Abstract:
Disclosed herein is an apparatus for improving plant growing conditions, the apparatus in one form comprising: a housing; a carbon dioxide (CO2) producing section; and an exhaust section. The CO2 producing section in form comprises: an inlet through the housing for ambient air, an inlet through the housing for fuel gas, a burner for oxidizing the fuel gas; an oxidized gas outlet flue, and a dehydrator for removing the water vapor from the oxidized gas produced in the CO2 producing section. The dehydrator section may in turn comprise: a cooling water inlet through the housing; a plurality of heat exchangers in fluid communication with the cooling water inlet and in fluid communication with the oxidized gas outlet flue; and at least one condensate trap in fluid communication with a condensate outlet. The dehydrator section may comprise a cooling water outlet through the housing in fluid communication with the heat exchangers.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority benefit of U.S. Ser. No. 61/411,571 filed on Nov. 9, 2010 incorporated herein by reference. 
     
    
     BACKGROUND OF THE DISCLOSURE 
     a) Field of the Disclosure 
       [0002]    This disclosure relates to the field of a carbon dioxide generator with water vapor removal system (dehydrator). One significant use of such a device is in greenhouse use or elsewhere where plants are grown. 
       SUMMARY OF THE DISCLOSURE 
       [0003]    Disclosed herein is an apparatus for improving plant growing conditions, the apparatus in one form comprising: a housing; a carbon dioxide (CO2) producing section; and an exhaust section. The CO2 producing section in form comprises: an inlet through the housing for ambient air, an inlet through the housing for fuel gas, a burner for oxidizing the fuel gas; an oxidized gas outlet flue, and a dehydrator for removing the water vapor from the oxidized gas produced in the CO2 producing section. The dehydrator section may in turn comprise: a cooling water inlet through the housing; a plurality of heat exchangers in fluid communication with the cooling water inlet and in fluid communication with the oxidized gas outlet flue; and at least one condensate trap in fluid communication with a condensate outlet through the housing. The dehydrator section may also comprise a cooling water outlet through the housing in fluid communication with the heat exchangers. The apparatus in one form comprising: an exhaust section downstream of the heat exchangers, the exhaust section comprising a flue gas exhaust releasing the oxidized fuel/air mixture into the atmosphere. 
         [0004]    In one embodiment, the condensate trap comprises: a water collecting and diverting trough; a fluid drain in the lowermost portion of the trough; a plurality of angled wings positioned above and outward of the trough; and the angled wings may be angled so as to direct rising oxidized gas away from the center of the trough and direct water dripping thereupon into the trough. 
         [0005]    In one form the apparatus as recited in claim  1  wherein the cooling water enters the uppermost heat exchanger and then enters lower heat exchangers in series. 
         [0006]    The apparatus as described may further comprise; sensors to monitor the temperature and/or water vapor content of the oxidized fuel/air mixture in the exhaust section; and control devices which adjust the flow rate of the cooling water flow rate and/or fuel gas flow rate in relation to the temperature and/or water vapor content of the oxidized fuel/air mixture in the exhaust section. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a front isometric view of one embodiment of a carbon dioxide generator and dehydrator. 
           [0008]      FIG. 2  is a front isometric view of the embodiment of  FIG. 1  with the outer casing removed to show the internal components. 
           [0009]      FIG. 3  is a rear isometric view of the embodiment of  FIG. 1  with the outer casing removed to show the internal components. 
           [0010]      FIG. 4  is a rear isometric detail view of the burner portion of the embodiment shown in  FIG. 1 . 
           [0011]      FIG. 5  is a front isometric detail view of the embodiment shown in  FIG. 4 . 
