Abstract:
A spark suppression device includes a plurality of blades or vanes that are mounted transversely in a duct of an air handling/dust collection system communicating with a spark source. A controlled flow of air carries sparks from the spark source through the spark suppression device. Sparks are suppressed by turbulence created in the airstream from the blades that have a downstream curvature. The turbulence strips away a hot air bubble surrounding a spark ember, thereby effectively cooling the spark and significantly reducing combustion at the spark ember. Other attributes of the invention contributing to spark suppression include an overlapping arrangement of the blades that results in high-velocity impact of the sparks against the blades, thereby breaking up the spark embers into smaller embers, and creation of rapid increased pressure within the spark suppression device that also helps to strip away the spark ember from the surrounding hot air bubble.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to devices that manage, control, or suppress sparks, and more particularly, to a method and apparatus for suppressing sparks that are produced in industrial processes and become conveyed in air handling systems and dust collection systems.  
       BACKGROUND OF THE INVENTION  
       [0002]     There are many industrial processes that result in the production of sparks, either actively, passively or accidentally. Active production of sparks include those processes that generate a tremendous quantity of sparks, for example, welding and plasma cutting operations. Passive production of sparks refers to processes that are known to periodically generate sparks, yet spark production is relatively infrequent, for example a drying process that produces sparks primarily during startup and shutdown periods of operation. Accidental spark production refers to spark generation as the result of an accidental occurrence, for example, sparks are generated by the impact between two objects in an industrial process, and then the sparks become entrained in a process airstream. In many of these processes, the sparks are conveyed in a dust collection or air handling filtration system that treats the air surrounding the industrial process. The sparks are relatively small embers of burning substances discharged from a body in combustion. These sparks can cause damage to dust collection and filtration systems. For example, in a dust collection system, nuisance sparks carried downstream in a duct can burn through-holes in the filtration system&#39;s filter media, resulting in hazardous fires, or at a minimum, degradation in the filtration system&#39;s ability to effectively treat the air stream. Relatively large sparks are capable of also igniting combustible dust that may collect on the filter media, potentially causing catastrophic fires. Even without such fires, smaller sparks may burn-damage the filter media, requiring frequent replacement of the filter media, thereby significantly adding to the cost of operating and maintaining the filtration system.  
         [0003]     Conventional spark detection and extinguishment systems for reducing the threat and incidence of fire are typically complex and may involve the application of a chemical retardant and/or water to the affected area upon detection of a spark(s). These conventional suppression systems are expensive, vulnerable to drift, tampering and malfunction. Additionally, activation of these systems often results in compromising the filtration system, because the system may need to be cleaned to remove the extinguishing substances and/or the byproducts of mixing and reacting of extinguishing substances with particulates in the process stream. Conventional extinguishment systems often use water deluge; these systems may be incompatible and potentially hazardous with particulate loading (i.e., some metal dusts) in certain industrial air streams. Also, filter media wetted in deluge systems may need to be removed and replaced with dry filter media, incurring significant maintenance costs and operational downtime.  
         [0004]     Particularly for those industrial processes that take place on a smaller scale, incorporating known spark suppression systems is prohibitively expensive; therefore, there are few economically viable options available for smaller scale operations to have effective spark suppression capability.  
         [0005]     Therefore, there is a need to provide a simple, economical and effective spark suppression system that may be easily and affordably installed in both large and small-scale industrial processes.  
       SUMMARY OF THE INVENTION  
       [0006]     In accordance with the present invention, a spark suppression device is provided that effectively extinguishes sparks, yet is easily installed in any duct of an industrial process, such as air handling or dust collection systems, hereinafter collectively referred to as air handling systems. The term “suppress” as used herein shall mean the general management or control of sparks to include, but not limited to, the ability to extinguish and arrest sparks in an industrial process. According to a preferred embodiment, the spark suppression device is in the form of a static mixer or tubulator device that is mounted within the duct of the air handling system upstream of the filter media. The static turbulator includes a plurality of vanes or blades that extend substantially transverse to a general direction of air flow through the duct. The device extinguishes sparks by taking advantage of various thermo-fluid principles discussed further below, as well as by physical impact of the sparks against the blades of the device.  
