Patent Application
20110311928
1. Technical Field
Embodiments described in the present disclosure are directed generally to catalytic heaters and heaters for warming storage tanks containing fluids that are normally gaseous at normal atmospheric pressure and typical ambient temperatures, and in particular to catalytic heaters configured to be coupled to such storage tanks, and including pilot heaters to enable rapid activation of the heaters.
2. Description of the Related Art
A number of fluids that are normally found in gaseous form are commonly stored and transported under pressure as liquids, including, for example, methane, butane, propane, butadiene, propylene, and anhydrous ammonia. Additionally, fuel gasses comprising one or more constituent gasses are also stored and transported under pressure as liquids, including, e.g., liquefied petroleum gas (LPG), liquefied natural gas (LNG), and synthetic natural gas (SNG). Of these, LPG is perhaps the most commonly used. Accordingly, the discussion that follows, and the embodiments described, refer specifically to LPG. Nevertheless, it will be understood that the principles disclosed with reference to embodiments for use with LPG tanks can be similarly applied to tanks in which other liquefied gases are stored or transported, and are within the scope of the invention.
LPG is widely used for heating, cooking, agricultural applications, and air conditioning, especially in locations that do not have natural gas hookups available. In some remote locations, LPG is even used to power generators for electricity. LPG is typically held in pressurized tanks that are located outdoors and above ground. Under one atmosphere of pressure, the saturation temperature of LPG, i.e., the temperature at which it boils, is around −40° C. As pressure increases, so too does the saturation temperature. LPG is held in a liquid state by gas pressure inside the tank. As gas vapor is drawn off from the tank for use, the pressure in the tank drops, allowing more of the liquefied gas to boil to vapor, which increases or maintains pressure in the tank.
As the gas boils, the phase change from liquid to gas draws thermal energy from the remaining liquid, which tends to reduce the temperature of the LPG in the tank. If LPG temperature drops, the boiling slows or stops, as the LPG temperature approaches the saturation temperature. Thus, boiling LPG tends to increase pressure and saturation temperature, while at the same time tending to decrease the actual temperature of the LPG in the tank, until an equilibrium temperature is reached, at which the saturation temperature is equal to the current temperature of the LPG. Provided the energy expended to vaporize the gas does not exceed the thermal energy absorbed by the tank externally, from, for example, sunlight and the surrounding air, the LPG will continue to boil as vapor is drawn off, until the tank is empty. On the other hand, if more energy is expended to vaporize the gas than is replaced by external sources, the temperature in the tank will drop toward the equilibrium temperature, resulting in less energetic boiling, and a drop in tank pressure. If tank pressure drops too low, it can interfere with the operation of appliances and equipment that draw gas for use, such as furnaces, ovens, ranges, etc.
For purposes of the following disclosure, the maximum continuous rate at which gas can flow from a supply tank using only ambient energy to vaporize the LPG, without causing the tank pressure to drop below an acceptable level, will be referred to as the maximum unassisted flow rate. It will be recognized that this rate will vary according to the ambient temperature near the tank.
Low tank pressure is a particular concern in regions where ambient temperature can drop to very low levels, such as during the winter at high latitudes, or at very high altitudes. For example, when ambient temperature drops very low, the heat energy available to warm an LPG storage tank is reduced, while at the same time, the cold temperature prompts an increased draw of gas to fuel furnaces to warm homes and other buildings. As gas pressure drops below the regulated pressure of the gas line, flames in furnaces, water heaters, and other gas consuming appliances reduce in size, producing less heat and prompting users to open gas valves further, which only accelerates the pressure drop. Eventually, tank temperature can drop below the boiling point of unpressurized gas, at which point, no gas will flow. It can be seen that, as ambient temperature drops, the potential for unacceptable loss of pressure increases, as does the potential demand for gas, such as for heating.
To prevent such a pressure reduction, there are a number of measures that can be taken, which fall into three general categories, each with its own advantages and disadvantages.
In the first category, LPG is drawn from the bottom of a tank as a liquid, and passed through a separate vaporizer in the supply line, to meet demand. The volume of liquid flow has relatively little effect on tank—or system—pressure, because the liquid in the tank boils only to the extent necessary to replace the volume of fluid drawn from the tank. Thus, the limiting factor is more frequently the capacity of the vaporizer. In some limited situations, where, for example, the ambient temperature is very low, and the draw by the load is very high, tank pressure can still drop. In such cases, a vapor return line is frequently employed from the outlet of the vaporizer to the tank to increase the tank pressure.
There are a number of types of LPG vaporizers, including direct gas-fired and electrically heated. Some electric vaporizers with explosion-proof electrical connections can be mounted on or near the storage tank. However, safety regulations in most jurisdictions require that sources of combustion, such as an open flame, or heat sources that exceed the auto-ignition temperature of LPG, cannot be located in a same enclosure with an LPG storage tank, or within some minimum distance. Thus, a gas fired vaporizer must be positioned away from the storage tank, which adds cost and complexity, and increases maintenance requirements. Nevertheless, gas-fired vaporizers are more commonly used with large LPG storage systems, because the heating cost is generally lower than with electrically heated vaporizers. Additionally, gas-fired units can be used in locations where electricity is unavailable. A disadvantage of in-line vaporizers in general is that because they draw liquid from the bottom of the tank, they are always in operation, even when the maximum unassisted flow rate exceeds the current vapor demand.
