Device for producing a gaseous fuel composite and system of production thereof

The invention relates to a gaseous fuel composite, a device for producing the gaseous fuel composite, and subcomponents used as part of the device for producing the gaseous fuel composite, and more specifically, to a gaseous composite made of a gas fuel such as natural gas and its oxidant such as air for burning as part of different systems such as fuel burners, combustion chambers, and the like. The device includes several vortex generators each with a curved aerodynamic channel amplifier to create a stream of air to aerate the gas as successive stages using both upward and rotational kinetic energy. Further, a vortex generator may have an axial channel with a conical shape or use different curved channel amplifiers to further create the gaseous fuel composite.

FIELD OF THE INVENTION

The invention relates to a gaseous fuel composite, a device for producing the gaseous fuel composite, and subcomponents used as part of the device for producing the gaseous fuel composite, and more specifically, to a gaseous fuel composite made of a fuel such as natural gas and its oxidant such as air for burning as part of different systems such as fuel burners, combustion chambers, and the like.

BACKGROUND

Mixing of components is known. The basic criteria for defining efficiency of a mixing process relates to those parameters that define the uniformity of a resultant mix, the energy needed to create this change in parameters, and the capacity of the mix to maintain those different new conditions. In some technologies, such as the combustion of a biofuel, an organic fuel, or any other exothermic combustible element, there is a desire for an improved method of mixing a combustible element with its oxidant or with other useful fluids as part of the combustion process. The mixture of a liquid fraction with a gas is visible to the human eye, and as such, a person can easily understand the need to reduce a liquid into small droplets to improve contact surface area between the carburant and its oxidant.

The mixture of two liquids is also as equally intuitive to comprehend. Most people are experienced with mixing two liquids in a volume to achieve a complete mixture. For example, it is known that some liquids mix easily such as a syrup into sparkling water, while others such as vinegar in oil do not. The mixture of two gasses is harder to observe, even more so when the gasses are invisible to the human eye. The false belief that two gasses mix completely without the need for activation energy or dynamic energy is widespread. For example, tritium gas has unique properties: it is explosive and the molecules adhere to surfaces and flow downward under normal gravity. Each gas and thus any mixture of gases is accordingly unique, and the mixture of gasses presents challenges that are often complex and counterintuitive.

One known example of a visible gas-gas mixture is the creation of smoke rings by a smoker into the atmosphere. Another example is the release of a warm, humid, CO2-enriched breath on a cold winter day, creating a plume of visible water condensation and evaporation in the cold atmosphere. One of the main problems with gas-gas mixtures is the failure to understand how molecules of gas interact and move in contact with other molecules where a first set of molecule has a first kinetic energy level and a first specific linear velocity and the second set of molecules has a second kinetic energy level and a second specific linear velocity.

Several technologies are known to help with the combustion of fuel, such as nozzles that spray a fuel within an oxidant using pressurized air, eductors, atomizers, or venturi devices. Some of these technologies are more effective than mechanical mixing devices, and these devices generally act upon only one components to be mixed (i.e., the fuel or the oxidant) to create a dynamic condition and an increase of kinetic energy. Engines such as internal combustion engines burn fuel to power a mechanical device. The inefficiencies of internal combustion engines result in a portion of the fuel failing to combust during a fuel cycle, the creation of soot, or the burning of fuel at less than optimal rates. The inefficiency of engines or combustion chamber conditions can result in increased toxic emissions into the atmosphere and can require a larger or inefficient amount of fuel to generate a desired level of energy. Various processes are used to attempt to increase the efficiency of combustion.

In chemistry, a mixture results from the mix of two or more different substances without chemical bonding or chemical alteration. The molecules of two or more different substances, in fluid or gaseous form, are mixed to form a solution. Mixtures are the product of blending of substances like elements and compounds, without chemical bonding or other chemical change, so that each substance retains its own chemical properties and makeup. Composites can be the mixture of two or more fluids, liquids, gasses, or any combination thereof. For example, a fluid composite may be created from a mixture of a fossil fuel and its oxidant such as air. While one type of composite is described, one of ordinary skill in the art will recognize that any type of composite is contemplated.

Another property of composites is the change in overall properties while each of the constituting substances retains its own properties when measures locally. For example, the boiling temperature of a composite may be the average boiling temperature of the different substances forming the composite. Some composite mixtures are homogenous while others are heterogeneous. A homogenous composite is a mixture whose composition in one area of space cannot be identified, while a heterogeneous mixture is a mixture with a composition that can easily be identified since there are two or more phases are present.

