High Temperature Combustion Device

FIELD OF THE INVENTION

This patent specification relates to the field of high temperature combustion devices. More specifically, this patent specification relates to a high temperature combustion device configured to enable dynamic changes in the combustion environment to provide neutral, oxidizing, or reducing combustion environments, as needed.

BACKGROUND

Several sectors within the art industry—in particular, glass blowing, blacksmithing, metal foundries, and ceramics—require high levels of process heat (2000°-3000° F.). In many such art-related applications, the state of the combustion environment—oxidizing, reducing, or neutral—can have a dramatic impact on the condition of the final products. However, most combustion appliances utilize a burner control system that fixes the fuel/air ratio at or slightly above the stoichiometric point for a given fuel, resulting in a continual oxidizing environment within the combustion chamber. To ensure proper color rendition and reduce the negative impacts of oxidation for art-based operations, a control system must be introduced that is capable of initiating dynamic changes within the combustion environment.

Typically, art furnaces and kilns are fueled by natural gas or propane, resulting in high fuel costs and significant environmental impact. Waste vegetable oil (WVO) offers a clean-burning, sustainable alternative to these fossil fuels. However, currently-available waste oil burner systems are unable to effectively and efficiently reach the combustion temperatures required (2000°-3000° F.) for these firing activities. At these temperatures, the radiant heat being reflected back into the burner blast tube is high enough to deform or even melt the brass or copper fittings associated with the atomizing nozzle.

Therefore, a need exists for a novel high temperature combustion device configured to enable dynamic changes in the combustion environment to provide neutral, oxidizing, or reducing combustion environments.

BRIEF SUMMARY OF THE INVENTION

A high temperature combustion device is provided. In some embodiments, the device may include a blast tube and an air blower configured to motivate air through the blast tube. A nozzle for atomizing a fuel may be disposed in the blast tube. A fuel pump may be configured to motivate the fuel to exit the nozzle. An air supply line may be in fluid communication with the nozzle and may be configured to supply high-pressure air to the nozzle. The high-pressure air may exit the nozzle with the fuel in a first direction, and air motivated through the blast tube by the air blower may pass around the nozzle in a second direction that is substantially parallel to the first direction.

In further embodiments, the device may include a blast tube and an air blower configured to motivate air through the blast tube. A nozzle for atomizing a fuel comprising vegetable oil may be disposed in the blast tube, and a swirl ring may also be positioned within the blast tube. A fuel pump may be configured to motivate the fuel to exit the nozzle. A heating element may be configured to raise the temperature of the fuel before the fuel contacts the nozzle. An air supply line may be in fluid communication with the nozzle and may be configured to supply high-pressure air to the nozzle. The high-pressure air may exit the nozzle with the fuel in a first direction, and air motivated through the blast tube by the air blower may pass around the nozzle in a second direction that is substantially parallel to the first direction.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments of the present invention are illustrated as an example and are not limited by the figures of the accompanying drawings, in which like references may indicate similar elements and in which:

FIG. 1 depicts a rear perspective view of an example of a high temperature combustion device according to various embodiments described herein.

FIG. 2 illustrates a front perspective view of an example of a high temperature combustion device according to various embodiments described herein.

FIG. 3 shows a sectional view of an example of a blast tube and the positioning of some exemplary components which may be positioned within the blast tube according to various embodiments described herein.

FIG. 4 depicts a perspective view of an example of a swirl ring according to various embodiments described herein.

FIG. 5 illustrates a perspective exploded view of an example of a nozzle according to various embodiments described herein.

FIG. 6 shows a block diagram showing example directions of fuel and air passing through a blast tube and from a nozzle according to various embodiments described herein.

FIG. 7 depicts a block diagram of an example of a high temperature combustion device according to various embodiments described herein.

FIG. 8 illustrates a block diagram of another example of a high temperature combustion device according to various embodiments described herein.

FIG. 9 shows a block diagram of a further example of a high temperature combustion device according to various embodiments described herein.

DETAILED DESCRIPTION OF THE INVENTION

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

In describing the invention, it will be understood that a number of techniques and steps are disclosed. Each of these has individual benefit and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques. Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination of the individual steps in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combinations are entirely within the scope of the invention and the claims.

For purposes of description herein, the terms “upper”, “lower”, “left”, “right”, “rear”, “front”, “side”, “vertical”, “horizontal”, and derivatives thereof shall relate to the invention as oriented in FIG. 1. However, one will understand that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. Therefore, the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

Although the terms “first”, “second”, etc. are used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. For example, the first element may be designated as the second element, and the second element may be likewise designated as the first element without departing from the scope of the invention.

As used in this application, the term “about” or “approximately” refers to a range of values within plus or minus 10% of the specified number. Additionally, as used in this application, the term “substantially” means that the actual value is within about 10% of the actual desired value, particularly within about 5% of the actual desired value and especially within about 1% of the actual desired value of any variable, element or limit set forth herein.

A new high temperature combustion device is discussed herein. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details.

The present disclosure is to be considered as an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated by the figures or description below.

The present invention will now be described by example and through referencing the appended figures representing preferred and alternative embodiments. FIGS. 1, 2, and 7-9 illustrate examples of a high temperature combustion device (“the device”) 100 according to various embodiments. The device 100 may be configured to deliver high temperature process heat (3000°+F) for combustion chambers of any size, and preferably sized from 2 ft³to 20 ft³, using vegetable oil, including waste vegetable oil, for fuel or any other suitable fuel. The device 100 may be configured to enable a user to independently control combustion variables, such as fuel pressure, fuel flow, atomizing air pressure, and combustion air flow, to maintain or dynamically change the combustion environment/combustion flame characteristics. In this manner, the device 100 enables the creation of a neutral, oxidizing, or reducing combustion environment, as needed which may be used to create (or prevent) certain surface effects or material structural changes during glassblowing, blacksmithing, and ceramics firing.