In a second system configuration, gas for normal use is drawn from the top of the tank, but when pressure drops below a threshold, liquid is drawn from the bottom and boiled to vapor in a vaporizer and returned to the top of the tank to re-pressurize the tank. On one hand, such systems have more complex control, plumbing, vapor, and fluid circuits. On the other hand, these systems employ the vaporizer only when tank pressure drops below the threshold, so they tend to be more fuel efficient than in-line vaporizer systems. In a third configuration, a tank heater is activated to warm the tank and its contents when tank temperature or pressure drops below a threshold. One type of tank heater comprises an electric element strapped to the tank. In another type, indirect heat is used, in which a medium, such as water or steam, is heated at a remote location, then piped to a heat exchanger in contact with the tank walls. Indirect heat is advantageous in situations where waste heat is available, such as where water is used to cool industrial machinery, etc.
Generally, disadvantages of many of the systems available are often related to the difficulty of providing heat in the close vicinity of an LPG tank without creating a condition that would be dangerous in the event of a tank leak or tank over-pressure. The complexity of systems in which a heat source is remotely located not only increases the cost, but also the likelihood of malfunction. Additionally, vaporizers and heaters that employ electric heating elements, or that are electrically controlled, are impractical for use in applications where electrical power is not available. In such cases, an electric generator is required to provide the electricity, resulting in costly efficiency losses.
One problem associated with electric tank heaters, in particular, is that the heating element is in direct contact with the tank wall. Temperature differentials between the element and the tank can promote water condensation, which can be trapped between the heating element and the surface of the tank, resulting in deterioration of the paint and subsequent corrosion of the steel tank wall.
Most jurisdictions have stringent regulations regarding the use of combustion sources near LPG tanks and gas transmission lines. These regulations dictate explosion-proof requirements for electrical connections, minimum distances to open flames, etc. The restrictions vary according to the size of a tank and proximity to public areas.
According to an embodiment, a catalytic heater system includes a catalytic heating element supported on an LPG storage tank by a support structure that holds the element in a position facing the tank. When a load draws sufficient vapor to cause the tank to self refrigerate and lose pressure, the catalytic heating element is operated to warm the tank and restore pressure. Vapor from the tank is provided as fuel to the heating element, and can be regulated to increase heat output as tank pressure drops.
According to an embodiment, the catalytic heating element is internally separated into a pilot heater and a main heater, with respective separate fuel inlets. In use, the pilot heater remains in continual operation, but the main heater is operated only as required. Operation of the pilot heater keeps a portion of the catalyst hot, so that, when fuel is supplied to the main heater, catalytic combustion quickly expands from the area surrounding the pilot heater to the remainder of the catalyst in the main heater.
According to an embodiment, a catalytic heating system is provided, including a catalytic heating element separated into a pilot heater and a main heater, with respective separate fuel inlets. A pressure regulator controls fuel flow to the main heater, and a shut-off valve controls fuel to both the pilot and main heaters. A heat sensor positioned in or near the pilot heater operates to hold the shut-off valve open. If the pilot heater stops producing heat, the shut-off valve closes, terminating all fuel flow to the heating element. Where this catalytic heating system is employed to warm an LPG storage tank, a control terminal of the pressure regulator is coupled to a direct tank pressure feedback line, and configured to control fuel flow to the main heater in inverse relation to the tank pressure. If tank pressure drops below a threshold, the regulator permits fuel to flow to the main heater, and as tank pressure drops further, the flow increases, to produce more heat. One or more temperature sensors positioned on the tank wall near the heating element detect reduced levels of liquid in the tank, and signal a fuel interrupt to the main heater or to the main and pilot heaters, according to the embodiment and specific conditions.
According to an embodiment, a catalytic heating element is coupled to a mounting structure configured to be coupled to a cylindrical tank, and to support the heating element facing the tank wall. The mounting structure includes a shroud that extends around at least a portion of the heating element and that conforms, on one side, to the contour of the cylindrical tank. The shroud can be in the form of a cabinet that substantially encloses the heating element against the tank wall, or can be an extension of a housing of the heating element. The shroud can also be configured to enclose heater controls as provided in other embodiments.
The heater control 118 is in fluid contact with the interior of the tank via an input line 115, and controls operation of the catalytic element 106 via output line 117. The catalytic element 106 is configured to operate by oxidation of vaporized gas from the tank 102 in accordance with known principles of catalysis, as regulated by the heater control 118.
The heater control 118 is configured to monitor the pressure in the tank 102, to control operation of the catalytic heater element 106 in response to variations in the tank pressure, in order to maintain supply pressure above a selected threshold. The pressure threshold is selected according to the requirements of the particular application, and will generally be higher than an anticipated maximum load pressure requirement, so that the tank heater system can come on line and begin to restore the pressure before it drops to a critical level.
Accordingly, when the tank pressure drops below the selected threshold, the heater control 118 detects the drop and initiates activation of the catalytic element 106. While the element 106 is in operation, vaporized gas from the tank is fed to the catalytic element 106, where it undergoes catalytic combustion, i.e., flameless oxidation of the fuel in the presence of a catalyst, which is accompanied by the release of heat. The heat is transmitted by radiation from the front face of the catalytic element 106 to the wall of the LPG storage tank 102, where it is absorbed and conducted to the liquefied gas inside, offsetting the temperature and pressure drop caused by self-refrigeration as gas is drawn from the tank.