What is needed is a new fluid composite having desirable overall properties and characteristics, and more specifically, a new fuel composite with properties of enhanced fuel burning, improved burn rates, greater heat production from the fuel, better spread of the thermal distribution in an environment, and other such gains. What is also needed is an improved device for mixing gasses using turbulent stream technology.

SUMMARY

The invention relates to a gaseous fuel composite, a device for producing the gaseous fuel composite, and subcomponents used as part of the device for producing the gaseous fuel composite, and more specifically, to a gaseous composite made of a gas fuel such as natural gas and its oxidant such as air for burning as part of different systems such as fuel burners, combustion chambers, and the like. The device includes several vortex generators, each with a curved aerodynamic channel amplifier to create a stream of air to aerate the gas in successive stages using both upwards and rotational kinetic energy. Further, a vortex generator may have an axial channel with a conical shape or use different curved channel amplifier to further create the gaseous fuel composite.

DETAILED DESCRIPTION

For the purposes of promoting and understanding the principles disclosed herein, reference is now made to the preferred embodiments illustrated in the drawings, and specific language is used to describe the same. It is nevertheless understood that no limitation of the scope of the invention is hereby intended. Such alterations and further modifications in the illustrated devices and such further applications of the principles disclosed and illustrated herein are contemplated as would normally occur to one skilled in the art to which this disclosure relates.

Incorporation by Reference

The following specification incorporates by reference all figures, disclosures, claims, headers, and titles of International Application Nos. PCT/US08/75374, filed Sep. 5, 2008, entitled “Dynamic Mixing of Fluids,” and PCT/US08/075,366, also filed on Sep. 5, 2008, entitled “Method of Dynamic Mixing of Fluids,” along with nationalized U.S. application Ser. Nos. 12/529,625, filed Sep. 2, 2009, entitled “Dynamic Mixing of Fluids,” and 12/529,617, filed Sep. 2, 2009, entitled “Method of Dynamic Mixing of Fluids,” and International Application No. PCT/US2009/043547, filed on May 12, 2009, also entitled “System and Apparatus for Condensation of Liquid from Gas and Method of Collection of Liquid.”

Energy Efficiency Test

In one embodiment, methane gas (CH4) is used as the fuel gas and air containing oxygen gas (O2) is used as the oxidant of the methane gas. The chemical equation associated with the combustion of the methane is described as: CH4+2O2═CO2+2H2O. Two molecules of water are created during this process and two molecules of oxygen are needed for the combustion.

At room pressure, with 1 mol of gas taking the volume of 22.4 liters, a volume of 22.4 m3of methane gas corresponds to 1000 mol of gas where this gas having a molar mass of 16.042 g/mol producing a weight of 16.042 kg of CH4for the 1000 mol of gas. The weight of the oxygen needed for the combustion is 64.0192 kg based on a molar mass at room temperature of 32.0096 g/mol and produces 36.03 kg of water at a molar mass of 18.015 g/mol.

In a burner, a flow of methane of 1000 scf/h enters the combustion chamber (1 scf=28.32 liters, 1000 scf/h=28.32 m3/h, or 1264 mol/h). At the flow rate of 1000 scf/h, the reaction requires 80.92 kg/h of oxygen, and produces 45.514 kg/h of water.

In one test, 9,700 scf/h of air is introduced into the device to produce a gaseous fuel composite. Air has 21% oxygen, so the oxygen introduced is 2,037 scf/h. This volume is taken as the stoichiometric ratio of methane to air for combustion. The gaseous fuel composite has a total weight of 10,670 scf/h (1000 scf/h of methane and 9,700 scf/h of air).

The optimal thermal output for methane gas is 891 kj/mol or 840 BTU/mol (1 BTU=1.06 kj). Burning of 1000 scf/h of methane or 1264 mol/h of methane corresponds to 1,061,760 BTU/h of thermal output. The real thermal energy released is found to be 90% of the maximal output or approximately 955,585 BTU/h for a natural gas.

A test was conducted with and without the device shown inFIG. 1installed on a commercial burner. Without the device, the following was measured: air input Tai=3° C. (37° F.), air output To=66° C. (152° F.), with ΔT=To−Tai=63° C., air input humidity 68% with cair=1.018 kj/(kg° K) resulting in 64.134 kj or 60.848 BTU of energy used to heat the air from the combustion of the gaseous fluid composite. As 10,911 scf of air was used, corresponding to 309 liters of air or 370.8 kg of air, the heating energy was 23,780 kj or 22,652 BTU.

