The present invention relates to fuel transport, and more particularly, is related to conveying solid fuel.
Solid fuel material is used in many applications. For example, combustible materials may be pelletized to simplify handling, transport and use. Examples of solid fuel material include coal, grains, wood chips and fuel pellets. Handling of solid fuel material for solid fuel burners provides unique challenges. The solid fuel should be continuously fed to the burner to maintain constant heat output and high efficiency. While liquid fuel or gas and propane burners may be regulated by forcing the fuel by pressure or by gravity, solid fuel feeders typically require mechanical means to transport fuel from a solid fuel hopper to the burner. Examples include augers and conveyor belts. These mechanical solid fuel feeders add costs to the burner, consume energy and require maintenance.
In addition to requiring a constant flow of fresh solid fuel, the spent fuel in a solid fuel burner should be removed. As used within this disclosure, the term “spent fuel” may refer to fuel that has been only partially combusted, or may refer to fuel that has been entirely combusted, for example in the form of fly ash, heavy ash, and/or clinkers. When many forms of solid fuel are burned, they produce particle emissions, known a fly ash, and leave spent fuel behind, known as heavy ash. The heavy ash can clog the airways required in the burner for efficient combustion. Therefore, the heavy ash should be systematically removed as fresh solid fuel is replenished. Heavy ash that is exposed to high heat may fuse, forming clinkers. Partially consumed fuel should not be removed until the combustible material in the solid fuel is fully spent. Mechanized conveyor methods may thus be monitored so the solid fuel is not fed through the burner too quickly, resulting in removing unspent fuel and producing additional waste material, or removing spent fuel too slowly, reducing burner efficiency.
In solid fuel combustion systems, “under air” refers to air that passes generally upward from beneath the fuel and up through the fuel, while “over air” refers to air that passes near or above the top of the fuel. Solid fuel is typically burned using a combination of under air and over air. Adjusting the amount of air, both over air and under air, can achieve higher or lower firing rates with the same size grate. There are both maximum and minimum limitations to the amount of air that can be introduced to a particular sized grate.
The heavy ash should be cleared from the burner to make way for fresh solid fuel. A known method for removing ash from a burner is to agitate the burning surface, or grate, so that the spent ash drops away through openings in the grate. However, such agitating grates have heretofore been excessively power consuming, complex, and expensive, making them impractical for some applications, for example, domestic or other low cost installations. Therefore a need exists for a simple, low power agitating grate.
Embodiments of the present invention provide a moving grate device, method and system for combustion. Briefly described in architecture, a first aspect of the present invention is directed to an agitating grate, with a movable grate element. The movable grate element includes a solid fuel supporting surface, a bottom surface disposed substantially opposite the solid fuel supporting surface, a first side, a second side opposite the first side, a cam end, a slide end opposite the cam end, a cam bore disposed substantially at the cam end, the cam bore passing through the movable grate element between the first side and the second side. A first rotating camshaft is disposed through the cam bore. A first cam is disposed upon the first rotating camshaft within the cam bore. A camshaft drive is configured to rotate the first rotating camshaft.
Briefly described, a second aspect of the invention is directed to a method for agitating a burner grate, including the steps of providing a camshaft, providing a movable grate element having a cam end, a slide end, a cam bore disposed substantially at the cam end, and a slide bore disposed substantially at the slide end, providing a cam disposed along the rotating camshaft, the cam disposed within the cam bore in the movable grate element, and rotating the camshaft with a camshaft drive.
A third aspect, briefly described, is directed to a solid fuel transport and system. The system includes a solid fuel feeder having a chute configured to accommodate a solid fuel pile having a solid fuel surface, and a conveyer configured to receive solid fuel from the solid fuel feeder and convey the solid fuel away from the solid fuel feeder and convey the solid fuel to a destination.
Other systems, methods and features of the present invention will be or become apparent to one having ordinary skill in the art upon examining the following drawings and detailed description. It is intended that all such additional systems, methods, and features be included in this description, be within the scope of the present invention and protected by the accompanying claims.
The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principals of the invention.
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.