In operation, the tank 102 supplies vaporized gas to the load as required, according to known processes, absorbing heat from its environment to boil the liquefied gas as it is drawn. As long as the gas pressure remains above a selected threshold, the pressure at the control terminal 167 of the second regulator valve 166 is sufficient to hold the valve closed. However, in the event the pressure drops below the threshold, the valve 166 opens and the catalytic heater element 106 is activated to produce radiant heat by catalytic oxidation of the gas. As pressure drops in the tank 102, the reduction of pressure, as transmitted by the feedback line 177 to the control terminal 167 of the second regulator valve 166, opens the valve further, increasing the gas flow to the heater element 106, and thereby increasing the amount of heat produced. As heat from the catalytic heater element 106 is absorbed by the tank 102, it is conducted to the interior of the tank, and transferred to the liquefied gas inside, warming the gas and increasing the equilibrium temperature, resulting in an increased rate of boiling, thereby increasing tank pressure. The increased tank pressure is fed back, via the feedback line 177, to the second regulator valve 166, which reduces gas flow as the pressure rises, thereby regulating the tank pressure.
There are a number of parameters associated with operation of the second regulator valve 166 including the threshold at which the valve opens as tank pressure drops, the threshold at which the valve closes as tank pressure rises, and the change in aperture size per unit of change in control pressure (Δa/Δp), i.e., the degree to which the valve opens or closes in response to a given change in pressure at the control terminal 167. Additionally, the Δa/Δp may in some cases be non-linear, so that, for example, at a relatively high level of tank pressure, a change of one psi at the control terminal 167 may produce one change in aperture, while at a lower tank pressure, a one psi change may produce a larger or smaller change in aperture. The values may also be selected to include hysteresis, so that drops in pressure produce one value of Δa/Δp, while rises in pressure produce a different value. Values for such parameters can be selected according to the particular application.
For example, in an application where the load requirements and the ambient temperature are such that the rate of draw by the load normally exceeds the maximum unassisted flow rate by a small amount, the tank heater system, if configured with typical parameter settings, will turn on as the tank pressure drops, warming the tank and bringing the pressure up to an acceptable level, at which point the system will shut off, whereupon the tank pressure will immediately begin to drop again, until the heater system is again required to turn on, to repeat the cycle. To avoid the continual cycling of the system, and improve efficiency, parameters of the second regulator valve 166 can be selected so that the catalytic heater element is always in operation, but at a lower average output. This might involve reducing the Δa/Δp at pressure levels close to the thresholds, but increasing the Δa/Δp at lower tank pressures. In this way, the heater output initially increases by very small amounts as the tank pressure drops below the turn-on threshold, then increases by larger amounts if the tank pressure drops significantly below the threshold. As a result, the average tank pressure is lowered slightly, preferably to a value below the turn-off threshold. However, the more continual operation avoids constant repetition of the relatively less efficient warm up period during which the catalytic heating element is warmed to its light-off temperature.
For most applications, it is preferable that the turn-on threshold be set to a pressure corresponding to an equilibrium temperature that is greater than 32°. This will prevent the formation of ice on the outside of the tank, which might otherwise interfere with proper and efficient operation of the heater.
Also shown in
Additional heater control circuits are described later according to respective embodiments. While they are not shown as having optional alternate fuel sources, it will be recognized that an alternate fuel source can be provided for such control circuits as necessary, and can be configured substantially as shown with reference to
Turning now to
Mounting brackets 141 are coupled to the back panel 122 of the housing 120, and, in the embodiment shown, extend the length of the housing, although most of the central portions are cut away so as not to obscure other details of the drawings. Tabs 143 extend from the mounting brackets toward the front of the housing 120, and provide means for mounting the heater element 106 to additional support structure. Where the catalytic element 106 is employed in a tank heater system like that described with reference to
The catalytic heater element 106 is divided into a main heater 139 and a pilot heater 140 by sidewalls 142, coupled to the back panel 122 in a substantially gas-tight fashion. The pilot heater 140 includes a pilot supply port 144 and a thermocouple 146. In
To initiate combustion, the temperature of the catalyst must be raised above the activation temperature, i.e., the temperature at which catalysis of the particular fuel and catalyst combination is self-sustaining. In the case of petroleum gas, the reaction temperature is about 250°-400° F. (about 120°-200° C.), depending on factors that include the formulation of the gas and the catalyst employed. In the embodiment of
For initial operation, an electrical power source 152 is coupled to terminals 150 of the heating element 148, which heats to a temperature above the light-off temperature of the fuel supplied to the element 106. As the temperature of the catalyst in the catalyst layer 132 rises, the thermocouple 146 begins to produce a small electric current. When the temperature reaches a selected threshold, the heater control 154 begins to supply fuel at least to the pilot heater 140, and catalytic combustion is thereby initiated in the pilot heater. The power to the electric element 148 is then removed. The fuel supplied to the pilot heater 140 via the pilot supply port 144 is controlled by the heater control 154 to continue flowing as long as the current from the thermocouple 146 is greater than a selected value. Thus, once the pilot is initially activated, absent a system malfunction or complete exhaustion of the available fuel, the pilot heater will continue to operate perpetually.
Once the pilot heater 140 is initially activated, any time thereafter that the main heater 139 is operated, combustion will be initiated by heat from the pilot heater, as described below. Thus, there is generally no requirement for a permanent connection of the system to an electric power source for operation of the electric heating element 148. Instead, electric power can be provided via a temporary connection or source. In a preferred embodiment, the catalyst layer 132 extends unbroken across the entire housing 120, including the pilot heater 140. During pilot operation, fuel that enters via the pilot supply port 144 is constrained by the sidewalls 142 to the pilot plenum chamber 129. As fuel rises through the catalyst layer 132, it dissipates beyond the perimeter of the pilot heater 140 to a small degree, but is largely constrained to that portion of the heating element, where it reacts with the catalyst layer to oxidize, and release heat, thereby maintaining that part of the catalyst layer at a temperature well above the reaction temperature of the fuel.