In some embodiments, the device 100 may comprise a blast tube 14 and an air blower 9 configured to motivate air through the blast tube 14. A nozzle 21 for atomizing a fuel, such as vegetable oil, may be disposed in the blast tube 14. A fuel pump 12 may be configured to motivate the fuel to exit the nozzle 21. An air supply line 18 may be in fluid communication with the nozzle 21 and may be configured to supply high-pressure air to the nozzle 21.

The high-pressure air may exit the nozzle 21 with the fuel in a first direction 71, and air 45 motivated through the blast tube 14 by the air blower 9 may pass around the nozzle 21 in a second direction 72 that is substantially parallel to the first direction 71. In some embodiments, the first direction 71 and second direction 72 may be approximately parallel by being approximately plus or minus 10 degrees of each other and/or the axis 81. In preferred embodiments, the first direction 71 and second direction 72 may be substantially parallel by being approximately plus or minus 5 degrees of each other and/or the axis 81.

In some embodiments, high-pressure air and fuel 44 exiting the nozzle 21 may be directed in a first direction 71 while having a first rotation 76 that is imparted by the axial channels 33 of the nozzle 21, and air 45 motivated through the blast tube 14 by the air blower 9 may be directed in a second direction 72 while having a second rotation 77 that is imparted by the swirl channels 40 and vanes 41 of the swirl ring 26. In preferred embodiments, the first rotation 76 may be clockwise (as viewed from the first end 38 of the blast tube 14 to the second end 39) and the second rotation 77 may be counter-clockwise (as viewed from the first end 38 of the blast tube 14 to the second end 39). In other embodiments, the first rotation 76 may be counter-clockwise (as viewed from the first end 38 of the blast tube 14 to the second end 39) and the second rotation 77 may be clockwise (as viewed from the first end 38 of the blast tube 14 to the second end 39). In still other embodiments, the first rotation 76 may be counter-clockwise (as viewed from the first end 38 of the blast tube 14 to the second end 39) and the second rotation 77 may be counter-clockwise (as viewed from the first end 38 of the blast tube 14 to the second end 39). In still yet other embodiments, the first rotation 76 may be clockwise (as viewed from the first end 38 of the blast tube 14 to the second end 39) and the second rotation 77 may be clockwise (as viewed from the first end 38 of the blast tube 14 to the second end 39).

In some embodiments, the device 100 may comprise a cast aluminum or other material burner base or frame 30 which may be used to support the elements of the device 100. A frame 30 may be configured in any shape and size to support one or more elements of the device 100. One or more elements of a frame 30 may comprise or be made from steel alloys, aluminum, aluminum alloys, copper alloys, other types of metal or metal alloys, ceramics such as alumina, porcelain, and boron carbide, earthenware, natural stone, synthetic stone, various types of hard plastics, such as polyethylene (PE), Ultra-high-molecular-weight polyethylene (UHMWPE, UHMW), polypropylene (PP) and polyvinyl chloride (PVC), polycarbonate, nylon, Poly(methyl methacrylate) (PMMA) also known as acrylic, melamine, hard rubbers, fiberglass, carbon fiber, resins, such as epoxy resin, wood, other plant based materials, or any other material including combinations of materials that are substantially rigid and suitable for providing structural support.

In some embodiments, and as shown in FIG. 8, the device 100 may comprise integrated fuel pump 12 and air blower 9 which may be both mounted on the drive shaft or otherwise coupled to a single motor 29, such as a 1/7 horsepower, 120-volt AC motor 29. In other embodiments, and as shown in FIG. 7, the device 100 may comprise a fuel pump 12 which may not be integrated with an air blower 9, and the fuel pump 12 and air blower 9 may be motivated by independent motors 29.

In some embodiments, a motor 29 may comprise a brushed DC motor, brushless DC motor, switched reluctance motor, universal motor, AC polyphase squirrel-cage or wound-rotor induction motor, AC SCIM split-phase capacitor-start motor, AC SCIM split-phase capacitor-run motor, AC SCIM split-phase auxiliary start winding motor, AC induction shaded-pole motor, wound-rotor synchronous motor, hysteresis motor, synchronous reluctance motor, pancake or axial rotor motor, stepper motor, or any other type of motor. In further embodiments, a motor 29 may comprise a hydraulic motor such as a Gear and vane motor, Gerotor motor, Axial plunger motors, Radial piston motors, or any other hydraulically motivated motor. In still further embodiments, a motor 29 may comprise a pneumatic motor, such as a linear pneumatic motor and a pneumatic rotary vane motor, other any other type of motor capable of generating mechanical energy.

In some embodiments, the device 100 may comprise one or more fuel pumps 12 which may be used to motivate fuel from a fuel tank 31 to a nozzle via a fuel supply line 13. Additionally, a fuel pump 12 may provide the motivation to motivate fuel through a fuel recirculation line 8. In further embodiments, a fuel pump 12 may comprise a hydraulic pump such as a gear pump, rotary vane pump, screw pump, bent axis pump, inline axial piston pumps and swashplate principle pumps, radial piston pumps, peristaltic pumps, or any other suitable type of fluid motivating pump.

In some embodiments, the device 100 may comprise a fuel tank 31 which may be configured to hold a volume of fuel such as vegetable oil, including waste vegetable oil, or any other suitable fuel. A fuel tank 31 may be made from metal, such as steel or aluminum, plastic, such as high-density polyethylene (HDPE), or any other suitable material. A fuel tank 31 may be configured to hold any volume of fuel, such as 5 gallons, 10 gallons, 20 gallons, etc., and may be configured in any size and shape. In preferred embodiments, a fuel tank 31 may be removably coupled to another element of the device 100, such as by being removably coupled to a fuel inlet line 17 via a quick disconnect coupling.