           [0012]      FIG. 6  is an isometric view of one embodiment of a condensate trap. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0013]    Looking to  FIG. 1 , the CO2 generator and dehydrator  20  is shown with the housing  34  shown substantially transparent so as to allow a relational view of the housing  34  to the internal components. Generally, in a production model, the housing  34  would not be transparent or translucent, as most end-users would not desire to see the internal components during operation. By way of description, the housing  34  in one form comprises a front housing  22  and a rear housing  24 , although other arrangements could be utilized. By way of orientation, the apparatus  20  comprises a right side  26 , left side  28 , front side  30  and back side  32 . In one form, the housing  34  includes a right vent  36  and left vent  38 , which are generally openings from ambient air to the internal components to allow passage of ambient air for reasons that will be described herein. To further aid in describing the apparatus  20 , an axes system  10  is utilized, comprising a vertical axis  12  and a transverse axis  14 , which is perpendicular to the vertical axis  12  and parallel to the left side  28 . A lateral axis  16  is also described as being perpendicular both to the vertical axis  12  and the transverse axis  14 . This axes system  10  is not intended to be limiting, but is utilized herein to further aid in describing the relationship between individual components. 
         [0014]    In addition to the vents  36  and  38 , the housing  34  may comprise a fan opening  40 , generally in line with a flue gas exhaust fan  42 . Additionally, an opening for a carbon dioxide temperature indicator  44  may be provided. The carbon dioxide temperature indicator  44 , in one form, displays the temperature of the exhausting gases, and may also display the water content/humidity, CO2 level, etc., which may be of great assistance to the user. Additionally, openings may be provided for a water inlet temperature indicator  46  and a water outlet temperature indicator  48 . In general, the apparatus  20  accepts water through a water inlet  50 , and the temperature of the water entering the water inlet  50  may be indicated at the water inlet temperature indicator. Additionally, the apparatus comprises a water outlet  52 , and it may be desired to have the indicator  48  display the water outlet temperature. 
         [0015]    Looking now to  FIG. 2 , one form of the apparatus  20  is shown comprising several interoperating components. A control section  54  is shown at the lowermost portion and generally comprises conduits for the passing of fuel gas, ambient air, and water. Above the control section  54  is a burner section  56 , which generally comprises a fuel burner  58  and is connected to the control section  54 . Above the burner section  56  is a dehydrator section  60 , generally comprising a plurality of heat exchangers  62 ,  64  and  66 . Additionally, the dehydrator section  60  in one form comprises a condensate trap  68 , which is connected by way of piping  70  to a condensate outlet  72 . Above the dehydrator section  60  is an uppermost exhaust section  74 , which comprises the flue gas exhaust  42 , as shown in  FIG. 1 . 
         [0016]    In operation, in one form, when the apparatus  20  is energized or turned on, gas enters the gas inlet  76  and passes to the adjustment valve  78 , which is attached to a control knob  81 . If the valve  78  is opened, the flow of gas will increase through the valve  78  to the fuel burner  58 , at which point it may be ignited, such as by a piezzo electric igniter  80  or equivalent device, commonly known in the art. In one form, the valve  78  is not a shutoff style valve, but is a valve operatively selected and configured to limit the burner to a temperature range of 12K-36K BTU. The burning of the fuel creates a convection draft upward as the heated air rises from the burner  58 , through a flue  82  and towards the first heat exchanger  62 . In one form, rising of the heated air creates a partial vacuum in the control section  54 , which is filled as ambient air enters through the vents  36  and  38  of the housing  34 . Inlet fans may also be utilized. As the exhaust gas rises through the flue  82  into the first heat exchanger  62 , some of the heat is absorbed by the fins  84  of the heat exchanger  62 . These fins  84  are connected to piping  86  (through which cooling water flows) and thus, through thermal convection, the heat is transferred from the exhaust gas to the fins  84  to the cooling water within the piping  86 , whereupon it is drained by way of the water outlet  52 . At this point, the flue gas will have been cooled very little and convection will still draw the flue gases upward through the condensate trap  68 . 
