The present invention generally relates to a system for reducing the discharge of pollutants from gasoline storage tanks, typically installed underground, at gasoline distribution facilities (GDFs). More particularly, an active adsorption system discharges non-pollutant air from an associated gasoline tank when the pressure within the tank reaches a predetermined level. Non-pollutant air is separated from a gasoline vapor/air mixture by passage through a container holding an adsorbent material. An electric pump and a network of electrically operated valves connected to the pump and the container are controlled so that non-pollutant air is discharged to the atmosphere and gasoline vapors are retained and recovered into the tank. The system can be controlled in response to pressure within the tank, the level of hydrocarbons in the vapor/air mixture and/or the weight of the adsorbent material within the container.
Pollutant discharge reduction systems are well known and used to reduce pressure that can otherwise buildup within a gasoline storage tank, such as an underground storage tank (UST), without polluting the atmosphere. One variety of known systems uses membranes for the reduction or retention of pollutants. These systems pass the vapor/air mixture from the ullage of a gasoline storage tank through membranes that retain gasoline vapor pollutants within the systems but pass non-pollutant air which is then vented to atmosphere. Membrane systems are exemplified by U.S. Pat. Nos. 5,464,466; 5,571,310; 5,985,002; 6,293,996; and 6,608,484, which are all incorporated by reference herein.
Other systems use adsorbent material, such as activated carbon, to reduce the discharge of pollutants from gasoline storage tanks. Known adsorbent systems used for gasoline storage tanks are passive in that they adsorb and de-adsorb pollutant vapors for associated storage tanks by using storage tank pressure differentials relative to atmospheric pressure to vent out from the storage tank to atmosphere, and vent into the storage tank from atmosphere. Thus, when pressure inside a storage tank increases due to an increase in vapor, the vapor is adsorbed by an appropriate material in a container or canister that is sized to accommodate the associated storage tank. Underground storage tanks (USTs) tend to pressurize during periods of inactivity, such as during the night or when an associated GDF is closed, so that a passive system needs to be sized to be able to adsorb all of the vapor that needs to be collected during this segment of a twenty four hour period.
A passive adsorption system relies on the interaction of onboard refueling vapor recovery (ORVR) compatible vapor recovery systems that are present in GDFs, such as a Balance system commercially available from Vapor Systems Technologies, Inc., the assignee of the present application, to purge the canister daily of the adsorbed vapor. Due to the interaction of the vapor recovery system and ORVR equipped vehicles, no air or vapor is returned to the UST during a vehicle refueling, which tends to reduce the pressure in the UST, typically to a vacuum level. The passive system relies on the tank vacuum to draw air back through the canister and into the UST. The airflow back through the canister tends to de-adsorb the vapor from the adsorbent material.
One drawback to the way that the passive system de-adsorbs vapor from the system is that the air ingestion into the tank during de-adsorption will itself tend to create vapor growth and re-pressurization of the UST. Another negative aspect of the passive system is that it is only applicable to regions that have vehicles with ORVR, such as in the United States, since the passive system relies on the interaction of the vapor recovery system with ORVR equipped vehicles to allow for canister purging.
The active adsorbent pollutant reducing system of the present invention comprises a container or canister that holds an adsorbent material, such as activated carbon, a pump and a series of valves that are connected to the canister and the pump. The valves and pump are controlled so that a vapor/air mixture in the ullage of an associated gasoline storage tank is pumped to the canister for evacuation of non-pollutant air from the tank. During evacuation, the vapor is adsorbed by the adsorbent material in the canister and non-pollutant air which passes through the canister is discharged to atmosphere. Once an amount of non-pollutant air has been removed from the tank and discharged to atmosphere, the valves are reconfigured around the pump so that a vacuum is drawn on the canister to pump adsorbed vapor back to the tank. The system can be activated in response to pressure within the tank reaching a first level, reconfigured in response to the pressure in the tank reaching a second level and deactivated after vapor within the adsorbent material in the canister has been removed, purged or de-adsorbed from the adsorbent material so that the system can once again be used for evacuation. When tank pressure is the control parameter, a pressure transducer or sensor monitors the pressure in the tank. The system can also be controlled based on the hydrocarbon level within vapor/air streams passing through the system and/or the weight of the adsorbent material as vapor is adsorbed by and removed from the adsorbent material.
The following detailed description of various embodiments of the present invention can best be understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals, and in which:
In the detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration, and not by way of limitation, specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and that changes may be made without departing from the spirit and scope of various embodiments of the present invention.
