The present invention relates generally to steam generators. More particularly, the present invention relates to a gas, diesel, oil or biomass operated steam generator.
A continuous supply of hot steam is essential for the provision of many services in hotels, restaurants, hospitals and other public or private establishments. Hot steam is generally produced by boiling water under atmospheric pressure by directly heating a water vessel. Gas is widely used for generating hot steam. In conventional hot steam generating apparatuses using gas burners, a gas burner is placed underneath the bottom of a water vessel. Water contained in the vessel is heated by direct heating of the bottom of the water vessel by flames and heat generated by fuel gas combustion. In a conventional burner, the flames are pushed by gas pressure towards the bottom of the water vessel and spread over the bottom surface of the vessel, thereby heating the bottom surface of the vessel. However, conventional gas water steam generators are known to have relatively low thermal efficiency due to dissipation of the heat from the vessel into the atmosphere and also because the flame contact area only represents a small percentage of the combustion area. Typically, the thermal efficiency for conventional water steam generators or steam generators is below 80% for a large-size gas burner or for a heated water vessel with a flat vessel bottom.
The present invention recognizes and addresses disadvantages of prior art constructions and methods. Various combinations and sub-combinations of the disclosed elements, as well as methods of utilizing same, which are discussed in detail below, provide objects, features and aspects of the present invention.
One embodiment of the present invention provides a steam generator including a steam chamber with an enclosed body having an inner wall and a spaced apart outer wall defining an enclosed fluid chamber therebetween. The inner wall defines an enclosed steam chamber, a fluid input port in fluid communication with the enclosed steam chamber, a steam output port in fluid communication with the enclosed steam chamber, and a plurality of tubes passes through the enclosed steam chamber, wherein the plurality of tubes each define a first end, a second end and a passageway therebetween. A combustion chamber has an outer wall and a spaced apart inner wall defining a closed fluid chamber therebetween. The combustion chamber inner wall defines an air channel having a first end and an opposite second end, the combustion chamber air channel first end being coupled to a burner and the combustion chamber air channel second end being in fluid communication with the steam chamber plurality of tube first ends. A heat transfer section has an outer wall and at least one inner wall spaced apart from the outer wall so as to define a closed fluid chamber therebetween. The at least one inner wall defines an air passage having a first end and an opposite second end, the heat transfer section air passage second end being in fluid communication with the steam chamber plurality of tube second ends and the heat transfer section air passage first end being in fluid communication with a vacuum source. The heat transfer section fluid chamber is in fluid communication with the steam chamber fluid chamber, the steam chamber fluid chamber is in fluid communication with the combustion chamber fluid chamber, the combustion chamber fluid chamber is in fluid communication with the enclosed steam chamber, and when the burner generates a heated air mixture in the combustion chamber air channel, the vacuum source draws the heated air mixture from the combustion chamber air channel, through the steam chamber plurality of tubes and through the heat transfer section air passage so as to heat fluid passing through the heat transfer section, the steam chamber and the combustion chamber fluid chamber.
Another embodiment of the present invention provides a method of generating steam including the steps of providing a steam chamber having an outer wall and a spaced apart inner wall, the outer wall and the inner wall defining a closed fluid chamber therebetween. The inner wall defines an enclosed space, a fluid input port in fluid communication with the enclosed space, a steam output port in fluid communication with the enclosed space, and a plurality of tubes passes through the steam chamber enclosed space, wherein each of the plurality of tubes define a first end, a second end and a passageway therebetween. A combustion chamber has an outer wall and a spaced apart inner wall, the outer wall and the inner wall defining a closed fluid chamber therebetween and the inner wall defining an air passage having a first end and an opposite second end. The combustion chamber closed fluid chamber is in fluid communication with the steam chamber closed fluid chamber, and the combustion chamber closed fluid chamber is in fluid communication with the steam chamber enclosed space. A heat transfer section has an outer wall and at least one spaced apart inner wall so as to define a closed fluid chamber therebetween. The at least one inner wall defines an air passage having a first end and an opposite second end, wherein the heat transfer section closed fluid chamber is in fluid communication with the steam chamber closed fluid chamber. The method further includes pumping a fluid through the heat transfer section closed fluid chamber, the steam chamber closed fluid chamber and the combustion chamber closed fluid chamber into the steam chamber enclosed space; generating a heated air mixture in the combustion chamber air passage; drawing the heated air mixture through the combustion chamber air passage, the steam chamber plurality of tubes and the heat transfer section air passage; and generating steam in the steam chamber enclosed space using the heated air mixture passing through the steam chamber plurality of tubes.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of stacked displays of the present invention.
A full and enabling disclosure of the present invention, including the best mode thereof, to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying drawings, in which:
Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention according to the disclosure.
Reference will now be made in detail to presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation, not limitation, of the invention. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary constructions. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope and spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
Referring to
It should be understood that in other embodiments, combustion chamber 12 may be formed with a single wall and a fluid jacket may surround the outer surface of the combustion chamber. In these other embodiments, the purpose of the fluid jacket or fluid chamber 20 is to allow water to circulate around the outside surface of the combustion chamber so that the water absorbs the radiant heat generated by the combustion chamber. In all embodiments, it is important to understand that airflow into combustion chamber 12 must be controlled to increase the efficiency of combustion of the fuel delivered to burner 14. That is, the construction of combustion chamber 12 is designed to increase the efficiency of fuel burn while decreasing the byproducts of fuel combustion exhausted into the atmosphere.