In some embodiments, a fuel tank 31 may comprise a stand-alone, 5-gallon fuel tank which may be fabricated from 16-gauge steel, although other containers may be used. For ease of refilling, the fuel tank 31 may incorporate a vented screw cap on top for manual refueling. In further embodiments, the device 100 may comprise a fuel transfer pump 2, such as a 120-volt AC fuel transfer pump, which may optionally be mounted at the rear of the fuel tank 31 or in communication with the fuel tank 31 via a transfer line 19 which may comprise any suitable type of substantially rigid or flexible fluid bearing conduit. A fuel transfer pump 2 may comprise any pumping device which may be suitable for motivating combustible fuels, such as positive-displacement (either bulk-handling or metering pumps) pumps and nonpositive-displacement (centrifugal) pumps. During operation, a fuel transfer pump 2 may be configured to motivate a fuel from a fuel source into the fuel tank 31 to refill the fuel tank 31. Optionally, a fuel transfer pump 2 may be configured to drain fuel from the fuel tank 31, such as for storage or travel purposes. The fuel transfer pump 2 and control box 3 may be connected by a preferably 16-gauge water-tight connector, which can be disconnected for ease of transport. In further embodiments, the fuel tank 31 may incorporate a quick disconnect fitting to allow the fuel transfer pump 2 to be easily and cleanly disconnected from the fuel tank 31.

In preferred embodiments, the device 100, preferably including a fuel tank 31, may be completely mobile and weigh less than 35 pounds. In further preferred embodiments, the device 100 may be mounted on or comprise a hinged plate, which allows the blast tube 14 of the device 100 to be raised or lowered using an adjustable screw foot or other mechanism. Raising or lowering the blast tube 14 changes the incident angle of the flame body with respect to the combustion chamber's inlet port, providing better alignment of the flame to ensure a cyclic rotation within the combustion chamber.

A fuel inlet line 17 may provide fluid communication between the fuel pump 12 and the fuel tank 31. In preferred embodiments, a fuel inlet line 17 may comprise a 0.25-inch braided steel conduit. In other embodiments, a fuel inlet line 17 may comprise any other suitable type of substantially rigid or flexible fluid bearing conduit. Optionally, one or more isolation valves may be coupled to the fuel inlet line 17.

Fuel may exit the fuel pump 12 via a fuel supply line 13, and the fuel supply line 13 may enable fluid communication between the fuel pump 12 and the nozzle 21. In preferred embodiments, the fluid communication between the fuel pump 12 and the nozzle 21 may be governed by a fuel supply valve 11 which may be coupled to the fuel supply line 13.

In some embodiments, the device 100 may comprise a fuel recirculation line 8 which may be coupled to the fuel supply line 13 before the fuel supply valve 11, and the fuel recirculation line 8 may provide fluid communication between the fuel supply line 13 and the fuel tank 31. In preferred embodiments, the fluid communication between the fuel supply line 13 and the fuel tank 31 may be governed by a fuel recirculation valve 10 which may be coupled to the fuel recirculation line 8.

In some embodiments, fuel pressure in the fuel supply line 13 may be controlled via the fuel pump 12. In preferred embodiments, fuel pressure in the fuel supply line 13 may be controlled by operating a fuel recirculation valve 10 located in the fuel recirculation line 8. Closing or motivating towards closing of the fuel recirculation valve 10 decreases fuel recirculation flow (into fuel tank 31), causing the fuel pressure in the fuel supply line 13, and therefore the delivery pressure at the nozzle 21, to increase in response until it reaches the maximum output pressure of the fuel pump 12. Increased fuel pressure allows the flame body to project further into the combustion chamber, as needed for larger chambers.

In further preferred embodiments, fuel flow rate may be controlled by operating a fuel supply valve 11 or other suitable device located in the fuel supply line 13. Opening the fuel supply valve 11 increases the fuel flow rate, which increases combustion levels and ultimately the heat flow rate into the combustion chamber that the flame body is projected towards or into. A reductive (fuel rich, oxygen starved) atmosphere can be created within the combustion chamber by increasing fuel flow until the fuel/air mixture drops below its stoichiometric point. Reduction is necessary for proper color rendition of many glass and ceramic coloring agents and helps to reduce scaling during forging and foundry operations. Similarly, an oxidizing (oxygen rich) or neutral environment can be created within the chamber by decreasing fuel flow as needed.

Generally, the device 100 may comprise one or more valves, such as the fuel recirculation valve 10 and fuel supply valve 11, which may enable, disable, or otherwise modulate the flow of fuel to or through one or more elements or components of the device 100 and may comprise or include a flow control valve, pressure regulating valve, relief valve, ball valve, a gate valve, butterfly valve, diaphragm valve, needle valve, globe valve, check valve, pressure balanced valve, locking valve, solenoid valve, or any other type of valve or controller which may be used to enable, disable, or otherwise modulate the flow of fuel to or through one or more elements or components of the device 100. In some embodiments, one or more of these valves 10, 11, may be a manually operated valve so that the valve 10, 11, may be manually opened or closed by a user. In further embodiments, one or more of these valves 10, 11, may be an automated valve so that the valve 10, 11, may be opened or closed without physical interaction of a user with the valve 10, 11.

In some embodiments, the device 100 may comprise one or more strainers, such as 150-micron stainless steel strainers, which may be coupled to a fuel tank 31, fuel line 17, 8, 13, transfer pump 2, or any other component to remove any remaining particulates from the fuel. Preferably, the fuel inlet line 17 from the fuel tank 31 to the fuel pump 12 may be 0.25-inch braided steel over polyethylene tubing, and can be disconnected by releasing the quick-disconnect fittings which may be located at the fuel tank 31 between two isolation valves.

In some embodiments, the device 100 may be in communication with a high-pressure air source 32. In further embodiments, the device 100 may comprise a high-pressure air source 32. In preferred embodiments, a high-pressure air source 32 may be configured to supply high-pressure air of approximately 20.0 cubic feet per minute (CFM) at approximately 30 pounds per square inch (PSI). In other embodiments, a high-pressure air source 32 may be configured to supply high-pressure air having any pressure greater than ambient air pressure.

