Heating, Ventilation and Air-Conditioning (HVAC) are standard in virtually every modern building. Indeed, HVAC is often the largest part of the entire energy budget of most buildings, and this is particularly the case in extreme climates, both hot and cold. The goal of HVAC systems is to provide comfortable and healthy conditions for the building occupants, in terms of temperature, humidity, composition and cleanliness of the air.
Central HVAC systems typically include one or more central air handling unit and an air distribution system, where supply air is directed to the various parts of the building through a network of ducts, and return air flows from these spaces, through ducts or a plenum, back to the air handling unit. In the air handling unit, air is cooled or heated, as well as filtered and often dehumidified or humidified, as needed. Thus HVAC systems constantly circulate air through the building while continually adjusting is temperature and humidity to maintain comfortable conditions.
However, in order to maintain good air quality, not all the air is recirculated: some fraction of the circulating air is constantly exhausted outside the building—hence exhaust air—and is replaced by an intake of outside air also known as makeup air, to make up for the exhaust air. In other places this is also referred to as “fresh air” or ventilation. This replacement of the air is done because the occupants of the building and the equipment consume oxygen and emit carbon dioxide (CO2) and a variety of other contaminants that would gradually compromise the quality and safety of the air. This replacement of the air maintains fresh air quality.
Oxygen represents about 21% of atmospheric air and that is normally the desired level of indoor air as well. On the other hand CO2 is present only in very low levels in outside air, typically a few hundred ppm (parts per million). Once breathing produces elevated levels of CO2 and some of the indoor oxygen is consumed, a fairly significant amount of outside air is used to bring their respective concentrations close to the desired level. Indeed, to fully restore oxygen and CO2 concentration virtually all the air would need to be replaced.
The outside air represents an additional, and—depending on outside climate conditions—often a significant, thermal load on the air handling unit. In the case of a hot and humid climate, for example, the outside air injected into the HVAC system requires additional energy for cooling and dehumidifying the outside air, and can represent a significant fraction of the entire thermal load, hence energy usage, of the HVAC system.
The amount of exhaust air and outside air can adjusted to meet the air quality standards. A certain minimum amount is often set to maintain air quality, in terms of levels of oxygen, CO2 and other contaminants. In the USA, the American Society of Heating, Refrigeration and Air-conditioning Engineers (ASHRAE) issues guidelines for the minimum amount of outside air ventilation recommended for a given space and number of occupants. However, the greater the rate of air replacement, the more energy is consumed by the HVAC system.
The amount of supply air used by an HVAC system, and hence the amount of energy used for heating and cooling, while maintaining desirable air quality and composition, is reduced by removing unwanted gases, such as carbon dioxide (CO2), using scrubbers or other devices that separate these gases from the circulating air. Optionally, the air can be further improved with injection of concentrated oxygen. While in a normal HVAC system frequent extensive replacement of the building air is performed, scrubbing of CO2 and other unwanted gases and vapors, with or without additional oxygen, would achieve the same goal, but with much lower thermal load on the HVAC system, providing significant energy saving for the building and reducing demands on the entire electrical grid.
In one embodiment, the HVAC system also has an oxygen injection system that injects oxygen-enriched air into the circulated air.
In one embodiment, a control system for use with an HVAC system has a gas scrubbing system for removal of an unwanted substance gas from circulated air. The control system includes a sensor for determining an amount of the unwanted substance gas in the circulated air. controller modifies a rate of exhaust of circulating air and intake of outside air so as to adjust overall air replacement according to the measured amount of unwanted substance gas in the circulated air. The control system also can include an oxygen sensor for determining an amount of oxygen in circulated air, and wherein the controller modifies the rate of oxygen injection.
In another embodiment, the system is a modular system can be connected to an HVAC system that circulates air in an enclosed environment. The modular system comprises a module for scrubbing configured to reduce a level of an unwanted substance in the circulating air.
The enclosed environment can be an office building, commercial building, residential building, house, school, factory, hospital, store, mall, indoor entertainment venue, storage facility, laboratory, vehicle, aircraft, ship, bus, theatre, enclosed arena, education facility, library or other enclosed structure which can be at times occupied by breathing things, such as humans or animals.