Burner 14 is coupled to combustion chamber 12. In one preferred embodiment, burner 14 is a Power Flame CX40 burner manufactured by Power Flame Incorporated of Parsons, Kans. Burner 14 has valve 30 intermediate burner 14 and a controller 32 that allows the fuel supply to be cut-off from the burner by way of control lines 34. In this way, the burner may be adjusted to regulate the amount of heat generated in combustion chamber 12. Burner 14 may have an electronic computer controlled pilot light (not shown) associated with the burner. Each burner may be a fixed BTU burner or a modulating burner. The burner may also contain a fan to provide positive air pressure to burner 24. Suitable fuel for burner 14 may be propane, natural gas, biomass fuel or any other combustible fuel.
Referring particularly to
Extending between steam chamber first end 38 and steam chamber second end 40 are a plurality of hollow tubes 48 having first open ends 50 opening into combustion chamber 12 and second open ends 52 that open into elbow 44. Steam chamber 16 may be formed from any suitable material such as metal, metal alloys, ceramics or polymers. Hollow tubes 48 may be formed from any heat conducting material such as metals, metal alloys, ceramics, polymers and other suitable materials. The length of tubes 48 may be equal to or greater than the length of steam chamber 16, or in some embodiments, may be longer if the tubes are zigzagged or coiled within steam chamber 16. In one preferred embodiment, tubes 48 are circular in cross-section. However, it should be understood that a cross-section of tubes 48 taken perpendicular to their length may be of various shapes, including by not limited to, a circle, a square, and other polygonal shapes. The number of tubes may also increase or decrease depending on the design of steam chamber 16.
The number of tubes and the physical dimension of the tubes should be chosen to increase the surface area between the walls of tubes 48 and fluid 54 contained in steam chamber 16. That is, tubes 48 are submerged in fluid contained in steam chamber 16 so that heat received in the hollow openings 56 of tube 48 (
A float 70 is operatively coupled to a switch 72 by a wire 74 or other suitable connection. Switch 72 is operatively coupled to controller 32 (
Referring again to
As previously discussed above, elbow joint first end 42 is coupled to steam chamber 16 by a suitable connection. The connection may be formed by threads, screws, weldments or any other suitable means for connecting the elbow to the stream chamber. Elbow second end 43 is coupled to heat transfer section 18.
Still referring to
Referring particularly to
The length of tubes 94 may be less than or equal to the length of heat transfer section 18, or in some embodiments, may be longer if the tubes are zigzagged or coiled within heat transfer section 18. It should be understood that a cross-section of tubes 94 taken perpendicular to their length may be of various shapes, including by not limited to, a circle, a square, and other polygonal shapes. The number of tubes may also increase or decrease based on the outer diameter of each individual tube. In one preferred embodiment, the diameter of each tube is decreased and the number of tubes is increased to increase the surface area of the tubes that are in contact with the fluid surrounding the tubes.
The number of tubes and the physical dimension of the tubes defines a space 102, intermediate an outside surface of tubes 94 and an inner wall 104 of heat transfer section 18 that is sealed off from elbow joint open channel 46 and vacuum pump 100. Closed space 102 defines a chamber in which a fluid may be pumped through so that heat received in tubes 94 from elbow joint open channel 46 may be exchanged into the fluid via the tube walls. Tubes 94 are held in place in heat transfer section 18 by a plate 106 that defines a plurality of holes (not numbered) that receive a respective tube first open end 90. Each tube first open end 90 may be secured in a respective plate opening by welding or other suitable means that forms a sealed attachment. A similar plate 108 (
In other embodiments, heat transfer section 16 may be formed from a hollow cylinder that defines at least one bore extending from one end to the other. In this embodiment, an outside wall defining the bore and an inside wall of the hollow cylinder defines space 102. In this embodiment, a plurality of bores may be formed to increase the surface area exposed to elbow joint open channel 46 to increase the heat transfer efficiency.
In some embodiments, elbow joint 44 may be constructed similar to heat transfer section 18 where a plurality of tubes extend through a chamber defined by an outer wall. In other embodiments, elbow joint 44 may be eliminated and heat transfer section second end 92 may be bent to form a 180 degree turn so as to couple directly to steam chamber 16. In these embodiments, heat transfer section fluid chamber output port 114 would be in fluid communication with steam chamber fluid chamber input port 89.