         [0017]    Looking to  FIG. 6 , the condensate trap  68  in one form generally consists of a trough  88  comprising a plurality of sidewalls  90  and  92 , end walls  94  and  96 , and a base  98 . The rising flue gases pass around the base  98  and sidewalls  90  and  92 , through the gaps  100  and  102  between the trough  88  and the outer housing  34 , which is not shown in  FIG. 6 . The condensate trap  68  further comprises a drain  104 , which connects to the condensate outlet drain  72 . It can be seen how the rising flue gases rise through the heat exchanger  62 , past the sidewalls  90  and  92 , and are directed outward by way of the angled wings  106  and  108  away from center of the condensate trap  68 . As previously mentioned, the flue gases are considerably warmer than the ambient air entering the lower portion of the apparatus  20  and, therefore, continue to rise due to convection. The flue gases then pass through heat exchangers  64  and  66 , which operate in the same manner as the heat exchanger  62 . 
         [0018]    The apparatus, in one form, is arranged such that the cooling water enters via the inlet  50  and goes first to the upper heat exchanger  66 , which will be the coolest of the heat exchangers. Once the cooling water passes through the heat exchanger  66  and a significant portion of the heat is removed from the flue (oxidized) gases, the cooling water then enters the heat exchanger  64 , travels downward toward the heat exchanger  62 , and then exits by way of the water outlet  52 . As the flue gases cool, water condenses upon the fins and tubes of the heat exchangers  64  and  66 . This condensed water tends downward due to gravity toward the condensate trap  68 , whereupon it drips upon the base  98  and wings  106 / 108 . As the wings  106 / 108  are angled inward, and wherein the inner edges  110  and  112  are transversely inward from the sidewalls  90  and  92 , the water will drip from the wings into the trough  88 , whereupon it will be directed toward the drain  104  and out through the condensate drain  72 , whereupon it may be collected and recycled. 
         [0019]    Looking now to  FIG. 3 , it can be seen how in this embodiment the exhaust section  74  sits above the uppermost heat exchanger  66 . As the flue gases, at this point, may be substantially the same temperature as or potentially cooler than ambient air, convection will not exhaust the cooled air or flue gases upward and may tend to force the cooled gases downward back through the apparatus, which is undesired. Therefore, an exhaust fan  42  is provided in the exhaust section  74 . Additionally, sensors and an indicator  44  (which may include an outlet air temperature indicator) may be provided, such that a user can configure the apparatus to provide exhaust gases at the proper temperature, water content, and/or carbon dioxide level. The exhaust section  74  may alternatively be positioned to a side of the heat exchanger  66 . 
         [0020]    Looking to  FIG. 5 , the control section  54  is shown quite clearly. This portion is also shown quite clearly from the opposite angle in  FIG. 4 . When the apparatus is turned off, the fuel flow control knob  81  may be positioned so as to close the adjustment valve  78  such that fuel gas will not flow through the system. In one form, the apparatus  20  comprises failsafe devices, such as an automatic shutoff, should water flow, gas flow, or gas pressure drop below a certain level. In one form, an inlet pressure gauge  114  is provided, which may be connected to display the inlet pressure of the fuel and/or to shut off the gas pressure when the gas pressure drops below a certain level for safety reasons. 
         [0021]    Additionally, a water flow control knob  116  is disclosed connected to a water flow control valve  118 , which controls the volume of water between the water inlet  50  and conduits  120  leading toward the heat exchangers previously described. Additionally, pressure sensors, flow sensors, and/or temperature sensors may be included in the water supply line, which are then displayed, in one form, in the water inlet temperature indicator  46 . For safety reasons, a water/gas interconnect valve  122  may be provided, which stops the flow of gas to the burner portion  58  when the water pressure drops below a certain level, again for safety reasons. 
         [0022]    Additionally, it is obvious that when the flow of gas to the burner  58  is shut off that the flame in the burner  58  will go out. Thus, it may be desired to have a relight circuit connected to the pressure gauge  114 , such that when the pressure again rises to an adequate level at the fuel inlet  76 , actuated valves would re-open between the inlet  76  and the burner  58  and the piezzo igniter  80  will reinitialize to relight the apparatus without requiring a manual reset. 
         [0023]    While the present invention is illustrated by description of several embodiments and while the illustrative embodiments are described in detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications within the scope of the appended claims will readily appear to those sufficed in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicants&#39; general concept.