         [0007]     Most sparks created in the industrial processes are small and burn out almost immediately on their own, thus not causing any damage to the air handling system. Nevertheless, some sparks are indeed large enough and hot enough to be conveyed through ductwork for relatively long distances. These sparks are typically between 100-200 microns in size. Because spark embers are buoyant due to a bubble or casing of hot air that surrounds each spark, sparks in this size range may travel relatively long distances in ductwork. Thus, sparks may move at velocities that substantially match the air stream, until the spark is arrested against the filter media. Upon contacting the filter media, the hot air bubbles get stripped from the spark embers, leaving the burning embers in contact with the combustible filter media. If a spark is large enough and hot enough, the filter media will ignite, and so too will combustible dust caked on the filter media. Sparks generated from many well-known industrial processes may have temperatures between 700-1400 deg. F. It is also known that a spark measuring approximately 150 microns in diameter and over 700 deg. F can provide enough heat to start a fire or burn a sizeable through-hole in filter media. The actual spark ember may have a temperature between 1200-1400 deg. F, and the bubble or casing around the ember may be between 700-800 deg. F.  
         [0008]     The spark suppressor of the present invention takes advantage of various thermo-fluid principles to extinguish sparks. One attribute of the present invention that helps to extinguish sparks is disruption of the spark ember/hot air bubble equilibrium. A spark passing through the spark suppressor is subjected to a sudden increased pressure that disrupts the hot air bubble surrounding the spark ember. This pressure increase is due to a decreased air velocity of the airstream as it passes across an enlarged entrance section of the spark suppressor. This enlarged entrance section can also be described as providing a sudden entrance expansion, thereby creating the pressure increase. Accordingly, the ember/hot air bubble equilibrium is disrupted under the influence of increased pressure and becomes unstable, and the spark ember begins to separate from the hot air bubble. The cooler air that subsequently surrounds the spark ember more rapidly transfers heat away from the ember and thereby helps to extinguish the spark.  
         [0009]     Another attribute provided by the present invention can be referred to as a “sling-shot” effect or momentum conservation that also helps to separate the spark ember from the hot air bubble. Due to expansion as mentioned above, the airstream velocity on the upstream side of the turbulator decreases rapidly in approaching blades of the turbulator. However, because a spark ember is of much greater density than the surrounding airstream, the ember, in maintaining momentum, separates from the surrounding hot air bubble. Thus, the spark ember is slung forward and away from the slower moving hot air bubble. Therefore, in addition to the increased pressure that helps to strip away the hot air bubble from the spark, the momentum of the spark ember itself also helps to separate the hot air bubble from the spark ember.  
         [0010]     Another attribute of the present invention that helps extinguish sparks is the turbulence created by the blade arrangement as the sparks travel downstream beyond the device. The swirling and counter-swirling blade arrangement greatly increases turbulence downstream of the spark suppressor that contributes in extinguishing spark embers, because a source of cooler air continually swirls around the ember, rapidly transferring heat away by convection. Turbulent air enveloping the sparks is of sufficient magnitude that extinguishes sparks in a manner similar to a person blowing out the already dying flame of a candle.  
         [0011]     Yet another attribute of the present invention that helps extinguish sparks is the physical contact/impact of the spark embers against the blades of the device. The blades are preferably arranged such that the leading edge of each blade overlaps the trailing edge of one adjacent blade when viewing the device along a longitudinal path through the duct passageway. Thus, open gaps between the blades as viewed in the longitudinal direction are effectively eliminated. Accordingly, the great majority of spark embers will physically impact the blades. Depending on the speed of the spark embers, contact of the embers against the blades can cause the embers to break up and disintegrate into smaller-sized embers, which overall provides larger surface area for convecting heat, thereby cooling the spark faster. Also, contact of the spark embers against the blades rapidly slows their speed and causes them to drop out of the airstream sooner than if they were still moving unimpeded with the airstream. Thus, if the spark suppression device is placed far enough upstream of an air filtration unit, many sparks will not travel the distance required to contact the filter elements.  
         [0012]     Yet another attribute of the present invention that helps to extinguish sparks is the redirecting effect of the blades&#39; curvature wherein spark embers conveyed across the static mixing portion of the spark suppressor are redirected from largely a longitudinal path of travel to a path of travel that has a radial component. With a radial component in the path of travel, the spark embers impact the inside walls of a downstream converging section of the spark suppressor and/or the inside walls of the downstream duct that adjoins the converging section.  