The operating cycle of an active adsorbent pollutant reducing system of the present invention comprises an inactive portion and an active or run portion. The run portion of the operating cycle of the system comprises two states: an evacuation state during which gasoline vapor is adsorbed in a canister and non-pollutant air is evacuated from an associated storage tank; and a purge state during which gasoline vapor is de-adsorbed or purged from the canister and returned to the tank. Embodiments of active adsorbent pollutant reducing systems of the present application will now be described with reference to the drawing figures.
The schematically illustrated system 100 shown in
The valves 106, 108, 110, 112, 114 and pump 104 of the system are controlled, for example, by a controller 116, via connections C to the controller 116. The controller 116, for example, can be a stand-alone controller for the active adsorbent pollutant reducing system 100, can be the controller of a gasoline distribution facility (GDF) using the system 100 or can be a controller dedicated to the system 100 that shares control of the system with another controller, for example the controller 116′ of a GDF, see
Optionally, a restrictor 115 may be placed on the end of the canister 102 that is connected to atmosphere through the valve 114 to increase the pressure in the canister 102 during one or more operating states of the system 100 as will be described below. Increasing the pressure in the canister 102 will increase the capacity of the adsorbent. Additionally, a thermal device, for example, a heating blanket 117 may be associated with the canister 102 to provide heat to the canister 102 during one or more operating states of the system 100. Increasing the temperature of the adsorbent may increase the capacity of the adsorbent, or can be used to assist de-adsorbtion.
As shown in
The pressure within the ullage 118 of the tank 120 can be monitored by a pressure sensor 122 which is connected to the controller 116 via a connection C1. In one control arrangement, the pressure in the ullage 118 of the tank 120 can be monitored by the GDF controller 116′ with the pressure measurements being used for general operation of the GDF, for example for diagnostics of GDF operation, and also for operation of the system 100. In that case, the controller 116 of the system 100 can be the GDF controller 116′ or the controller 116 can work with the GDF controller 116′ as suggested in
For the state of the system shown in
It is noted that increased pressure within the canister 102, provided, for example, by the restrictor 115 as described above and shown in
When the second pressure level is achieved in the tank 120, the valves 106, 108, 110, 112, 114 are controlled to reconfigure the passage from the canister 102 through the pump 104 to what is referred to as the purge state of the system 100, see
It is noted that increased temperature within the canister 102, provided, for example, by the thermal blanket 117 as described above and shown in
The time period for purge state operation of the system 100 can be determined in a number of ways. One control strategy is to maintain the purge state for a period of time sufficient to remove substantially all gasoline vapor from the adsorbent material presuming that the adsorbent material is saturated with vapor. For example, a purge time period of 15 minutes was found to perform satisfactorily in a working embodiment under what is anticipated to be substantially worst case conditions at the GDF. However, this strategy tends to operate the pump 104 for longer time periods than are often required to adequately purge the canister 102. Accordingly, to extend the life of the pump 104 and the system 100 overall, it is possible to operate the pump 104 only for the time necessary to adequately purge the adsorbent material in the canister 102 for operation once again in the evacuate state.
One way of determining an appropriate time period for operation of the system 100 in the purge state is to monitor the time that the system 100 is operated in the evacuation state during which it is sending vapor to the canister 102. When operation in the evacuation state is terminated, the elapsed run time in the evacuation state can be used to determine a corresponding operating time for the system in the purge state. For example, an appropriate factor can be used to multiply the evacuation operating time, Te, by a factor X so that the purge time Tp would be equal to X·Te, Tp=X·Te. In a working embodiment of the system 100, the factor was set to 15, however, the actual factor for a given system would depend on a number of variables including, for example, the size and amount of adsorbent material in the canister 102 and the flow rate of the gaseous vapor/air mixture. Accordingly, the factor or the correspondence of purge time to evacuate time can vary dependent of a given application and installation of the system 100.
If the restrictor 115 is used in the system 100, the increased pressure within the canister 102 improves vapor adsorption by the adsorbent material in the canister 102. Vapor purging improvement can be provided by heating the canister 102, for example by means of the optional heating blanket 117 shown in
In a time control arrangement for the evacuation state of the active portion of the operating cycle of the system 100, when the pressure in the tank 120 exceeds the first pressure level, e.g., a tank pressure of about +0.2 inches of water, the system 100 is activated to operate in the evacuation state for a given period of time. However, after operation in the evacuation state for a maximum predetermined amount of time, for example 1 minute, the system 100 ceases to operate in the evacuation state and initiates the purge state, although other time periods are contemplated for use in the system 100 of the present application. It is noted that an average time period of 30-45 seconds was found in a working embodiment to reduce the tank pressure from about +0.2 inches of water to about −1.0 inches of water. This arrangement, which uses a maximum predetermined amount of time for operation of the evacuation state, can be used to prevent the adsorbent material in the canister 102 from being over-filled with adsorbed vapor.