With the device, the volume of the fuel composite being 1000 scf/h and 2,448 scf of air with a 29% volume of gas in the fuel composite, a total of 45.51 kg of water is released per hour if no other source of intake is taken outside of the gaseous fuel composite. The thermal efficiency taken at 90% of the theoretical value of 955,585 BTU/h for a gas with 29% of methane is 277,119 BTU/h.

With the device for producing the gaseous fuel composite, air input Tai=11° C. (52° F.), air output To=85.5° C. (185.5° F.), with ΔT=To−Tai=74.5° C., air input humidity 87% with cair=1.027 kj/(kg° K) resulting in 76.5115 kj or 72.59 BTU of energy used to heat the air from the combustion of the gaseous fluid composite. With a volume of air of 10,741 scf during the heat exchange corresponding to 365.022 kg of air, the energy needed to heat is 26,497 BTU.

As a consequence, 26,497 BTU are used to warm the air using the device for producing the gaseous fuel composite when compared with 22,652 BTU without the device. The increased output with the device is 3,845 BTU or approximately 17%. This corresponds to the increase in thermal efficiency of burning of the natural gas when it is first transformed into a gaseous fuel composite.

Carbon Oxide Release Test

Under normal circumstances, gas is sent out into a burner using an atomizer where the natural gas is dispersed in air in an open chamber. In the gaseous fuel composite device as shown inFIG. 1, a gas fuel composite created with air is merged into the natural gas before it is released into the burner. In a test, 100% of stoichiometric air was provided in a furnace via the atomizer with at least 10% excess air. The monoxide of carbon concentration under high fire is 1,093 ppm (or mg) for a gas flow of 1000 scf/h, and with a ratio of 1:5 on the concentration of CO and CO2, the concentration is 5,465 ppm (or mg) for the same input volume. For a lower gas flow of 505.241 scf/h corresponding to a low-fire condition, the CO concentration is 3,999.36 ppm and the concentration of CO2is 20,000 ppm.

In a test with the device for producing a gaseous fuel composite as shown inFIG. 1, only 25% of the stoichiometric air is inserted into the natural gas to form the composite at a ratio of 1:2.425. In addition, another 10% in volume of air was added from the furnace for a total of 35% air. For a high-fire condition with a natural gas flow of 1000 scf/hr, 259.76 ppm of CO were measured, and by analogy, 1298.8 ppm of CO2are found. At a low-fire condition of 504.76 scf/hr of natural gas, the concentration of CO measured is 823.46 ppm and CO2is 4,115 ppm.

When compared to high-fire conditions, the production of CO is reduced from 1,093 to 259.76 ppm, and at low-fire conditions is reduced from 3,999.36 to 823.46 ppm, reductions of 23.8% and 20.6%, respectively. Therefore, it is found that by creating a gaseous fuel composite, even with a small fraction of the stoichiometric air, thermal efficiency improves significantly and production of undesired byproducts is reduced greatly. Atomizer design in the device for producing a gaseous fuel composite allows for optimization of fuel burning and the degradation of unburned fuel. When using an actual gas burner where the thermal efficiency can be as low as 60% to 65%, what is contemplated is improvements in thermal efficiency and degradation of byproducts, impurities, or other unburned fuel elements as part of the process.

Device for Producing a Gaseous Fuel Composite

A device for the production of a gaseous fuel composite10is shown inFIGS. 1, 2, and11-15. The different views and embodiments show different possible vortex generators20that are described and shown with greater detail inFIGS. 3-10 and 16-19. The system centers on the passage of a fuel gas112shown at the bottom ofFIG. 1inside of an axial chamber formed in one example by stacking a plurality of vortex generators103,104,105,106, and107, each having an axial opening for the passage from one end shown as area1inFIG. 1to the other end shown as area7such as a nozzle108or another connector pipe (not shown). The axial opening as shown inFIG. 1Ahas a constant section until it enters a vortex generator as shown inFIGS. 16-19.

As the section of the axial opening is reduced, either the speed of the gaseous fuel composite is increased, the density of the gaseous fuel composite is increased, or a combination of both based on upstream conditions. The device10as shown includes an upper flange114and a lower flange113connected hermetically with a housing102as shown in the shape of a cylinder with inlets for an external oxidant gas.FIG. 1Ashows how multiple sources of air may enter the housing into the ring channels structure also shown inFIG. 2. The air201,202,203,204, and205enters the ring channels and moves upward into transit apertures leading up to tangential channels until the air is released in the axial chamber as shown by206,207,208,209, and240, respectively.