According to an embodiment, the pilot heater 140 consumes less than about 20% of the fuel consumed by the heater element 106 when the heater element is operating at full power. According to another embodiment, the pilot heater 140 consumes less than about 15% of the fuel consumed by the heater element 106 when the heater element is operating at full power. According to a further embodiment, the pilot heater consumes about 10% or less than of the fuel consumed by the heater element 106 when the heater element is operating at full power.
When the heater control 154 initiates operation of the main heater 139, fuel is supplied to the fuel supply port 136, from which it flows into the plenum chamber 128, and rises through the diffusion/insulation layer 130 to the catalyst layer 132. In the area immediately surrounding the pilot heater 140, the catalyst layer 132 is already at or above the activation temperature, so fuel immediately begins catalytic combustion, releasing additional heat and quickly bringing the remainder of the catalyst layer beyond the activation temperature. Thereafter, the heat produced by the main heater 139 is controlled by regulation of the fuel to the fuel supply port 136. When heat is no longer required, the supply to the fuel supply port 136 is shut off, after which the main heater 139 shuts down, leaving only the pilot heater 140 in operation.
In the embodiment of
If the requirement for heat from the catalytic element 106 is seasonal, the pilot heater can be shut down once the likely need has passed, in order to conserve the small amount of fuel consumed by the pilot heater.
In the embodiment of
In some embodiments, heat conductors, such as, for example, steel or aluminum rods, are provided, embedded in the catalyst layer and extending through the pilot heater and into the main heater, substantially as shown with reference to the electric element 148. The heat conductors conduct heat from the pilot heater to the catalytic material of the main heater, maintaining a portion of the catalytic material above the light-off temperature, to quickly initiate catalytic combustion when the main heater is activated. Heat conductors are particularly useful in embodiments that do not include an electric heating element like the element 148 described above, which otherwise serves a similar purpose.
Turning now to
A pilot supply line 179 is coupled to the gas supply line 176 at a point between the shut-off valve 162 and the second regulator valve 166, and extends to the pilot supply port 144. Accordingly, fuel for the pilot heater 140 is regulated by the first regulator valve 163 and controlled by operation of the shut-off valve 162, but is not subject to control by the second regulator valve 166. Because the first regulator valve is configured to supply fuel at a volume and pressure appropriate for operation of the main heater element 139, an orifice 170 is provided to limit the flow of fuel to the pilot element, which requires much less fuel for operation. While shown as a separate component, such an orifice may be incorporated into the pilot supply port 144, or its function may be accomplished simply by selection of the bore size of the pilot supply line.
The thermocouple 146 of the pilot element 140 is coupled in series, via electrical lines 178, with the temperature-controlled switch 116, the pressure limit switch 168, and the solenoid 164, with ends of the resulting circuit coupled to circuit ground 180. The feedback line 177 is coupled to the control terminal 167 of the regulator valve 166, as previously described, and also to a control terminal 169 of the pressure limit switch 168.
When the pilot heater 140 is in operation, the thermocouple 146 produces an electric current that is transmitted to the solenoid 164 via the temperature-controlled switch 116 and the pressure limit switch 168. When sufficient current is provided, the solenoid 164 acts to move or hold the shut-off valve 162 open so that gas can flow through the valve to the catalytic heater element 106. If combustion in the pilot heater 140 stops, the thermocouple will stop producing current, and the solenoid 164 will permit the shut-off valve 162 to close, shutting off fuel supply to the heater element 106. Likewise, if the temperature of the tank wall rises above the switching threshold, the temperature-controlled switch 116 will open, the current will be interrupted, and the shut-off valve will close. Finally, if tank pressure at the control terminal 169 rises above a maximum pressure threshold, the pressure limit switch 168 will open, interrupting the current and closing the shut-off valve 162. In other respects, the heater control circuit 161 operates substantially as described with reference to the heater control circuit 119 of
As the level of liquefied gas in the tank 102 drops, eventually, the liquid level inside the tank drops into a region directly opposite the catalytic element 106 outside the tank. As the liquid level continues to drop, an increasing portion of the heat produced by the element 106 heats the outside of the tank above the fluid level inside the tank. Efficiency of heat transfer from the tank wall to the liquid LPG drops significantly as more and more of the tank wall is exposed to heat from the element 106, without liquid on the opposite side to which heat can be directly transmitted. Accordingly, the temperature of the tank wall at the level of the temperature-controlled switch 116 begins to rise. At the same time, because the surface area of the remaining liquefied gas in contact with the tank wall diminishes significantly as the tank nears empty, less of the heat from the tank wall is transmitted to the liquid, and the rate of self refrigeration increases. This further reduces tank pressure, causing the second regulator valve 166 to open further, and resulting in an increase of fuel to the heater element 106 to restore tank pressure. In such a case, there is a potential danger of damage to the painted surface of the tank by the excessive heat produced. To prevent the possibility of such damage, the temperature threshold at which the switch 116 opens is selected to interrupt the current from the thermocouple before the tank wall temperature reaches a dangerous level. When the switch 116 opens, current to the solenoid 164 is interrupted, permitting the shut-off valve 162 to close. This shuts off not only the main heater 139, but also the pilot heater 140. If the rate of draw by the load continues, it is likely that tank pressure will shortly thereafter drop below the regulated pressure, affecting operation of the gas-powered devices of the load.
Ideally, the tank 102 is refilled before the level drops to this point, but loss of function of gas appliances can at least serve as a reminder that the tank should be filled. Nevertheless, even if the tank is not refilled, the pilot heater can be restarted once the temperature of the tank wall has dropped below the threshold. Thus, in exigent circumstances, the remaining fuel in the tank can be accessed, although unless the load demand is reduced, the same outcome will eventually occur.