In another control arrangement for the system 100, a sensor, such as a hydrocarbon (HC) sensor 124, may be used to monitor the output from the canister 102 to determine the condition of the adsorbent material in the canister 102, see
The detection of non-pollutant output to the atmosphere from the canister 102 having a first level of hydrocarbons, above about 2% HC content, can be used to both deactivate evacuation states of the system 100 and also to activate purge states of the system 100 to prepare the system 100 for operation in its next evacuation state. In addition, the HC sensor 124 can be used to terminate purge states of the system 100 when the detection of hydrocarbons in output from the canister 102 to the tank 120 goes below a second level of hydrocarbons. For deactivation of evacuation states and/or activation of purge states, the output of the canister to atmosphere must be monitored by the HC sensor. For deactivation of purge states, the output of the canister 102 to the tank 120 must be monitored by the HC sensor 124. To enable use of a single HC sensor 124, a pair of single acting valves 126, 128 can be used to connect the canister 102 to the HC sensor 124, see
As shown in
As described above with reference to
In a further control arrangement, the weight of the canister 102 (or the adsorbent material therein) could be monitored during operation in the evacuation state, such as, for example, by a load cell 130 which could be incorporated into the canister 102 or into its supporting structure as shown in
It is understood that several of the above control arrangements could be combined to define a desired control scheme for operating the system 100. In the system 100 shown in
Where the system 100 is partially controlled by another controller, such as when the controller 116′ of a gasoline distribution facility (GDF) is used to send signals corresponding to tank pressure, the dedicated controller of the system 100 uses the tank pressure signals to effectively operate the system 100. An example of operation of the system 100 with an existing system will be briefly described relative to a Pressure Management Control/In Station Diagnostics (PMC/ISD) system commercially available from the Veeder-Root Company. This system currently operates with an Emission Control System (ECS) available from Vapor Systems Technologies, Inc., the assignees of the present application. When operating with the ECS, the PMC/ISD sends an on signal and an off signal to the ECS. These signals can be used by the system 100 with the aid of a dedicated controller to operate the system 100 by activating the system 100 to operate in the evacuation state in response to the on signal and operating the system 100 in the purge state in response to the off signal. By operating in response to signals currently provided by the PMC/ISD, the system 100 of the present application can be conveniently retrofitted into existing GDFs and also can be used in new installations with no change required for the PMC/ISD.
There are several advantages of the active adsorbent pollutant reducing system 100 of the present application over known passive adsorbent systems. Initially, the system 100 can be cycled indefinitely as needed to control the UST pressure, so it does not have the capacity constraints of a passive system. Further, the system 100 does not rely on the functions of other variables at the GDF, such as the vapor recover system or system leakage, to function correctly. Also, the system 100 does not allow air to be ingested as part of system operation, but the passive system does allow air to be ingested and in fact relies on the ingestion of air which is counter-productive to the goals of systems for reducing the discharge of pollutants from gasoline storage tanks. Furthermore, the size of the system 100 is substantially reduced in comparison to corresponding passive systems.
With regard to size, most USTs are between 10 K gallons and 15 K gallons, and there are anywhere from two to four USTs at a GDF or gasoline station. Based on test data, it is estimated that a passive adsorption system using activated carbon would have to be able to adsorb approximately seven pounds of gasoline. For that capacity, the adsorption canister would have to have about twenty four (24) pounds of activated carbon to be able to meet these demands. Accordingly, the canister size would have to be around six (6) inches in diameter and forty eight (48) inches long. Comparably, the active system 100 of the present application would require only about five and three quarter (5¾) pounds of activated carbon so that the canister 102 would only be about five (5) inches in diameter and about eighteen (17) inches long. Accordingly, the canister 102 of the system 100 can be substantially smaller in size than that required by a passive system.
Having thus described the invention of the present application in detail and by reference to embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.
This application claims the benefit of U.S. Provisional Patent Application No. 60/985,040 filed Nov. 2, 2007, and entitled REDUCING POLLUTANT DISCHARGE FROM GASOLINE STORAGE TANKS which is incorporated herein by reference in its entirety.
Number | Date | Country | |
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60985040 | Nov 2007 | US |