         [0013]     There are a number of factors that affect the performance of the spark suppressor device. One factor is the particular arrangement, size, and curvature of the blades. Smaller blades with less curvature create less pressure drop across the device as compared to larger blades with greater curvature. Spark embers extinguish quickly upon impacting a surface; a spark suppressor with overlapping blades virtually eliminates the chance that a spark may pass through without impacting blade surfaces. Typically, the greater the blade overlap, the larger the blade required, which results in higher pressure drop for the same airstream flowrate.  
         [0014]     Another factor affecting performance is airstream velocity. At less than approximately 400 fpm airstream velocity in the duct (duct velocity), the turbulator is appreciably less effective in creating sufficient turbulence downstream to suppress sparks. At duct velocities in excess of 7,500 fpm, the blades are less effective in creating sufficient turbulence downstream to suppress sparks; at duct velocities greater than 7,500 fpm, gaps between the blades behave more as orifices, which reduces the influence of blade curvature. Also, at high velocities, the pressure drop across the spark suppressor is exceedingly high. The spark suppressor of the present design should ideally be operated at duct velocities between 1000 to 6000 fpm to achieve maximum spark suppression. Most industrial processes are designed and operated at duct velocities between 1000 to 6000 fpm. Therefore, with respect to duct velocity, pressure drop and spark suppression, the present invention is ideal.  
         [0015]     The spark suppressor of the present invention is successful in suppressing sparks by rapidly lowering the temperatures of the sparks to within 50 deg. F. of the surrounding airstream, and wherein the spark suppressor operates at pressure drops of 1 inch water gage or less for duct velocities less than 4000 fpm. The present invention offers a lower pressure drop alternative over conventional spark drop-out boxes. The present invention operates under a lower pressure drop and therefore lowers power requirements, thus energy costs are significantly reduced.  
         [0016]     In addition to suppressing sparks, the static mixing portion of the spark suppressor also destratifies temperature and concentration gradients; therefore, in applications where relatively high temperatures may threaten to cause duct fires, the device rapidly drives localized extreme high temperature in the flow stream toward the average temperature and thereby decreases the threat of fire. In applications where the concentration of particulate and other constituents elevate locally to lower explosive limits, there is threat of fire. The static mixing portion of the device decreases this threat of fire by homogenizing particulate concentration, which prevents concentrations from reaching lower explosive limits.  
         [0017]     The monolithic design of the present invention has no moving parts that could potentially malfunction, which is most favorable for seeking absolute fire and burn-damage prevention. Being integral to the duct work, the spark suppressor does not rely on any auxiliary power or controls, rather, it is always working whenever the fan of the air handling system is running, which results in 100% spark detection and 100% response to sparks.  
         [0018]     Other features and advantages of the present invention will become apparent from review of the following detailed description taken in conjunction with the drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]      FIG. 1  is a schematic diagram of an air handling system incorporating a spark suppression device of the present invention;  
         [0020]      FIGS. 2A and 2B  illustrate an example of a prior art spark suppressing device;  
         [0021]      FIG. 3  is a perspective view of a first preferred embodiment of the spark suppression device of the present invention installed within a length of duct;  
         [0022]      FIG. 4  is a perspective view of a second preferred embodiment of the spark suppression device of the present invention;  
         [0023]      FIG. 5  is a perspective view of an air booster assembly that can be used in conjunction with the spark suppression device in order to help clean the blades of the device;  
         [0024]      FIG. 6  is a perspective view of the air booster assembly installed upstream of the spark suppression device; and  
         [0025]      FIG. 7  is a front or upstream elevation view of the spark suppression device of the present invention further illustrating the arrangement of the blades and particularly the overlap of the blades to eliminate open gaps as viewed longitudinally through the device. 
     
    
     DETAILED DESCRIPTION  
       [0026]     Referring to  FIG. 1 , the spark suppressor  10  of the present invention is illustrated as being installed within an air handling system. A typical air handling system includes the machine/process  16  which generates sparks, either actively, passively or accidentally, and a filtration inlet line/duct  18  which conveys contaminated air and sparks to a filtration unit  12 . The filtration unit  12  includes a filter housing  22 , and one or more filter elements  24 . In this particular system, the filter elements  24  are shown as cartridge-type filters, which are replaced periodically over time as they become clogged/caked over with particulate. A filtration outlet line/duct  20  allows conveyance of filtered air back into the environment through discharge exit duct  21 . A fan  14  draws the airstream through the filtration unit. The fan  14  is representative of any standard process fan providing enough power to draw air-flow through the system and to thereby draw particulate away from the machine/process  16 , so that particulate carried in the airstream can be treated within the filter unit  12 .  