Exemplary embodiments of a low power agitating burner grate are presented. In one exemplary embodiment, solid fuel may be conveyed from a hopper to the surface of an agitating grate, where combustion of the solid fuel occurs. The burner may be incorporate an updraft burner, where flames are drawn upward from the burner grate, or a downdraft burner, where flames are drawn downward through the bottom of the burner grate, for example, by an impelled air flow. When solid fuel is burned on the grate, the ash is removed. Fuel and ash from consumed fuel may be further conveyed by the movement of the low power movable grate. One or more cams deployed on a camshaft positioned through apertures in grate elements may cause the grate elements to move and convey fuel in a desired direction, and may similarly break up ash to facilitate removal.
While air passages 550 may serve to provide an outlet for hard ash to fall through the grate elements 510, 520 after the solid fuel is spent, it may be preferable that the ash be conveyed to an ash collection area at the end of the grate 500. It should be noted that while the spent fuel is generally referred to herein as ash, persons having ordinary skill in the art will recognize the spent fuel may take on other forms, such as fused ash or melted ash (clinker), and/or unspent fuel.
The grate elements 510, 520 may be supported by one or more substantially horizontal support rods 526, which may be held in place with a securing mechanism, for example, a retaining spring 527. For example, the retaining springs 527 may be any type of spring or flexible material to maintain a light pressure against the two outer stationary elements 510 to ensure all the elements 510, 520 remain in close proximity with each other. The retaining springs 527 allow for expansion and contraction as the elements 510, 520 heat and cool all the while remaining juxtaposed.
The support rods 526 may pass through a grate aperture 525 in the fixed grate element 510, and may similarly pass through a slide aperture 560 (
While the first embodiment of the low power agitating grate 500 has fixed grate elements 510 held in place with a support rod passing through the fixed grate elements 510, there is no objection to other embodiments having different means for holding fixed grate elements 510 in place, for example, a clamp or bracket at the end of the fixed grate element 510, or other mechanisms, such as pins, screws, or bolts. In such embodiments, there may be no need for a support rod, so the support rod aperture 527 may be omitted. The slide aperture 560, depicted in
The slide aperture 560 may be configured be at a variety of angles with respect to the surface of the element 520 or parallel with the surface of the movable element 520 to give the desired effect. As shown in
The top surface of the movable grate elements 520 may be formed to have shapes such as a sawtooth profile to aid in moving material forward. The top surface of the grate elements 510, 520 may be shaped differently in different portions of the grate to affect different results. For example, there may be a first surface contour for use in a fuel burning portion, and/or a second surface contour used in an ash conveying portion. Irregular shapes in the fuel burning portion may conduct more heat into the grate elements 510, 520, which may not be desirable. The entire grate 500 may be oriented in a substantially horizontal fashion, or angled somewhat in an upward or downward orientation, depending on the type of solid fuel being burned and the desired results.
The movable grate element 520 has a cam aperture 570. In the first embodiment of the agitating grate 500 (
The cam lobes 535 may generally be timed differently to prevent all movable elements 520 (
The cams 535 may be oriented so the top surface of each of the movable grate elements 520 (
A snapshot detail of the end of a second embodiment of a moving grate 500 is shown by
In the second embodiment, each movable grate element 520 is separated by a fixed grate element 510. As pictured, the rotation of the cam shaft assembly 590 positions a first moving grate element 520A relatively high above the surface plane of the fixed grate elements 510. A second moving grate element 520B is positioned somewhat lower in elevation compared to the first moving grate element 520A. Similarly, a third moving grate element 520C is shown at a position with an elevation below the fixed grate elements 510, and a fourth moving grate element 520D is shown with an elevation essentially coplanar with the fixed grate elements. Similarly, the movable grate elements 520 move laterally back and forth in relation to one another and the fixed grate elements 510. The up and down movement of the movable grate elements 520 helps break up ash and keep ash broken up as it is conveyed, also helping prevent bridging across the entire grate 500. An opening at the end of the firebox 130 (
The motion of the movable grate elements 520 in relation to one another and the fixed grate elements 510 may assist in breaking up heavy ash and/or clinkers on the surface of the grate 500. In addition, the agitating motion of the movable grate elements 520 may convey items upon the grate surface, for example clinkers and/or solid fuel, in a desired direction.