A rectangular element has one line, lying parallel to a longitudinal axis of the tank, along which it lies closest to the tank, and along which heat is most effectively transferred to the tank. In contrast, the catalytic heater element 190 of
According to one method of operation, the first, second, and third elements 232, 234, 236 collectively function substantially as the catalytic element 106 described with reference to
According to another method of operation, the first, second, and third elements 232, 234, 236 collectively function substantially as the three sections 214, 216, 218 of the catalytic heater element 210, as described above with reference to
Turning to
The second heater unit 244 comprises a catalytic heater element 260, a temperature-controlled switch 262, and a shut-off valve 264. A thermocouple 266 is positioned in the heater element 260 and is electrically coupled in series with the switch 262 and a solenoid 268 of the shut-off valve 264. A fuel supply port 269 of the heater element 260 is coupled to the supply line 176 via the shut-off valve 264. Fuel entering the catalytic heater element 260 first passes through an orifice 267.
The third heater unit 246 comprises a catalytic heater element 270, including a thermocouple 276, a fuel supply port 279, and an orifice 277. The thermocouple 276 is electrically coupled in series with the temperature-controlled switch 116 and the solenoid 164 of the shut-off valve 162. The fuel supply port 279 is coupled to the supply line 176 via the orifice 277.
The first, second, and third heater units 242, 244, 246 are positioned in the order shown, with the first heater unit positioned above the second heater unit, and the first and second heater units positioned above the third heater unit. The temperature controlled switch 252 is positioned against the wall of an LPG storage tank at a height that corresponds to the position of the catalytic heater element 250, and similarly, the temperature controlled switch 262 is positioned against the wall of the storage tank at a height that corresponds to the position of the catalytic heater element 260. The temperature controlled switch 116 is positioned against the wall of the storage tank at or above the height of the temperature controlled switch 252.
The first, second, and third heater units 242, 244, 246 normally operate together as a single heater element controlled by the second regulator valve 166. If the liquid level within the tank drops into the range that is directly heated by the first heater unit 242, so that a portion of the heat from the catalytic heater element 250 strikes the tank wall above the level of the liquid in the tank, the tank wall above the liquid will become warmer than below the liquid level. The switching temperature of the temperature controlled switch 252 is selected so that the switch will open once the liquid level drops a small distance below the switch, thereby interrupting the current to the solenoid 257 and closing the shut-off valve 254. The heater unit 242 is thus shut down when the liquid level drops below that unit. Similarly, the second heater unit 244 is configured to shut down when the liquid level drops below its position. When a tank is heated at a point that is above the level of the liquid inside, a much greater portion of the heat is lost to the environment, which can significantly reduce efficiency of the heating system. Shutting down the first and second heater units 242, 244 when the liquid level drops below their respective positions therefore improves the overall efficiency of the system, in particular when such a heater system is used with LPG supply systems that are routinely drawn down below about 25% of tank capacity.
The temperature controlled switch 116 is configured to open at a much higher temperature threshold than the thresholds at which the temperature controlled switches 252 and 262 are configured to open, and acts as a safety device to protect the tank. If for any reason the tank temperature rises excessively, such as, for example, due to a malfunction in which one or both of the first and second heater units 242, 244 fail to shut down when the liquid drops below their respective levels, the temperature controlled switch 116 will open, interrupting the current to the solenoid 164, closing the shut-off valve 162, and shutting down the entire system.
When the first heater unit shuts down, as described above, the volume of fuel passing through the second regulator valve 166 is not proportionately reduced, so it is possible that the volume could exceed the combined capacities of the second and third heater units. The orifices 267 and 277 are provided to prevent a flow that exceeds the capacity of the respective catalytic heater element, but do not significantly limit normal levels of flow. This function may also be served by selection of the diameter of the individual supply lines or the size of the respective supply ports, or by other appropriate means.
The inventors built a prototype tank heater system substantially as described with reference to
Modifications and other components of the prototype embodiment were purpose built. These included components corresponding to the pilot heater 140, the mounting brackets 141, support frames 110, and shroud 108. The dimensions of the pilot heater, as defined by the sidewalls, was about 6 inches by 10 inches, or about 7% of the total area of the heating element, and in operation produced about 200-2000 btu/hr. In addition to the elements described with reference to
In initial testing of the prototype tank heater system, the system performed exactly as anticipated. The system was configured to turn on when tank pressure dropped below 25 psi, and to turn off when tank pressure reached 35 psi. Total activation time, i.e., the period from the moment the second regulator valve opened to send fuel to the main heater, to the moment the entire main heater was at or above the light-off temperature, was about 15 minutes. Fuel consumption of the pilot heater was about 1 cf/hr. Or approximately 10% of the overall heater output.
Straps 312 are attached to the tank 102 by buckles 302. Each of the straps 312 includes first and second connectors 311, 317 configured to engage corresponding first and second attachment features 313, 319 of the cabinet 308. As shown in
End walls 307 of the cabinet 308 can be shaped to conform to the curvature of the tank so that when installed, sidewalls 305, which extend between the end walls 307, can be positioned against the tank wall, so that substantially the entire perimeter of the cabinet contacts the tank wall. Alternatively, as shown in
A door 314 provides access through a back panel 303 to the interior of the cabinet 308. Inlet vents 318 provide passage of air through the back panel 303, and outlet vents 316 provide passage of air through the upper sidewall 305.