         [0027]      FIGS. 2A and 2B  are representative of the closest known prior art. This prior art consists of an air mixing apparatus  30  typically used in heating, ventilating and air conditioning (HVAC) systems for statically intermixing stratified airstreams, thereby improving the heating/cooling efficiency of the HVAC system. One such prior art air mixing apparatus has been installed at an industrial location for spark suppression on an industrial process. The structure of this static air mixing apparatus is defined by an outer sleeve or wrap  32  that houses a plurality of outer vanes  38 . An inner sleeve or wrap  34  houses an inner set of vanes  36 . A support panel  40  is sized to match the shape of the particular duct in which the static air mixing device is installed.  
         [0028]     Although the prior art illustrates a static air mixing device that has been used for spark suppression, the particular design considerations for a static air mixing device versus that of the spark suppression device of the present invention are significantly different. For example, with respect to the prior art shown in  FIG. 2B , the outer set of vanes  38  have substantial gaps  42  between some blades when viewed longitudinally. Similarly, there are relatively large gaps  44  that exist between the inner set of blades  36  when viewed longitudinally. Because of these large gaps, a significant number of sparks may pass unimpeded through the prior art spark suppression device, and consequently, the sparks are conveyed down the duct where they may potentially cause ignition and combustion. Whereas, in the present invention with overlapping blades, sparks inevitably impact the blades. Additionally, because of the overall geometry and gaps between the blades, the pressure drop across the prior art static air mixing device is less than that of the present invention. Accordingly, any inherent spark suppression benefits achieved by the prior art device due to spark equilibrium disruption or momentum conservation are significantly less in comparison to the present invention. Thus, the only attribute of the prior art device that absolutely contributes to spark suppression is the downstream turbulence of the airstream created by the blades of the prior art device. Therefore the present invention is superior over the prior art in suppressing sparks, thereby reducing the risk of sparks threatening life and damaging property.  
         [0029]     Referring to  FIG. 3 , the spark suppression device  10  of the present invention is characterized by a static mixer portion including set of inner vanes/blades  62 , a set of outer vanes/blades  64 , and an intermediate sleeve or wrap  60  interconnecting the distal ends of the inner set of blades to the proximal ends of the outer set of blades. The distal ends of the outer set of blades abut the interior surface of the outer sleeve or wrap. The inner set of blades  62  converge at their proximal ends and are joined by a central hub  66 . The inner set of blades  62  have a curvature in the downstream direction as shown, and the outer set of blades  64  have different curvature to the inner set of blades  62 , yet also a curvature in the downstream direction. The embodiment of  FIG. 3  provides inter-mixing of an airstream passing through the duct to effect destratification of the airstream.  
         [0030]     Referring again to  FIG. 3 , the static mixing portion of the spark suppression device  10  is preferably mounted between upstream and downstream transition sections  52 . The transition sections  52  may also be referred to as spark cones, or simply as sections of duct that increase in diameter as they approach the static mixer portion. As shown in  FIG. 1 , the cones  52  are mounted in line with the filtration inlet duct  18 . The device  10  preferably includes a pair of these spark cones  52 . An outer sleeve or wrap  54  interconnects the adjacent ends of the transition members  52 . The smaller-diameter openings at opposite ends of spark cones may include a flange  56  enabling the transition members to mount in line with an existing duct. In lieu of flanges  56 , the transition members may include other means of connection so that the transition members may mount in line with the adjacent upstream and downstream sections of duct.  
         [0031]      FIG. 4  illustrates another preferred embodiment of the present invention. In this preferred embodiment, there is a single set of blades  68  that extend from the central hub  66  to the inner surface of the outer wrap  54 . This simplified version of the spark suppression device of the present invention provides adequate intermixing of the airstream and at least equal capability with respect to spark suppression by disruption of spark equilibrium by momentum conservation. The hub  66  in  FIG. 4  is also larger than the hub  66  in  FIG. 3 . As discussed further below, some additional spark suppression benefits may be achieved with a larger hub.  