Referring again to
It should be understood that in
In operation, fluid used to generate steam is pumped from fluid source 120 into fluid input port 118. Fluid input port 118 allows fluid to enter heat transfer section 18 so that that fluid flow from source 120 enters into space 102 (
The fluid circulating through heat transfer section space 102 exits through heat transfer section output port 116, through piping 112 and into elbow joint fluid channel 82 via elbow joint input port 114. The fluid flow circulates about the length of the elbow joint and exits out of elbow joint output port 88 into piping 84. The fluid exits piping 84 and enters steam chamber fluid chamber 15 through steam chamber fluid chamber input port 89. The fluid circulates around steam chamber 16 and exits steam chamber fluid chamber 15 through steam chamber fluid chamber output port 91. The fluid travels through piping 87 and enters combustion chamber fluid chamber 20 via the combustion chamber fluid chamber input port 86. The fluid circulates around and along the length of the combustion chamber and exits the combustion chamber fluid chamber through combustion chamber fluid chamber output port 122. The fluid travels through piping 124 and passes through steam chamber input port 60.
As the fluid flows into steam chamber 16, the fluid level rises so that the fluid covers and circulates around steam chamber tubes 48. It should be understood that baffles (not shown) may be placed in any one of combustion fluid chamber 20, elbow joint fluid chamber 82 and heat transfer section fluid space 102 to help disburse the fluid throughout the various parts of the system to ensure even distribution of the fluid.
When controller 32 detects fluid flow at heat transfer section input port 118, controller 32 transmits a signal to burner 14 and vacuum source 100. Burner 14 ignites and generates an air and combustion mixture having a temperature of approximately 1600 degrees Fahrenheit. Vacuum source 100 generates negative pressure at heat transfer section first end 90 (
The temperature of the super heated air drops from around 1600 degrees Fahrenheit in combustion chamber 12 to around 900 degrees Fahrenheit in elbow joint 44. As the heated air mixture passes through elbow joint 44, additional heat is transferred from the elbow joint inner wall into the fluid passing though elbow joint fluid chamber 82 thereby further decreasing the temperature of the air mixture passing through elbow joint second end 46. Moreover, as the heated air mixture enters heat transfer section tube second ends 96 and travels along the length of the tubes, additional heat is transferred through the tube walls into the fluid circulating in heat transfer space 102. Thus, the temperature of the heated air mixture that exists from heat transfer section first end 90 is approximately at 80 degrees Fahrenheit or approximately 20-30 degrees higher than the input water temperature.
All heat transferred from the various steam generator parts into the circulating fluid raises the efficiency of steam generator 10. That is, as the fluid enters heat transfer section 18 at input port 118, it is initially heated as it travels along the length of the heat transfer section. As the fluid passes through elbow joint fluid channel 82, additional heat is transferred into the fluid. Finally, as the fluid passes around combustion chamber 12 through combustion chamber fluid chamber 20, the fluid temperature is raised to a near boiling temperature prior to it being deposited into steam chamber 16. As the super heated air mixture is drawn through steam chamber tubes 48, fluid 54 residing in steam chamber 16 is converted into steam, which is transferred out of the steam chamber through steam chamber output port 66. Conversely, as the superheated air mixture is drawn through elbow joint 44 and heat transfer section 18, the temperature of the air mixture drops as heat is transferred to the circulating fluid. As a result, heat not used to generate steam in steam chamber 16 is reused to heat the new fluid entering steam generator 10.
It should be understood based on the configuration of steam generator 10 that the super heated air mixture is drawn through each component by a single pass. That is, the air flow through each component enters the component one time and exits the same component one time as the air flow moves through the system. This is referred to a “single pass” steam generator in that the airflow is not passed through a component multiple times as it traverses from the burner end of the combustion chamber out the first end of the heat transfer section.
Various sensors (not shown) may be placed throughout the system to sense the temperature of the heated fluid passing through the system. Moreover, various sensors (not shown) may also be used to sense the temperature of the heated air mixture. If the temperature of the fluid or air mixture is below a set temperature, burner 14 may be adjusted to raise or lower the temperature of one or both of the air mixture and the fluid. Steam generator 10 may be provided with various controls and safety devices to ensure that fluid is flowing through the system and a vacuum or positive air pressure is applied prior to igniting burner 14. Steam generator 10 is also provided with safety switches to shutdown the system if the fluid temperature exceeds a predetermined temperature or if the fluid or steam pressure exceeds a predetermined threshold. Thus, safety measures ensure that the system will not operate if fluid or vacuum pressure is not detected.
A source of electrical power (not shown), such as a 120 volt AC, a 3-phase 240 volt AC connection, or a connection to a battery, connects to vacuum source 100. An on-off switch (not shown) is also provided intermediate the power source and the vacuum pump to cut power to the entire system. As a result, when the on-off switch is closed, power is supplied to vacuum source 100.
While one or more preferred embodiments of the invention are described above, it should be appreciated by those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope and spirit thereof. For example, the steam generator described herein may be used in various applications such as a steam generator for an apartment building, steam for sanitizing equipment, steam for food processing, or as a steam generator for a large-scale boiler system in a commercial setting. It is intended that the present invention cover such modifications and variations as come within the scope and spirit of the appended claims and their equivalents.
This application claims priority to U.S. Provisional Patent Application Ser. No. 61/420,005, filed Dec. 6, 2010, the entire disclosure of which is hereby incorporated in its entirety.
Number | Date | Country | |
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61420005 | Dec 2010 | US |