The multistage process shown inFIGS. 1 and 2where air enters ring channels using a plurality of stacked vortex generators20allows for the creating of a gaseous fuel composite in a multistep acceleration process. In this example, five air sources are used, each entering the five ring channels of the vortex generators at areas2,3,4,5, and6as shown inFIG. 1. For example, if the flow of air is constant at the five sources201,202,203,204, and205and represents a fixed fraction of the flow of gas112into the device10, then at the interface between areas2and3inFIG. 1, the gas is merged with a first portion of air to create the first stage of the gaseous fluid composite. At the interface between area3and4, the already partly aerated gas is further diluted by air, and so on in each successive stage. As the air enters into an area of constant volume, the pressure, density, and speed of the gaseous fuel composite increase. At the nozzle108, the final stage of the gaseous fuel composite is formed, which exits at109as a mixture of air from all of the sources and the gas fuel112.

Air is not mixed in the multistage process to produce a gaseous fluid composite simply by releasing air into the internal cavity.FIG. 1Bshows in a plan view how within a single device as shown inFIG. 1Cthe multiple vortex generators are stacked in zones2,3,4,5, and6. The device10as shown is compact and serves as a device that can be used to replace conventional nozzles.FIG. 1Dshows two possible inlet and outlet interfaces1and7, respectively, as part of the device10.

FIG. 3shows one vortex generator10where the axial channel301is shown in dashed lines and allows for the passage of the gas fuel and the ultimate creation of a gaseous fuel composite. A flange302shown with a square rim closes a channel303where air enters and travels upward via apertures304to tangential channels306via aerodynamic channel amplifiers305shown to be curved inwards to allow for the air within the channel303to travel upward in the apertures304and then to the tangential channels306in a 90 degree bend in an area where the flow is bent and pressure drops are observed because of the change in direction at the bend.FIGS. 3A-3Cillustrate the vortex generator10ofFIG. 3.FIGS. 3D and 3Eshow in close-up views how the air can travel upward from the channel303to the aperture304and then bend inwards over the curved aerodynamic channel amplifiers305.

Using a dark arrow,FIG. 4shows how the air moves around and out of the aperture304as illustrated401and slides402into the tangential channel306around a curved aerodynamic channel amplifier305in a resulting circular motion403. A different view of this effect is shown inFIG. 5where air201moves up502and slides401over the aerodynamic channel amplifier before it is released402into the circular motion403.

As shown inFIG. 5, the ring channel also includes an internal curve that results in a first curvature501of the flow before it enters the aperture. As the flow of air travels over the curved aerodynamic channel amplifier and slides401, the molecules of air have an upward portion of kinetic energy that remains in the air upon release402into the cavity for the circular motion403. Since the incoming gas fuel112has also an upward movement, the upward portion of the kinetic energy is conserved and amplifies the upward movement of the gaseous fuel composite.FIGS. 6A-6Cillustrate alternative views of the vortex generator20ofFIG. 6.

As the tangential channels create a vortex-like movement of the air as it enters the vertical cavity and mixes with the gas fuel112it has two vector components: a rotational energy that creates a rotational movement of the gaseous fuel composite and an upward energy that lifts the gaseous fuel composite and increases the speed and energy of the overall gaseous fuel composite. When both of these vectors are merged with the upward movement of the gaseous fuel composite, the resulting upward vortex701and702is created.FIGS. 7A and 7Billustrate alternative views of the vortex generator20ofFIG. 7.FIGS. 8 and 9are different views of the vortex generator20ofFIG. 7, which illustrates the dynamic flow created by the generator20within the gas fuel112.FIGS. 9A-9Cillustrate alternative views of the vortex generator20ofFIG. 9. Element901ofFIG. 9illustrates the upward vertical kinetic energy of the air after it is released within the gas fuel112.

Using arrows,FIG. 11shows how the gaseous composite goes from a first stage702upwards in one or two stages1101and1101where the axial channel is conical and results in the compression of the highly energized gas mixture in a nozzle1103. As shown inFIG. 12, not all aerodynamic channel amplifiers can be curved or bent with the same radius. Because of the way the plan view is cut in a vortex generator20having a good number of apertures and associated tangential channels and aerodynamic channel amplifiers, these appear as different configurations1201,1202,1203,1204, and1105. In one embodiment, the dimensions of the apertures and channels are the same across all vortex generators within a device10, and in other embodiments, the flow of air and the dimensions of apertures and channels differ from one vortex generator to the next to help regulate a multistep process.FIGS. 13-15are different views of the device10illustrating how configurations of the vortex generators103,104,105,106, and107, can differ1403,1404,1405,1406, and1407, and1501,1502,1503,1504, and1505, respectively. Associated ring channels1506,1507,1508,1509, and1510are also shown inFIG. 15.