         [0032]     Referring back to  FIG. 3 , the hub  66  may be modified to include a blocking or center plate  67 , shown in dashed lines, that is attached over the leading edge of the hub  66 . The center plate  67  prevents sparks from passing unimpeded through an otherwise more open center area. Use of a center plate also causes sparks traveling generally along the longitudinal center axis of the airstream to be deflected radially outward, thus causing the sparks to make contact with the more radially outward lying portions of the inner blades. This radial deflection of a spark, being transverse to the longitudinal centerline of the duct, is a result of vortex shedding of the airstream created by the blocking effect of the center plate. The enlarged hub  66  of  FIG. 4  can also achieve some of the same benefits of the blocking plate  67  since some of the center open area is covered by the enlarged hub.  
         [0033]      FIG. 5  illustrates an air booster assembly  70  that can be used to apply a pulse of compressed air across the spark suppression device, thereby helping to clean particulate and debris that may adhere to the blades. Therefore, there may be a need to periodically remove the adhered material from the blades by providing a pulse of air (by automatic or manual means) that effectively dislodges the particulate and debris from the blades. The air booster assembly  70  includes a pulse valve  72  and a supply of compressed air/fluid connected to the valve that is delivered via pipe  74 . A pulse distribution pipe  76  is mounted transversely within a section of duct  86  just upstream of the spark suppression device  10 . The pulse distribution pipe includes one or more orifices  78  that release a pressure wave through the duct and against the spark suppression device  10 . A control line  80  (either electric or pneumatic) is used to selectively control the operation of valve  72  for delivering a desired frequency and duration of pulse air. Conveniently, a pulse orifice alignment indicator  82  may be mounted to the pulse distribution pipe  76  enabling a user to confirm the direction that the orifices  78  face. Preferably, the pulse distribution pipe extends through the center of the duct section  86 . Openings may be formed through the duct walls allowing the ends of the pipe  76  to pass therethrough. A sealing gasket  84  may be used to seal the openings in the duct with respect to the installed distribution pipe  76 . The control line  80  may communicate with either an industrial controller (not shown) for automatic pulse control, or to a manual switch (not shown), which would allow an operator to selectively control passage of compressed air/fluid through the valve  72 .  
         [0034]     Referring to  FIG. 6 , an elevation view taken along a longitudinal centerline of the preferred embodiment of  FIG. 3  is illustrated. The leading or upstream edges  88  of the inner set of blades  62  are illustrated as continuous lines, while the trailing or downstream edges  90  of the blades  62  are illustrated as dashed lines. As shown, when viewed along the longitudinal centerline, for each inner blade, there is a definable overlap between the leading edge  88  of each inner blade and the trailing edge  90  of one adjacent inner blade. As the inner blades extend radially outward, the overlap may decrease; however, there is preferably no clear open gap between adjacent blades, which prevents sparks having a linear path of travel to pass unimpeded therethrough. Although it is theoretically possible for a spark to pass through the spark suppression device without actually contacting a blade, such clear passage could only occur if the spark rapidly changed direction as it passed through the device, which is a highly unlikely event at any flowrate. As previously mentioned, because a spark ember has a density greater than the surrounding airstream, the spark ember tends to maintain its linear direction of travel through the duct; therefore, the overlapping blade arrangement of the preferred embodiment causes virtually all sparks to make contact with the blades.  
         [0035]     Also shown in  FIG. 6  is the particular arrangement of the outer set of blades  64 . The leading or upstream edges  92  of the outer set of blades  64  are illustrated as continuous lines, while the trailing or downstream edges  94  of the blades  64  are illustrated as dashed lines. A definable overlap also exists with respect to the leading edge of each outer blade and the trailing edge of one adjacent outer blade. Again, this overlap virtually eliminates the likelihood that a spark may simply pass through the outer set of blades without contacting the blades. In general, an increase in the depth of the blades, as measured by “D” in  FIGS. 3 and 4 , requires less curvature to achieve the same overlap between adjacent blades in preventing unobstructed passage of sparks.  
         [0036]     By the foregoing described invention, it is shown that a static spark suppression device is provided that effectively suppresses sparks to prevent fire and burn damage to air handling and dust collection systems. While the invention has been described with respect to preferred embodiments, it shall be understood that various changes and modifications may be effected that fall within the scope of the claims appended hereto.