The catalytic element 306 is mounted to the cabinet 308 by fasteners 310, extending from the element to mounting apertures in the end walls 307 of the cabinet. A heat exchanger 327 is positioned between the heating element 306 and an inner surface of the cabinet 308, along the length of the element.
During installation on the tank 102, the cabinet 308 is positioned so that the hook 311 of each strap 312 engages the respective aperture 313, so that the cabinet hangs from the two hooks. The cabinet 308 is then rotated so that the lower portion of the cabinet swings under the tank 102 until bails of the toggle buckles 317 can engage the lower hooks 319. The toggle buckles 317 are then rotated to their locked positions, pulling the cabinet tightly against the tank, and securely coupling the cabinet to the tank. According to an embodiment, a resilient insulator material is provided along the front edges of the sidewalls 305 of the cabinet 308 to provide a substantially complete seal between the cabinet and the wall of the tank.
Referring to
As hot air rises in front of the heating element 306, air pressure inside the cabinet is reduced, which creates a vacuum to draw fresh air into the inlet vents 318 of the cabinet. Outside air is pulled into the inlet vents 318 and into a fresh air inlet of the heat exchanger 327 as indicated by arrow A1. As the fresh air passes through the heat exchanger, heat from the exiting exhaust air is transferred to the incoming fresh air, thereby conserving a portion of the heat that would otherwise be lost with the exiting exhaust air. The preheated fresh air exits the heat exchanger 327 by a fresh air outlet to the interior of the cabinet, as indicated at arrow A3. The fresh air is then drawn down across the back of the heating element 306, where it is further heated, until it passes under the element and begins to rise across the face of the heating element, continuing the cycle. Insulating 325 can be provided in the interior of the cabinet 308 to reduce the amount of heat lost through the back and sides of the cabinet.
Turning now to
The catalytic heater element 320 is divided into a main heater 331 and a pilot heater 322 by sidewalls 332, coupled to the back panel 122 in a substantially gas-tight fashion. The pilot heater extends lengthwise for a substantial portion of the housing, although portions are shown larger than in practice, to better illustrate the various components. Preferably, the pilot heater 322 occupies about 3% to 25% of the area of the housing 120, and most preferably between about 8% and 20%. According to one embodiment, the pilot heater 322 occupies about 10% of the area of the housing 120.
The pilot heater 322 includes a pilot supply port 330 and an electric heating element 334. The heating element 334 is contained entirely within the perimeter of the pilot heater 322. In operation, the pilot heater achieves light-off much more quickly and efficiently, because all the heat produced by the electric element 334 serves to heat only the portion of the catalyst layer 132 that operates with the pilot heater. While the electric heating element 334 is shown extending through much of the pilot heater 322, according to an alternative embodiment, the electric element 334 occupies only a very small portion of the pilot heater, and requires a relatively much smaller amount of power to reach an adequate activation temperature. Accordingly, when the pilot heater 322 is initially placed in operation, the electric heater 334 is energized to heat a small portion of the catalyst over the pilot heater 322 to the activation temperature, using a small battery supply, and that small portion begins catalytic combustion. Within a short time, as heat spreads from the small portion, the entire pilot heater comes into operation, and continues as described with reference to previous embodiments.
A fuel distribution header 324 is provided to more evenly distribute fuel to the heating element, and includes fuel ports 326 through which fuel is supplied from the distribution header to respective portions of the housing 120. The fuel distribution header 324 includes a fuel supply port 328 to which fuel is supplied from the heater control 335.
A thermoelectric device 336 is coupled to an outer surface of the back panel 122 opposite the pilot heater 322, and includes one or more thermoelectric modules 340 sandwiched between a first heat sink 341 and a second heat sink 342. The first heat sink 341 is coupled to the back panel 122 to provide a rigid mounting surface for the modules 340. When the catalytic heater element 320 is used in an enclosure like the cabinet 308 of
Operation of thermoelectric devices are well known, and are commonly used to perform various functions, according to thermoelectric principles. For example, the Peltier effect refers to a phenomenon that occurs when an electrical potential is applied across a junction of two different conductive materials, in which heat is absorbed at one part of the circuit and released at another. This effect is often employed to cool microprocessors within a computer cabinet, by affixing a thermoelectric module similar to the modules 340 of
In the present embodiment, the thermoelectric device 336 is positioned on the back panel 122 of the housing 120, opposite the pilot heater 322. However, rather than operating the thermoelectric modules 340 as Peltier devices, to transfer heat from one location to another, as is typical with such devices, they are operated as Seebeck devices, to generate electricity to power the control circuit, using waste heat produced by the pilot heater 322. Because Seebeck operation relies on a temperature differential, it is important that the second heat sink 342 be cooled as efficiently as possible, so that the outer face of the thermoelectric moduled 336 are cooler than the opposite face, in contact with the first heat sink 341. Cooling of the heat sink 342 is generally greatly enhanced by extending the heat sink through the aperture 344 out of the cabinet 308.
While the thermoelectric device 336, like the thermocouple, operates on the Seebeck principle, it provides a couple of advantages over the thermocouple. First, better safety and efficiency: an opening must be made in the back panel 122 of
Turning now to
All of the electrically operated functions are shown as being powered by the thermoelectric device 336. However, as mentioned above, in systems that require more power than is available from a single thermoelectric device, additional such devices can be added. The pilot heater 322 remains in operation continually, and its heat, especially the heat emanating from the back side of the catalytic element 320, is usually waste heat, so placing two or more thermoelectric devices has no appreciable impact on the system's operation.