In one embodiment the CO2 scrubber utilizes a bed of adsorbent material, such as synthetic zeolite, placed in a container, canister or lining the inside of one or more tubes. Several zeolites have been shown to be effective adsorbents of CO2, notably zeolite-13X. These are readily available from a variety of commercial sources, such as W.R. Grace SYLOBEAD® C-Grade 13X, Pingxiang XINTAO Chemical Packing Co., Ltd. In China, GHCL Ltd., in India, and many others. Indeed, zeolite beds have been developed to extract CO2 from a gas stream for various industrial applications (Ventriglio et al, 1968; U.S. Pat. No. 3,619,130; Reyhing et al, 1971, U.S. Pat. No. 3,808,773; Collins, 1972, U.S. Pat. No. 3,751,878; Shermen et al, 1974, U.S. Pat. No. 3,885,927; Sirkar et al, 1979, U.S. Pat. No. 4,249,915; Grenier et al, 1991, U.S. Pat. No. 5,137,548). The same underlying technologies can readily be adopted for this invention, which in fact is more forgiving in terms of the allowed residual CO2 in the outflow. In certain embodiments adding other adsorbents, including multiple zeolites, porous alumina (Slaugh et al, 1981, U.S. Pat. No. 4,433,981; Kumar et al, 1986, U.S. Pat. No. 4,711,645) or the long established activated charcoal (Allen, 1921, U.S. Pat. No. 1,522,480; Bechthold, 1927, 1,836,301) may further improve air quality or energy efficiency by removing other gases, volatile organic compounds and humidity or by allowing lower-temperature release of adsorbates. In some embodiments the combination of several different adsorbents in the same unit or as separate units may offer the best performance. As such captured gases accumulate in the scrubber, at some rate these need to be removed from the scrubber, in what is commonly called “regeneration”. These unwanted gases can be released to the atmosphere or otherwise collected and disposed of or sequestered. In one embodiment the release is achieved by a combination of heating and purging with air or other purge gas. Thus an adsorption-desorption cycle sometimes referred to as temperature swing adsorption. During regeneration the scrubber is isolated from the HVAC circulation by a set of valves, shown in
The scrubber adsorbent bed design will include the appropriate choice of adsorbent material, its amount, its spatial distribution, the air flow pattern and its overall capacity to be compatible with the airflow design requirements. There are tradeoffs to consider in terms of system size and cost versus throughput, frequency of regeneration and energy requirements for regeneration. The amount of CO2 that can be collected and released in each temperature swing adsorption cycle is dependent on the amount of active and accessible adsorbent material, as well as the temperature gap between the adsorption and purge cycle. Thus to achieve a certain rate of gas capture one use less material and operate with more frequent purge cycles. However there are natural kinetic rates for adsorption and desorption that depend on material and temperature that constrain the cycle time for a given amount of material. To minimize the energy required, i.e. the energy required to heat the purge gas, one would design a lower purge gas temperature, however that would reduce the amount desorbed per cycle. In an application that is primarily driven by energy savings, one can start with the temperature and volume of purge gas that can be produced by the excess heat of the HVAC system and use that to design the thermal range of the temperature swing cycle, and based on that and the kinetics of the adsorbent design the dimensions of the bed. It is anticipated that different embodiments will be implemented in different settings to address these tradeoffs.
Solid adsorbents like zeolite 13X offer a preferred embodiment but there are many other ways to remove CO2 as well as other unwanted gases and vapors. In other embodiments CO2 scrubbing is achieved by reactions with alkaline hydroxide bases. In another embodiment CO2 scrubbing is achieved with amine gas solutions, such as monoethanolamine or other amines, that are well known in the art. Another embodiment scrubbing is achieved by a chemical cycle in which sodium carbonate combines with carbon dioxide and water to form sodium bicarbonate (Fuchs, 1967 U.S. Pat. No. 3,511,595). Yet other techniques for removal of CO2 include selective membranes, for example, PRISM membranes from Air Products, Inc, or CYNARA membranes from Cameron International Corp. Since the scrubber is a separate module in this systems, as new scrubbing technologies emerge they can readily be replaced in such a system without having to change its other components.