A high-pressure air source 32 may comprise any device that converts power (using an electric motor, diesel or gasoline engine, etc.) into potential energy stored in pressurized air, such as a positive-displacement compressor which works by forcing air into a chamber whose volume is decreased to compress the air, such as a Piston-type air compressor, Rotary screw compressor, and Vane compressor, a Dynamic displacement air compressor which uses centrifugal force generated by a spinning impeller to accelerate and then decelerate captured air, which pressurizes the air, such as a centrifugal compressor, and an axial compressor, or any other device for generating pressurized air. A high-pressure air source 32 may optionally include or be coupled to a tank for storing pressurized air.

An air supply line 18 may provide fluid communication of the high-pressure air (or other gas) between the high-pressure air source 32 and the nozzle 21. In preferred embodiments, an air supply line 18 may comprise a 0.25-inch braided steel conduit. In other embodiments, an air supply line 18 may comprise any other type of substantially rigid or flexible fluid bearing conduit.

In some embodiments, the device 100 may comprise an air regulator 16 that may be coupled to the air supply line 18. Generally, an air regulator 16 may comprise a pressure regulator, such as a control valve, that reduces the input pressure of a high-pressure air source 32 to a desired value at its output into the air supply line 18. Air regulators 16 are commonly used for compressed air, and can be an integral device with an output pressure setting, a restrictor and a sensor all in the one body, or be comprised of a separate pressure sensor, controller and flow valve. In further embodiments, an air regulator 16 may comprise a single stage regulator, double stage regulator, or any other suitable pressure regulating device.

In some embodiments, the device 100 may comprise an air supply valve 7 that may be coupled to the air supply line 18. Generally, an air supply valve 7 may comprise a valve for controlling the high-pressure air that is delivered to the nozzle 21 via the air supply line 18. In preferred embodiments, an air supply valve 7 may be coupled to the air supply line 18 between the nozzle 21 and air regulator 16. In further preferred embodiments, an air supply valve 7 may comprise a solenoid valve, or other automatically operated valve, that may open upon receipt of a run signal from the fuel pump 12, a fuel pump motor 29, or controller 3. In other embodiments, an air supply valve 7 may comprise any other type of valve or control device, such as may be used for a recirculation valve 10 and fuel supply valve 11.

High-pressure air provided to the nozzle 21 may be used to atomize or facilitate the atomization of fuel exiting the nozzle 21. In some embodiments, atomizing air pressure provided to the nozzle 21 via an air supply line 18 may be adjusted higher or lower by changing the setting on the compressed air regulator 16, high-pressure air source 32, and/or air supply valve 7. Atomizing air pressure determines the final size of fuel droplets exiting the nozzle 21. Higher pressure yields smaller droplet size, focusing the blue core of the flame body, and increasing combustion efficiency.

In preferred embodiments, the device 100 may comprise an atomizing type nozzle 21 which may be configured to atomize a fuel provided to the nozzle 21 via high-pressure air. In some embodiments, a nozzle 21 may comprise a body 36 which may be removably coupled to a head 37. Fuel may flow through the body 36 to exit a fuel exit aperture 35 while high-pressure air may flow around the body 36 and through axial channels 33. Fuel exiting the fuel exit aperture 35 may be atomized by the high-pressure air flowing around the body 36 and through one or more axial channels 33 to exit the nozzle aperture 34 of the head 37. In some embodiments, and as shown in FIG. 5, a nozzle 21 may comprise one or more, such as a set, of axial channels 33 that direct the high-pressure air in a cyclonic pattern, rendering the fuel exiting the fuel exit aperture 35 into droplets of approximately 3 to 5 microns in diameter, that ultimately exit the nozzle aperture 34 and greatly increasing the combustion efficiency. Axial channels 33 may be configured in any shape and size. Preferably, the axial channels 33 may be angled relative to the fuel exit aperture 35 of the nozzle 21 so that high-pressure air passing through the axial channels 33 may be directed in a cyclonic or spiral pattern. Fuel consumption rates may be varied, such as from approximately 0.5 gallons/hour to 3 gallons/hour, based on control settings, fuel recirculation valve 10 settings, fuel recirculation line 8 settings, fuel pump 12 settings, and/or and nozzle 21 size.

The device 100 may comprise any number and arrangement of pipes or conduits which may be used to route air from a blower, high-pressure air from a high-pressure air source 32, and fuel used by the device 100. Example pipe or conduit, such as which may be used to form a fuel supply line 13, air supply line 18, etc., may include Poly Vinyl Chloride (PVC) pipe and fittings, Chlorinated Poly Vinyl Chloride (CPVC) pipe and fittings, cross-linked polyethylene (PEX) pipe and fittings, galvanized pipe and fittings, black pipe and fittings, polyethylene pipe and fittings, copper pipe and fittings, brass pipe and fittings, stainless steel or other steel alloy pipe and fittings, vinyl pipe and fittings, or any other type of pipe or conduit. In preferred embodiments, a fuel supply line 13, air supply line 18, or other conduit may comprise a removable pneumatic coupling. A pneumatic coupling may comprise any male or female coupling or fitting commonly found in hydraulic applications and alternative compressed gas applications, such as CEJN type fittings, Duff-Norton type fittings, Foster type fittings, Hansen 2-HKIG type fittings, Hansen 2-HKIL type fittings, Milton type fittings, Parker type fittings, Schrader Twist-Lock type fittings, Snap-Tite type fittings, Tomco type fittings, ARO Interchange Profile type fittings, Automotive Interchange Profile type fittings, Industrial Interchange Profile type fittings, Lincoln Interchange Profile type fittings, Semi-Universal Interchange Profile type fittings, or any other type of fitting or coupling. Alternatively, the device 100 may utilize a flange connection, barbed connection, push to connect type connection, or threaded connection such as NPT (National Pipe Thread), NPTF (National Pipe Thread Fuel), BSPP (British Standard Pipe Parallel), BSPT (British Standard Pipe Thread) or any other type of fitting or coupling.