During normal operation, the heater control circuit 350 operates much as described with reference to previous embodiments. The first regulator valve 163 regulates supply pressure to the system; pressure feedback line 177 provides direct tank pressure to control terminals of the pressure switch 168 and the second regulator valve 358, which regulates operation of the main heater of the catalytic heater element 320, to maintain tank pressure above a threshold; and the pilot heater 322 draws fuel via the pilot supply line 179 from a point between the shut-off valve 162 and the second regulator valve 358. These operations are discussed in more detail above.
The first tank wall temperature sensor 352 is positioned at a point that is below the heater element 320, and preferably near the bottom of the tank 102, and the second tank wall temperature sensor 354 is positioned near or above the uppermost portion of the heater element as described elsewhere.
In operation, when the liquid level inside the tank drops into the region where heat from the catalytic element 320 directly impinges on the tank wall, the wall heats up, because of the less efficient heat transfer. When the temperature of the tank wall exceeds a selected threshold, the switch of the second temperature sensor 354 opens, removing power to the second shut-off valve 356, which closes, shutting off fuel to the main heater. However, the pilot supply line 179 is coupled to the fuel supply line upstream from the second shut-off valve 356, in contrast to the embodiment of
This operation continues until the tank level drops to below the first tank wall temperature sensor 352, positioned near the bottom of the tank. This portion of the tank wall will not begin heating until the tank is nearly or completely empty. Accordingly, when the first sensor reaches its threshold, it shuts of power to the shut-off valve 162, which is upstream from the pilot heater as well as the main heater. Therefore, when the shut-off valve 162 closes, the entire heater system shuts down, so that it cannot return to operation until it is manually relighted.
Features that distinguish the catalytic element 370 from elements of previously disclosed embodiments include a fuel distribution header 372 and a pilot heater 374. In particular, the pilot heater is positioned at the bottom of the housing 120, as viewed in
Additionally, the fuel distribution header 372 is positioned inside the housing 120, in the plenum chamber 376, rather than outside the housing, as described with respect to previous embodiments. While this may require a slight increase in the depth of the plenum chamber, relative to other embodiments, the overall dimensions of the heating element, including the header, are reduced. Additionally, with the distribution header 372 positioned inside the housing 120, clutter is reduced, as well as the number of apertures that are required to penetrate through the back of the housing, thereby also reducing the number of seals necessary, and improving safety and economy.
In the circuit of
The second pressure switch 412 is connected in series with the first tank wall temperature sensor 352 and the shut-off valve 162, and acts as an over-pressure shut-off. The switch is set to open if tank pressure rises above a selected maximum tank pressure threshold. When the second pressure switch opens, power is removed from the shut-off valve 162, which closes, thereby shutting off both the main and the pilot elements of the heater 370. As described above with reference to the circuit of
Turning now to
Connectors 390 are provided near the outer edges of the sidewalls 383 for coupling the tank heater system 380 to the tank 102. In the illustrated embodiment, the connectors 390 are shown as hooks, which are engaged by toggle buckles 317 substantially as described with reference to the connectors 319 of the embodiment of
The tank heater system 380 is shown positioned at the bottom of the tank 102, so that the face of the catalyst layer 132 is lying in a horizontal plane. In a typical catalytic heating element, such an orientation will permit combustion only around the perimeter of the heating element, as heated gas rising from the perimeter prevents oxygen from reaching much of the catalyst layer inside the perimeter. However, according to the embodiment of
The relative sizes of the apertures of the nozzles 404 and the inlets 402 are selected to admit an appropriate volume of fuel to operate the catalytic element, and to entrain a volume of air sufficient to provide the oxygen necessary for its operation. Because the necessary oxygen is premixed with the fuel, there is no requirement for air flow across the face of the catalytic element. The sidewalls 383 are provided with exhaust vents 386 to permit the escape of exhaust gas from the housing 381.
A particular advantage of the embodiment of
It should be noted that the tank heating system 380 of
Also shown in
The mounting structure 406 can be used as an alternative to the various structures that employ straps around the tank 102, as disclosed with reference to other embodiments.
In the embodiment shown, the aperture 405 is in the form of an elongated slot that permits some adjustment of the angle of the heater around a longitudinal axis of the tank 102. This is particularly useful when the mounting bracket is used to mount a heater that does not include venturi-type inlet ports, and that therefore requires a flow of air across the face of the catalytic layer. The slot 405 in the bracket 408 permits angular adjustment of the heater, upward to improve airflow, or downward to apply heat closer to the bottom of the tank.
In embodiments that include a pilot heater, the size of the pilot heater relative to the total size of the catalytic element is a design consideration that will be influenced by a number of factors, including the overall size and output of the heating element, the expected frequency and duty cycle of operation of the system, the cost and availability of LPG fuel, etc. For example, a relatively larger pilot heater will consume more fuel than a smaller one, but will bring the main heater to full operation more quickly. During the activation period between the time fuel begins to enter the main heater and the time the main heater reaches full operation, some amount of fuel will flow through portions of the catalyst that have not yet reached the activation temperature, and will thus be wasted. If the system cycles on and off at a relatively high frequency, it may be more efficient to use a larger pilot heater so that the system reaches full operation more quickly and with less loss of unburned fuel. On the other hand, in a system that requires supplemental heat only infrequently, a small pilot heater may be preferable, so as to consume less fuel while the system is not in active operation.