It should be noted that while the embodiment shown in
The motion of a movable grate element 520 is generally periodic, with the period equal to the time for the cam shaft 530 to make a single rotation. A first cam 535 may be oriented differently from a second cam 535, so the motion of an associated first movable grate element 520 is different from the motion of a second movable grate element 520. For example, if the first cam 535 and the second cam 535 are similarly shaped, a curve showing the motion of the first movable grate element 520 would differ from a curve showing the motion of the second movable grate element 520 only by the relative phases. The orientation of adjacent cams 535 may be adjusted to provide for variations in relative movements of adjacent grate elements. Similarly, cams 535 may be of different shapes and sizes to vary the movement cycles of individual grate elements. Note that while the discussion of the periodic movement of cams and grate elements assumes a constant rate of rotation of the cam shaft 530, there is no objection to the cam shaft 530 rotating at an irregular rate, or to sporadically or periodically start and stop rotation of the cam shaft 530.
The motion of the grate elements 520 need not be rapid, only fast enough to break up friable ash of spent solid fuel. The speed the rotating camshaft 530 may be relatively low, for example, on the order of one rotation every 5-10 seconds. However, there is no objection to rotating the camshaft 530 at a higher or lower speed. Similarly, as noted above, the grate elements may not need to be in continuous operation. For example, the grate 500 may generally remain stationary and be periodically activated for short time intervals to remove ash and/or advance fresh fuel to the burner. Indeed, in a system where the grate 500 is used with the gravity feed pellet feeder (described below), it may be preferable that the grate 500 may remain stationary except when a buildup of ash should be removed, as the conveyance of solid fuel by the grate 500 may counteract the desired burn rate characteristics of the gravity feed pellet feeder.
While it is preferable to convey ash from the burner by the agitating motion of the grate 500, once fragmented, the ash may fall through the air passages 550 (
In alternative embodiments, the fixed grate elements 510 may have air passages 550 formed in them. The combustion air passageways are recommended to be put into the moving elements, such that they are adjacent and open to the next element. This helps prevent material from plugging the passageways, as the movement can aid in breaking up trapped material.
In further alternative embodiments, all of the grate elements may be movable grate elements 520, with no fixed grate elements 510 used. Movable grate elements 510 may be arranged to alternate with fixed grate elements 520, or adjacent movable grate elements 510 may be used in the grate 500, occasionally interspersed with a fixed grate element 520. Of course, other combinations of fixed and movable grate elements 510, 520 may be used depending on the specific application for the grate 500.
A first exemplary embodiment of a solid fuel feeding system 300 is shown in
A second exemplary embodiment of a pellet feeding system 600 is shown in
Additional embodiments are also possible, for example, where the burner 320 is a downdraft burner, so that flames pass downward through the grate 500. Similarly, the bottom of the pellet feeder 400 may be adjacent to the grate 500, rather than incorporating the grate 500 as the floor of the pellet feeder 400 itself. In other embodiments, a second agitating grate may serve as the mechanized conveyer 620.
It should be noted the number of stationary elements between the moving elements may vary among embodiments, for example, a stationary element may be between all moving elements in some embodiments, while all elements could be moving in another embodiment. Each stationary element may be fixed in space. Each moving element may be fixed on a slide. It may be desirable for gap between adjacent elements to allow for expansion and contraction of the elements, for example, due to heat. The combustion air passing through the elements is generally preheated by the elements which my aid in combustion. Air generally passes through the firebox at a specifically engineered location for the over air, which is commonly used in solid fuel combustion.
The first exemplary method includes the step of providing a camshaft, as shown by block 710. A step includes providing a movable grate element with a cam end, a slide end, a cam bore disposed substantially at the cam end, and a slide bore disposed substantially at the slide end, as shown by block 720. A cam disposed along the rotating camshaft is provided, the cam disposed within the cam bore in the movable grate element, as shown by block 730. The camshaft is rotated with a camshaft drive, as shown by block 740. The camshaft drive may be a motor, as shown by block 750.
In summary, low power apparatuses for solid fuel feeding and an agitated burner surface have been presented. It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.