In some embodiments, the device 100 may comprise a heating element 23 which may be configured to raise the temperature of the fuel before the fuel contacts the nozzle 21 to preferably decrease the viscosity of the fuel. Optionally, a heating element 23 may be contained in or may be otherwise in thermal communication with a heater block 22. A heater block 22 may comprise a block or amount of thermally conductive material, such as aluminum, copper, other metal, etc., which may serve to evenly distribute the heat of the heating element 23 to the fuel supply line 13, nozzle 21, fuel tank 31, and/or other elements of the device 100.

In some embodiments, a heating element 23 may comprise a device that converts electricity into heat through the process of resistive or Joule heating. Electric current passing through the heating element 23 encounters resistance, resulting in heating of the heating element 23. An electric heating element 23 may comprise one or more Peltier chips, metal heating elements, such as nichrome, Kanthal (FeCrAl), and the like, ceramic heating elements, such as molybdenum disilicide (MoSi2), polymer heating elements, such as PTC rubber, composite heating elements, such as fine coil of nichrome (NiCr) resistance heating alloy wire, that is located in a metallic tube (of stainless steel alloys, such as Incoloy, or copper) and insulated by magnesium oxide powder, and combination heating element systems, such as those using thick film technology, or any other device that converts electricity into heat.

In preferred embodiments, prior to reaching the nozzle 21, the fuel supply line 13 passes through an aluminum or other material heater block 22 which may be fitted with a 300 watt cartridge type heating element 23 or other suitable heating device to increase the temperature and decrease the viscosity of the fuel in the fuel supply line 13. The fuel may then enter the nozzle's 21 nozzle mount 24 and is directed through the center of the nozzle 21 to the atomizing tip. The fuel, such as waste vegetable oil, is in effect transformed into an aerosol by the nozzle 21, allowing effective ignition even without heating the fuel, such as oil to its flash point of 621° F. Preferably, an internal heater block 22 may raise the fuel temperature to approximately 200° F. before reaching the nozzle 21, in order to reduce the fuel's viscosity and promote better atomization.

In some embodiments, the device 100 may comprise a temperature sensor 25 which may be configured to provide temperature data of the heating element 23 and/or heater block 22. For example, the temperature of the heating element 23 and/or heater block 22 may be monitored by a temperature sensor 25 comprising a 0.25-inch Type K thermocouple or other temperature measuring device. In further embodiments, a temperature sensor 25 may be integrated with a heating element 23. A temperature sensor 25 may comprise a thermocouple, a resistive temperature device (RTDs, thermistors), an infrared temperature sensor, a bimetallic device, a liquid expansion device, a molecular change-of-state device, a silicon diode, or any other type of temperature sensor configured to electrically communicate temperature information.

In some embodiments, the device 100 may comprise an air blower 9 which may be configured to motivate air past the nozzle 21. An air blower 9 may comprise any device configured to cause, motivate, or direct air flow. Example air blowers 9 include a rotating arrangement of vanes or blades capable of moving air, such as a rotary vane pump, a diaphragm pump, a piston pump, a scroll pump, a screw pump, a Wankel pump, an external vane pump, a roots blower or booster pump, a multistage roots pump, a blower fan, a vane pump, axial-flow fans, centrifugal fans, cross-flow fans, bellows, Coanda effect air movers, electrostatic air movers, or any other device or method capable of moving air.

In some embodiments, the velocity or amount of air motivated past the nozzle 21 may be controlled by controlling the speed of the air blower 9. In further embodiments, the device 100 may comprise one or more air dampers 28 which may control the amount of air that is able to enter the air blower 9 thereby controlling the velocity or amount of air motivated past the nozzle 21 by the air blower 9. Generally, an air damper 28 may comprise any type of valve, plate, or other movable device that can be moved to stop, enable, or otherwise regulate the flow of air inside a duct, chimney, VAV box, air handler, or other air-handling equipment.

The device 100 may comprise a blast tube 14 which may be coupled to or otherwise in fluid communication with air exiting, the air blower 9. A blast tube 14 may comprise a blast tube cavity 20 between a first end 38 and a second end 39. A first end 38 may be coupled to or otherwise in fluid communication with air exiting the air blower 9, while a second end 39 may be configured to enable air from the air blower 9 passing through the blast tube cavity 20 to exit the blast tube 14. A blast tube 14 may be configured in any size and shape. In preferred embodiments, a blast tube 14 may be generally cone or funnel shaped having a first end 38 that is relatively larger than the second end 39 to increase the velocity of the air exiting the second end 39. Higher combustion air velocity helps reduce the level of radiant heat reflected from the combustion chamber back towards the nozzle 21. In some embodiments, the blast tube 14 narrows from approximately 4 inches in diameter at the first end 38 to approximately 2 inches in diameter at the second end 39, although other sizes and reductions may be used. In preferred embodiments, the reduction in outlet size of the second end 39 causes the outlet speed of the combustion air flow to increase by approximately 400%, as dictated by mass flow balance. The increased air speed helps to cool the heater block 22 and prevent overheating of components and carbonization of the fuel.

In preferred embodiments, the nozzle 21 and swirl ring 26 may be positioned within the blast tube 14 proximate to the second end 39. The fuel supply line 13 may be in thermal communication with a heating element 23, preferably by passing through a heater block 22 that may optionally be positioned within the blast tube 14. A nozzle mount 24 may be used to provide fluid communication between the air supply line 18 and fuel supply line 13.