The scrubber will have to be regenerated and many of the above techniques require heat for regeneration. Some of that heat can be obtained by harvesting waste heat produced by other systems nearby, including the compressor and the air handling unit of the HVAC system, as well as solar energy. This could further improve the overall economics of the system. In certain embodiments the purging of the adsorbent bed utilizes warm air from the cooling unit to purge the bed during regeneration. In some embodiments solar energy is collected on a rooftop unit and used to heat the purge gas. Solar heating and harvesting compressor heat and other wasted heat can be used in combination, to minimize the energy usage of the system as a whole. Independent or additional heating may be performed to achieve a particular purge gas temperature in which case a heating coil, a furnace or a gas burner can be incorporated to the system before the entry point of the purge gas.
The scrubber will collect CO2 and potentially other substances that can be disposed of in various ways. They could be released to the atmosphere, or collected in containers for handling and disposing in another location, or flowed through pipelines to another location or facility, to be stored, processed or utilized. For example, CO2 is beneficial for greenhouses and could be directed to such greenhouses by pipes or by containers. Alternatively these byproduct gases can be sequestered indefinitely simply to avoid releasing them into the atmosphere. However there will be a higher cost to such disposition of these gases and it will not necessarily be economically justifiable to do so.
The oxygen concentrator can be implemented in many ways. In the preferred embodiment, the technique for oxygen concentration is Pressure Swing Adsorption (PSA) or Vacuum Swing Adsorption (VSA). This technique has been known since the 1960's, it is in widespread commercial use today, and is readily available from a variety of producers making many products with different sizes and output capacities, as stand-alone systems for providing concentrated oxygen directly from air. Example VSA oxygen generating systems include, but are not limited to, the PRISM VSA oxygen generation systems from Air Products Inc.; the OXYSWING product line from Innovative Gas Systems, Inc.; the ADSOSS line of oxygen generators from Linde; the VPSA oxygen generating system from Praxair Inc. These PSA/VSA systems utilize highly porous adsorptive solids, usually a synthetic zeolite bed, in one or more container, typically shaped as a cylindrical column, and use pumps and compressors to change the pressure of gases in these containers. The technique relies on differential adsorption of oxygen and nitrogen onto the adsorbent. Thus it takes an inflow of normal air (or other gas mixtures), and generates two separate outputs: oxygen concentrated air and oxygen depleted air. The advantage of PSA/VSA is that these systems can continually generate oxygen for extended periods without much maintenance.
Other ways to separate or concentrate oxygen exist. Cryogenic separation is an effective way for large volumes and high purity, where the different condensation/boiling temperatures of different gases are used to separate oxygen from air. Selective membranes and selective diffusion media have also been developed to separate oxygen from air. Concentrated oxygen can also be generated from electrolysis of water, where electrical current through water generates oxygen gas on one electrode and hydrogen gas at the other. While these are energy intensive processes, pure hydrogen or nitrogen created as by products and can be collected and utilized for other applications.
Even the presence of both the scrubber and the oxygen concentrator does not mean that exhaust air and outside air are necessarily eliminated altogether. In certain embodiments, exhaust air and outside air will be kept at a controlled level, lower than in a conventional HVAC system but a level that would still be warranted or desired in order to assure that there is no gradual deterioration in air quality despite the benefits of the oxygen concentrator and the scrubber.