In view of the difficulties associated with known systems for assisting in the vaporization of liquefied gas, the inventors have recognized that a catalytic tank heater can resolve many of the problems, and can provide additional benefits that are not available from prior art systems. First, a catalytic heating element operating on LPG gas cannot raise the temperature of LPG gas in its environment to the auto-ignition temperature of the gas, so there is no ignition or explosion danger in the event of a gas leak. The catalytic heater systems can meet or exceed the requirements for operation within a Class I, Division 1, Group D, hazardous location as governed by NFPA (National Fire Protection Agency) 58 and NEC (National Electrical Code) 70, and thus, in the U.S. can be used in close proximity to an LPG storage tank in any location where a storage tank is permitted. More expensive and complex systems can thus be eliminated, and the overall footprint of many LPG supply systems reduced by elimination of remotely located vaporizers and plumbing connections. Similarly, catalytic heaters can meet the requirements of equivalent regulations in many countries outside the U.S.
Because the catalytic heater element of the disclosed embodiments is not in physical contact with the tank, condensation is not trapped against the tank, but is permitted to evaporate, which substantially eliminates the corrosion problems associated with prior art tank heaters.
Many consumers of LPG are in locations that are remote from an electric grid, so any electric power must be generated at the site. The catalytic tank heater systems disclosed above do not require a regular source of electric power. Once the pilot heater is operating, no external power source is required, and the pilot heater can be started in a few minutes using a generator, a car battery, or even a smaller battery, depending on the configuration of the system.
In most jurisdictions, where permanent electrical connections are necessary within a specified distance from an LPG storage tank, those connections must be installed and serviced by electricians who are certified to perform the work, because of the potential dangers that could arise if the work is done improperly. Similarly, work that entails servicing or modifying gas connections within the same distance must be done by personnel who are certified to perform that work. This means that with prior art systems that employ an electric tank heater or vaporizer, installation and maintenance generally requires the services of at least two people: one to perform the electrical work, and another to perform the work on the gas equipment. In contrast, systems configured according to many of the present embodiments can be installed and serviced by one individual, because there are no permanent electrical connections required.
The term psi is commonly understood as referring, broadly, to pounds per square inch, but technically defines pounds per square inch relative to a vacuum. Where psi is used in the present specification or claims, it is to be understood as referring, more specifically, to psig, or psi gauge, which defines the pressure being measured relative to the ambient pressure, rather than to a vacuum.
In describing the embodiments illustrated in the drawings, directional references, such as right, left, top, bottom, above, below, etc., are used to refer to elements or movements as they are shown in the figures. Such terms are used to simplify the description and are not to be construed as limiting the claims in any way.
Where front and back are used in the specification and claims with reference to catalytic heater elements and associated features, front refers to the face of the element where the catalyst is located, and from which most of the heat is radiated when a fuel is catalyzed. Back, therefore, refers to the surface of the element opposite the front. In this context, front and face are used synonymously. Sidewall refers to the portions of a catalytic heater element housing that extend from the back of the element toward the front, and that define the perimeter of the element or portion of the element, as viewed in front or back plan view. The claims are not limited by the use of these terms in the specification to describe the disclosed embodiments.
A feature described as being gas-tight is one that will generally not permit passage of gas at that location at the pressure range that the described feature would be expected to be normally subjected to. For example, during operation, the gas pressure in the plenum chamber of a catalytic heater is normally equal to, or only slightly above ambient pressure, so where the sides and back panel of a housing of a heater element are described as being gas-tight, those features need only be capable of substantially preventing passage of gas at slightly above the ambient pressure. Thus, unnecessary gaps or openings or loose joints where gas could easily pass are not present, but special seals, hermetic sealing materials, or joints, such as would be necessary at higher pressure differentials are not generally required.
Ordinal numbers, e.g., first, second, third, etc., are used according to conventional claim practice, i.e., for the purpose of clearly distinguishing between claimed elements or features thereof. The use of such numbers does not suggest any other relationship, e.g., order of operation or relative position of such elements, nor does it exclude the possible combination of the listed elements into a single component, structure, or housing. Furthermore, ordinal numbers used in the claims have no specific correspondence to ordinal numbers used in the specification to refer to elements of disclosed embodiments on which those claims might read.
Where a claim limitation recites a structure as an object of the limitation, that structure itself is not an element of the claim, but is a modifier of the subject of the limitation. For example, in a limitation that recites “a shroud configured to conform to the wall of a cylindrical tank,” the cylindrical tank is not an element of the claim, but instead serves to define the scope of the term shroud. Additionally, subsequent limitations or claims that recite or characterize additional elements relative to the tank do not render the tank an element of the claim, except where the tank is recited as the subject of the limitation, rather than an object.
The term coupled, as used in the claims, includes within its scope indirect coupling, such as when two elements are coupled with one or more intervening elements, even where no intervening elements are recited. Coupled can also refer to a direct coupling, in which elements are directly coupled or are formed from a same piece of material so as to be monolithic or integral.
The abstract of the present disclosure is provided as a brief outline of some of the principles of the invention according to one embodiment, and is not intended as a complete or definitive description of any embodiment thereof, nor should it be relied upon to define terms used in the specification or claims. The abstract does not limit the scope of the claims.
Features of the various embodiments described above are generally disclosed with reference to particular embodiments as a matter of convenience. Individual features of one embodiment can be omitted, exchanged with corresponding features of another embodiment, or otherwise combined therewith, and further modifications can be made, to provide further embodiments, without deviating from the spirit and scope of the invention. All of the commercial devices and structures referred to in this specification, are incorporated herein by reference, in their entirety. Aspects of the embodiments can be modified, if necessary to employ concepts of the various patents, applications and publications to provide yet further embodiments.
These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.
This application claims the benefit of U.S. Provisional Patent Application No. 61/355,463, filed Jun. 16, 2010, which provisional application is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61355463 | Jun 2010 | US |