In some embodiments, the device 100 may comprise a blast tube tip 27. A blast tube tip 27 may extend from the second end 39 and be made from or comprise a material, such as stainless steel, that is of greater heat resistance than the blast tube 14. Generally, a blast tube tip 27 may direct air exiting the second end 39 towards a combustion chamber while allowing the second end 39 to remain relatively farther from the combustion chamber than the blast tube tip 27. In preferred embodiments, the device 100 may comprise a removable stainless-steel blast tube tip 27 is coupled to the blast tube 14 by set screws just inside the end of the blast tube 14 or any other suitable coupling method and is better able to withstand any reflective heat radiating out of the equipped combustion chamber than the blast tube 14. Preferably, a blast tube tip 27 may be generally cylinder shaped or cone shaped to increase the speed of the air exiting the blast tube 14 via the blast tube tip 27.

In some embodiments, the device 100 may comprise a swirl ring 26. A swirl ring 26 may comprise one or more vanes 41 and/or swirl channels 40. In preferred embodiments, which may direct air flowing past the vanes and through the swirl channels 40. In preferred embodiments, the vanes 41 may be angled relative to each other, similar to a fane blade or turbine blade arrangement, to direct air flowing past and through the vanes 41 in a spiral or cyclonic manner as perhaps best shown in FIG. 6

A swirl ring 26 may be located within the blast tube 14. In some embodiments, a swirl ring 26 may comprise a swirl ring aperture 46 which may be size and shaped to allow portions of the nozzle 21, nozzle mount 24, fuel supply line 13, air supply line 18, and/or other components to be inserted through the swirl ring aperture 46. In preferred embodiments, a swirl ring 26 may be positioned in the blast tube 14 between the air blower 9 and the nozzle 21. In further preferred embodiments, a swirl ring 26 may be mounted within the blast tube 14 proximate to the second end 39, just behind the nozzle 21 (closer to first end 38). The swirl ring 26 may directs low pressure/high volume air from the air blower 9 in a cyclic flow that encapsulates the aerosol fuel mixture exiting the nozzle 21, stabilizing the flame body and providing additional combustion air as needed. The volumetric flow rate of combustion air can be adjusted using a set of fine and/or coarse dampers 9 which may be mounted on the blower inlet or otherwise coupled to the air blower 9. Preferably, combustion air flow may be controlled by opening or closing a set of fine/coarse dampers 9 mounted proximate to the blower 14 inlet. Combustion air flow may be given a cyclonic spin due to the swirl ring 26 mounted inside the blast tube 14 as the air passes through or around the vanes 41. Opening the air flow dampers 9 provides significantly more oxygen to the flame, creating an oxidizing environment within the combustion chamber.

As perhaps best shown in FIG. 6, in preferred embodiments, the high-pressure air may exit the nozzle with the fuel 44 in a first direction 71, and air 45 motivated through the blast tube 14 by the air blower 9 may pass around the nozzle 21 in a second direction 72 that is substantially parallel to the first direction 71. Generally, the device 100 may comprise an axis 81 which the nozzle 21 and second end 39 and/or blast tube tip 27 may be aligned with. The axial channels 33 of the nozzle 21 may also direct the high-pressure and fuel 44 exiting the nozzle 21 in a spiral or cyclonic manner generally around the axis 81 in a first direction 71, and a swirl ring 26 may direct air flowing past and through the vanes 41 in a spiral or cyclonic manner generally around the axis 81 in the second direction 72.

The device 100 may comprise a control box 3 which may house one or more electrical or other control components which may be used to control the functions of the device 100. A control box 3 may be configured in any size and shape. In preferred embodiments, a control box 3 may comprise an approximately 6 inch by 9 inch NEMA 3× watertight control box or the like.

In some embodiments, the device 100 may comprise a temperature controller 15 which may be configured to govern the temperature of the heating element 23. In preferred embodiments, a temperature controller 15 may be coupled to or housed in a control box 3. In further preferred embodiments, a control box 3 may incorporate a temperature controller 15, such as a ColdFusionX JLD612 PID Temperature Controller, that may be used to display and maintain the temperature of a heating element 23, such as a 300 w cartridge heater, mounted within the heater block 22. In some embodiments, the device 100 may comprise a second temperature controller 15 may be used to display the internal temperature of a furnace or forge being fired by the nozzle 21.

In some embodiments, the device 100 may comprise one or more control inputs 42 that a user may interact with, such as turnable control knobs, a key pad, slide type switches, rocker type switches, toggle switches, rocker switches, illuminated rocker switches, push button or depressible button type switches, rotary switches, electromechanical relays, solid state relays, touch sensitive interfaces, and combinations thereof whether they are normally open, normally closed, momentary contact, latching contact, single pole, multi-pole, single throw, or multi-throw, touch screen graphical user interfaces (GUI), or any other suitable input that may be used to modulate electricity between components or to otherwise control functions of components of the device 100.

In some embodiments, the device 100 may comprise a heater control input 42A which may be configured to control power to the heating element 23. In further embodiments, the device 100 may comprise a pump/blower control input 42B which may be configured to control power to an integrated fuel pump 12 and air blower 9 (FIG. 8), and the pump/blower control input 42B may optionally also operate the air supply valve 7. In other embodiments, the device 100 may comprise separate control inputs 42 to separately a control fuel pump 12 and an air blower 9 (FIG. 7). In some embodiments, the device 100 may comprise a fuel transfer input 42C which may be used to control the operation of a fuel transfer pump 2. In further embodiments, the device 100 may comprise an air control input 42D which may be operable to control an air supply valve 7, such as a solenoid type air supply valve 7.

In some embodiments, one or more control inputs 42, 42A, 42B, 42C, 42D, may be configured as simple on/off switches. In other embodiments, one or more control inputs 42, 42A, 42B, 42C, 42D, may be configured to provide control over the functions of the components that they are operable to control.

In some embodiments, the device 100 may be configured as an “attended device”, requiring constant supervision during operations. Ignition of the fuel stream may be provided by an external ignition source, as the device 100 may not incorporate an internal ignition mechanism.