We describe systems both with and without the oxygen concentrator. Indeed in some embodiments the oxygen concentrator is eliminated, and the use of a scrubber by itself imparts the majority of the benefits. At first glance this may not be obvious, since oxygen consumption and CO2 emission go hand in hand and occur in almost identical molecular quantities, which implies that the drop in oxygen concentration would be commensurate to the rise in CO2 levels, and the sum of the two almost constant. However, as long as makeup air is reduced but not eliminated altogether, even without a scrubber and an oxygen source, the oxygen and CO2 levels will stabilize at certain asymptotical concentrations that together sum up to 21%, the same as that of outside air. The asymptotic level of oxygen, X, is given by
X=X
0
−B
o
/M
Where X0 is the concentration of oxygen in outside-air, Bo is the net amount of oxygen consumed (in CFM, liters/second or any other units) by the occupants and M is the amount of outside air injected (in same units, CFM, liter/second, etc respectively). Similarly CO2 level, Y, would be given by
Y=Y
0
+B
c
/M
where Y0 is the concentration of CO2 in outside-air and Bc is the net amount of CO2 exhaled by the occupants. Looking at the above it is clear that as long as Bc≈Bo, at least approximately, then X+Y≈X0+Y0. However, adding a scrubber that extracts CO2 at a rate of Sc (in same units, CFM, liter/second, etc. respectively) will result in
Y=Y
0+(Bc=Sc)/M
Analogously the impact of an oxygen generator injecting at a net rate of Go (in same units, CFM, liter/second, etc., respectively) would be to change the asymptotic value of X to
X=X
0−(Bo−Go)/M
For example, if outside air is at the normal 21% oxygen, and occupants consume 2 CFM net oxygen and exhale a similar amount of CO2, makeup air is at 100 CFM, and no further scrubbing or oxygenation are in effect, then oxygen will gradually approach 19% while CO2 approaches 2%. But whereas a 19% concentration of oxygen may be acceptable in some circumstances, a 2% concentration of CO2 is clearly not. Thus adding a scrubber with Sc=2 CFM capacity alone could bring CO2 levels down to normal. Oxygen will still be at approximately 19%, unless we inject supplemental oxygen, but even so air quality may be acceptable at this level even without an oxygen source, and would require less hardware and less operating costs, therefore might be a preferred embodiment for some buildings.
The control system can permit the amount of scrubbing or injection of oxygen to be adjustable, whether directly or indirectly, whether electronically or manually. Adjustments can be achieved by changing the power or settings applied to the various compressors, pumps, motors, heaters, actuators or valves associated with the scrubbers and the oxygen concentrators. The adjustments to the amount of scrubbing or oxygen injection can be automatically done in response to a measurement of air quality or air composition in one or more locations. The adjustments to the amount of scrubbing or oxygen injection can also be automatically done based on building occupancy, time of day, day of the week, date, season or outside climate.
In one embodiment, the scrubber is set to run at a constant operating mode. The capacity and efficiency of the scrubber in that mode should be selected based on the occupied space and the amount of activity in the occupied space, so as to maintain desirable levels of CO2 (or other gases). In this embodiment, the control system now controls the rate of exhaust air and outside air to either a preset minimum. If the capacity and efficiency of the scrubber is insufficient to handle the CO2 load, then the rate of exhaust air and outside air can be set to a higher level. The oxygen flow is separately controlled to maintain the target level of oxygen in the occupied space. Both the control of the exhaust air valves and the oxygen inflow can be subject to a simple feedback loop, with a proportional-integral-differential (PID) algorithm with upper and lower set points. The coupling of the oxygen concentrator to the air flow manifold can be done using any tube of duct fitting, with or without a control valve and/or a flow meter.
The system can be designed in a modular way so that it can be retrofitted on a pre-existing or pre-designed HVAC system. This will enable the benefit of this invention in buildings that already have HVAC systems, with relatively lower costs. The oxygen concentrator and scrubber, with a control system, can be installed and connected to a conventional HVAC system without having to replace the ductwork or the central air handling unit.
Having described an example embodiment, it should be apparent to those skilled in the art that the foregoing is merely illustrative and not limiting, having been presented by way of example only. Numerous modifications and other embodiments are with the scope of ordinary skill in the art and are contemplated as falling with the scope of the invention.
This application is a nonprovisional application of, and claims priority to and the benefit under 35 U.S.C. 119 of, provisional patent application 61/345,194, filed May 17, 2010, and provisional patent application 61/351,968, filed Jun. 7, 2010, each of which is hereby incorporated by reference.
Number | Date | Country | |
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61345194 | May 2010 | US | |
61351968 | Jun 2010 | US |