up to 3,500 pounds per square inch to remove impurities from the liquid while continually maintaining the pressure created by the displacement pump 108. The filters may allow for substantially clean and sludge-free passage of the liquid through the components of the oil burning system 202 and prevent clogging, while allowing for individual components to be in use longer, but most importantly to prevent sludge from building up within the oil burning system 202.
Lastly, the oil burning system 202 includes a distribution system having a burner or nozzle rod adaptor 240 having one or several nozzle tips 242 attached thereto for distributing the liquid to the combustion chamber of a boiler or furnace 250, preferably for heating residential/commercial dwellings as well as commercial properties/processes and industrial applications. The distribution system may also have a motor control (not shown) along with a nozzle assembly (not shown) for distribution of the liquid from the oil burning system 202.
When the fuel oxygenation system 100 is used with the high-efficiency oil burning system 202 of the type described in the aforementioned U.S. Pat. No. 8,052,418, the oil burning system 202 has been shown to produce more heat output in the combustion chamber of the boiler 250 per the same volume of fuel, reduce harmful emissions by forty to seventy-five percent, and reduce the overall volume of carbon dioxide by twenty-one to twenty-four percent.
To demonstrate the feasibility of the instant development, several tests were performed with different fuel oils and combinations thereof. They all showed similar results as noted below. Fire rate rages varied from 1.5 gallons per hour (gph) to 45 gph. No limit is placed on the ranges.
Table 1, column A, shows the typical emission reductions when using the oxygenation system of specific flue gasses as a measurement of TOTAL CUBIC FEET PER DAY of the flue gas compounds, while producing the same heat output, all used of the same heating appliance.
Table 1, column B, shows the percentage of improvement of heat output to those of standard systems when using the same volume of fuel oil input
When fuel oxygenation system 100 is used with the high-efficiency oil burning system 202, the ASHRE standards have shown improved combustion in both old and new boiler appliances.
The invention has been described with reference to the preferred embodiments. Modifications and alterations will occur to others upon a reading and understanding of the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations.
This application claims the priority benefit of U.S. Provisional Application No. 61/512,697 filed Jul. 28, 2011. The aforementioned application is incorporated herein by reference in its entirety. The present application is related to U.S. Pat. No. 8,052,418 issued Nov. 8, 2011, which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61512697 | Jul 2011 | US |