In further embodiments, the device 100 may be configured with a processing unit 50 which may be configured to provide an automatic control system to monitor and control one or more operations of the device 100 and optionally provide automatic relight capability. FIG. 9 shows a block diagram of an example of an optional processing unit 50 according to various embodiments described herein. In some embodiments and in the present example, the device 100 can be a digital device that, in terms of hardware architecture, comprises a processing unit 50 which generally includes a processor 51, input/output (I/O) interfaces 52, an optional radio 53, a data store 54, and memory 55. It should be appreciated by those of ordinary skill in the art that FIG. 9 depicts the processing unit 50 in an oversimplified manner, and a practical embodiment may include additional components or elements and suitably configured processing logic to support known or conventional operating features that are not described in detail herein.

The components of a processing unit 50 and other electronic components of the device 100 may be communicatively coupled via a local interface 58. The local interface 58 can be, for example but not limited to, one or more buses or other wired or wireless connections, integrated circuits, etc., as is known in the art. The local interface 58 can have additional elements, which are omitted for simplicity, such as controllers, buffers (caches), drivers, repeaters, and receivers, among many others, to enable communications. Further, the local interface 58 may include address, control, and/or data connections to enable appropriate communications among the aforementioned components.

The processor 51 is a hardware device for executing software instructions. The processor 51 can be any custom made or commercially available processor, a central processing unit (CPU), an auxiliary processor among several processors associated with the processing unit 50, a semiconductor-based microprocessor (in the form of a microchip or chip set), or generally any device for executing software instructions. When the processing unit 50 is in operation, the processor 51 is configured to execute software stored within the memory 55, to communicate data to and from the memory 55, and to generally control operations of the device 100 pursuant to the software instructions. In an exemplary embodiment, the processor 51 may include a mobile optimized processor such as optimized for power consumption and mobile applications.

The I/O interfaces 52 can be used to input and/or output information and power. In some embodiments, I/O interfaces 52 may include one or more turnable control knobs, depressible button type switches, a key pad, slide type switches, dip switches, rocker type switches, rotary dial switches, numeric input switches or any other suitable input which a user may interact with to provide input. In further embodiments, I/O interfaces 52 may include one or more light emitting elements or other display device, e.g., a LED (light emitting diodes), a speaker, or any other suitable device for outputting or displaying information. The I/O interfaces 52 can also include, for example, a serial port, a parallel port, a small computer system interface (SCSI), an infrared (IR) interface, a radio frequency (RF) interface, a universal serial bus (USB) interface, and the like.

A radio 53 enables wireless communication to an external access device or network. In preferred embodiments, a radio 53 may operate via WiFi communication standards. In further embodiments, a radio 53 may operate on a cellular band and may communicate with or receive a Subscriber Identity Module (SIM) card or other wireless network identifier. Any number of suitable wireless data communication protocols, techniques, or methodologies can be supported by the radio 53, including, without limitation: RF; IrDA (infrared); Bluetooth; ZigBee (and other variants of the IEEE 802.15 protocol); IEEE 802.11 (any variation); IEEE 802.16 (WiMAX or any other variation); Direct Sequence Spread Spectrum; Near-Field Communication (NFC); Frequency Hopping Spread Spectrum; Long Term Evolution (LTE);

cellular/wireless/cordless telecommunication protocols (e.g. 3G/4G, etc.); wireless home network communication protocols; paging network protocols; magnetic induction; satellite data communication protocols; wireless hospital or health care facility network protocols such as those operating in the WMTS bands; GPRS; proprietary wireless data communication protocols such as variants of Wireless USB; and any other protocols for wireless communication.

The data store 54 may be used to store data. The data store 54 may include any of volatile memory elements (e.g., random access memory (RAM, such as DRAM, SRAM, SDRAM, and the like)), nonvolatile memory elements (e.g., ROM, hard drive, tape, CDROM, and the like), and combinations thereof. Moreover, the data store 54 may incorporate electronic, magnetic, optical, and/or other types of storage media.

The memory 55 may include any of volatile memory elements (e.g., random access memory (RAM, such as DRAM, SRAM, SDRAM, etc.)), nonvolatile memory elements (e.g., ROM, hard drive, etc.), and combinations thereof. Moreover, the memory 55 may incorporate electronic, magnetic, optical, and/or other types of storage media. Note that the memory 55 may have a distributed architecture, where various components are situated remotely from one another, but can be accessed by the processor 51. The software in memory 55 can include one or more software programs, each of which includes an ordered listing of executable instructions for implementing logical functions.

In the example of FIG. 9, the software in the memory system 55 includes a suitable operating system (O/S) 56 and programs 57. The operating system 56 essentially controls the execution of input/output interface 52 functions, and provides scheduling, input-output control, file and data management, memory management, and communication control and related services. The operating system 56 may be, for example, LINUX (or another UNIX variant), Android (available from Google), Symbian OS, Microsoft Windows CE, Microsoft Windows 7 Mobile, iOS (available from Apple, Inc.), webOS (available from Hewlett Packard), Blackberry OS (Available from Research in Motion), Raspbian (available from the Raspberry Pi Foundation) and the like. The programs 57 may include various applications, add-ons, etc. configured to provide end user functionality with the device 100. For example, exemplary programs 57 may include, but not limited to, environmental variable analytics and modulation of input/output interface 52 functions. In a typical example, the end user typically uses one or more of the programs 57 to control functions of the device 100, such as to provide a neutral, oxidizing, or reducing combustion environments via the fuel combustion of the device 100.

Further, many embodiments are described in terms of sequences of actions to be performed by, for example, elements of a computing device. It will be recognized that various actions described herein can be performed by specific circuits (e.g., application specific integrated circuits (ASICs)), by program instructions being executed by one or more processors, or by a combination of both. Additionally, these sequences of actions described herein can be considered to be embodied entirely within any form of computer readable storage medium having stored therein a corresponding set of computer instructions that upon execution would cause an associated processor to perform the functionality described herein. Thus, the various aspects of the invention may be embodied in a number of different forms, all of which have been contemplated to be within the scope of the claimed subject matter. In addition, for each of the embodiments described herein, the corresponding form of any such embodiments may be described herein as, for example, “logic configured to” perform the described action.