FIGS. 16-19are different illustrations of a vortex generator1105as shown inFIG. 12, where a conical internal axial channel is present. In this embodiment, the flange1505remains at the same radius as the other vortex generators, creating a ring channel1510for the passage of air via the apertures1602over the curved aerodynamic channel amplifier1104with a first radius or a second type of aerodynamic channel amplifier1105with a second radius.FIGS. 16A-16Cillustrate alternative views of the vortex generator20ofFIG. 9.FIG. 17shows the external radius on the flange1701where tangential channels1607and apertures1602are located in close proximity to the reducing vertical passageway.FIG. 18shows as1801how some apertures can include a first type of aerodynamic channel amplifier1105and how a second type of apertures1407can include a second type of aerodynamic channel amplifier1104.FIG. 19is another illustration of the vortex generator according to a different view and illustrates how the air flows outside of the tangential channels.

What is shown inFIG. 1is a device10for producing a gaseous fuel composite with an inlet101connected a source of gas fuel112, a housing102between the inlet101and an outlet108for the passage a gas fuel112from the inlet102to the outlet108from the source of gas fuel, and a plurality of vortex generators103,104,105,106, and107, each with an axial channel301as shown inFIG. 3, the generators103,104,105,106, and107being in a stacked configuration in relation with the other vortex generators in the housing102between the inlet101and the outlet108, where each of the vortex generators103,104,105,106, and107include a flange302defining a ring channel303in fluid connection as shown by the arrows201,202,203,204, and205inFIG. 2with at least a source of air and a plurality of apertures304and associated tangential channels306for the passage of air from the ring channel303through the apertures304and the associated tangential channel306as shown inFIG. 4for release of the air from the ring channel303into the axial channel301to form a gaseous fuel composite made of the gas fuel112and at least air from the at least one source of air201,202,203,204, and205. Further, at least a connection between one of the apertures304and the associated tangential channels306includes a first curved aerodynamic channel amplifier305having a first curvature as shown inFIG. 3.

In one embodiment, the outlet108is a nozzle as shown inFIG. 1. In another embodiment, the gas fuel112is natural gas made of, for example, methane. In another embodiment, the device10is used in a commercial burner (not shown). As shown inFIG. 1, the inlet101is a cylindrical gas inlet. In another embodiment shown inFIG. 18, at least another connection between one of the apertures and the associated tangential channel includes a second curved aerodynamic channel amplifier having a second curvature1105when compared with1104.FIG. 17also shows an embodiment where at least one of the plurality of vortex generators includes a conical111axial channel.

What is also described is a system for the production of a gaseous fuel composite comprising the process of transforming a gas fuel into a gaseous fuel composite by successive steps of connecting a device for the production of a gaseous fuel composite to an inlet connected to a source of gas fuel as shown by the black arrows at the bottom ofFIG. 2, the system having a plurality of vortex generators each with an axial channel as shown, and aerating the gas fuel112as shown, for example, inFIG. 7with a stream of air402traveling from the ring channel via at least one of the plurality of apertures501and associated tangential channels into the axial channel for mixture of a first quantity of air with the gas fuel701,702using one of the plurality of vortex generators as shown. The stream of air includes an upward motion created by the first curvature401and a circular motion403as shown inFIG. 5to form a gaseous fuel composite as shown by the arrows in the upper portion ofFIG. 2.

There may be a subsequent step of using at least a second vortex generator for further aerating the gaseous fuel composite in a multistage process. Finally, a gaseous fuel composite as shown by the arrows in black in the upper portion ofFIG. 2is made of a first gas fuel112traveling linearly as shown by the arrows in the bottom ofFIG. 2and aerated by a series of at least two streams at different staggered distances along a linear axial chamber where each stream includes kinetic energy in the form of a circular motion403ofFIG. 5and kinetic energy in the form of an upward motion402ofFIG. 6, and where the stream is further compressed and accelerated in the axial chamber as shown by the arrows1101inFIG. 11by a conical reduction of the axial chamber and a nozzle release.

It is understood that the preceding is merely a detailed description of some examples and embodiments of the present invention and that numerous changes to the disclosed embodiments can be made in accordance with the disclosure made herein without departing from the spirit or scope of the invention. The preceding description, therefore, is not meant to limit the scope of the invention but to provide sufficient disclosure to one of ordinary skill in the art to practice the invention without undue burden.