The processing unit 50 may also include a main memory, such as a random-access memory (RAM) or other dynamic storage device (e.g., dynamic RAM (DRAM), static RAM (SRAM), and synchronous DRAM (SDRAM)), coupled to the bus for storing information and instructions to be executed by the processor 51. In addition, the main memory may be used for storing temporary variables or other intermediate information during the execution of instructions by the processor 51. The processing unit 50 may further include a read only memory (ROM) or other static storage device (e.g., programmable ROM (PROM), erasable PROM (EPROM), and electrically erasable PROM (EEPROM)) coupled to the bus for storing static information and instructions for the processor 51.

In some embodiments, the processing unit 50 may include automatic control of the fuel transfer pump 2, using a pressure sensor, float, or other device to determine the fuel level of the fuel tank 31, an LED scale mounted on the control box for a visual indication of fuel level, and the processing unit 50 may interpret the sensor signal and initiate operations. An example processing unit 50 may comprise a Raspberry Pi Zero, although other processing units/controllers may be used.

The device 100 may comprise or be in communication with a power source 43 which may provide electrical power to any component that may require electrical power. In some embodiments, a power source 43 may comprise a battery, such as a lithium ion battery, nickel cadmium battery, alkaline battery, or any other suitable type of battery, a fuel cell, a capacitor, a super capacitor, or any other type of energy storing and/or electricity releasing device. In further embodiments, a power source 43 may comprise a power cord, such as used with 120-volt, 240 volts, or any other power supply, kinetic or piezo electric battery charging device, a solar cell or photovoltaic cell, and/or inductive charging or wireless power receiver. In further embodiments, a power source 43 may comprise a power charging and distribution module which may be configured to control the recharging of the power source 43, discharging of the power source 43, and/or distribution of power to one or more components of the device 100 that may require electrical power.

In preferred embodiments, once the device 100 has been filled with fuel and connected to a high-pressure air source 32 and power source 43, exemplary device 100 operations may be as follows:

Open one or more fuel supply isolation valves to allow fuel to flow from the fuel tank 31 to the fuel pump 12.

Set the air regulator 16 to approximately 20 psig.

Move the heater control input 42A to the ON position, delivering power to both the temperature controller 15 and the heating element 23.

Allow the heater block 22 to reach its setpoint temperature (typically 200° F.) as displayed on the temperature controller 15.

Move the pump/blower control input 42B to the ON position. This action may send two signals. One signal opens the air supply valve 7, allowing high-pressure air to begin flowing to the atomizing nozzle 21. The other signal closes a relay optionally within the control box 3 to provide power to the blower/pump motor 29, causing both the combustion air blower 9 to exhaust air down the blast tube 14, and the fuel pump 12 to deliver fuel to the atomizing nozzle 21.

Open the fuel supply valve 11 one full turn or as desired.

Open the fuel recirculation valve 10 approximately ¼ turn or as desired.

Ignite the fuel/air mixture exiting the nozzle 21 by placing a propane torch or other combustion source near the second end 39 of the blast tube 14.

After ignition, adjust the fuel supply valve 11 as needed to create the appropriate oxidizing, reducing, or neutral combustion environment.

Adjust the fuel recirculation valve 10 as needed to regulate fuel delivery pressure and control flame body length.

Adjust the atomizing air pressure using the air regulator 16, as needed to increase combustion efficiency and maximize heat rate.

Adjust the combustion air flow using the fine and coarse air dampers 28 located on the air blower 9, to control the shape and length of the flame body as dictated by the dimensions of the combustion chamber.

While some exemplary shapes and sizes have been provided for elements of the device 100, it should be understood to one of ordinary skill in the art that the support structure or frame 30, blast tube 14, control box 3, and any other element described herein may be configured in a plurality of sizes and shapes including “T” shaped, “X” shaped, square shaped, rectangular shaped, cylinder shaped, cuboid shaped, hexagonal prism shaped, triangular prism shaped, or any other geometric or non-geometric shape, including combinations of shapes. It is not intended herein to mention all the possible alternatives, equivalent forms or ramifications of the invention. It is understood that the terms and proposed shapes used herein are merely descriptive, rather than limiting, and that various changes, such as to size and shape, may be made without departing from the spirit or scope of the invention.

Additionally, while some materials have been provided, in other embodiments, the elements that comprise the device 100 may be made from or may comprise durable materials such as aluminum, steel, other metals and metal alloys, wood, hard rubbers, hard plastics, fiber reinforced plastics, carbon fiber, fiber glass, resins, polymers or any other suitable materials including combinations of materials. Additionally, one or more elements may be made from or may comprise durable and slightly flexible materials such as soft plastics, silicone, soft rubbers, or any other suitable materials including combinations of materials. In some embodiments, one or more of the elements that comprise the device 100 may be coupled or connected together with heat bonding, chemical bonding, adhesives, clasp type fasteners, clip type fasteners, rivet type fasteners, threaded type fasteners, other types of fasteners, or any other suitable joining method. In other embodiments, one or more of the elements that comprise the device 100 may be coupled or removably connected by being press fit or snap fit together, by one or more fasteners such as hook and loop type or Velcro® fasteners, magnetic type fasteners, threaded type fasteners, sealable tongue and groove fasteners, snap fasteners, clip type fasteners, clasp type fasteners, ratchet type fasteners, a push-to-lock type connection method, a turn-to-lock type connection method, a slide-to-lock type connection method or any other suitable temporary connection method as one reasonably skilled in the art could envision to serve the same function. In further embodiments, one or more of the elements that comprise the device 100 may be coupled by being one of connected to and integrally formed with another element of the device 100.

Although the present invention has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present invention, are contemplated thereby, and are intended to be covered by the following claims.

High Temperature Combustion Device

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Provisional Applications (1)