Abstract:
The system for decontaminating industrial output gases may process both particulate and gaseous emissions from industrial facilities. The system may be located with or adjacent to an industrial facility or at some distance from the facility. In one embodiment the system includes a subsystem of alternating active and inactive filters, and a wash subsystem cleaning the inactive filters during the cycle. The wash water is captured in a basin for further processing of the chemical particulates therein. Fans located downstream of the filters draw the gaseous industrial output through the filters. Remaining vapor passes to a classification plant where the gases are separated into their constituent elements or compounds. Gases that are allowed to escape may be burned, and the resulting gases recirculated through the system. Another embodiment is adapted for processing steam, and cools the steam for use as liquid water, rather than allowing it to escape as vapor.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates generally to atmospheric emissions and pollution control systems, and particularly to a system for decontaminating industrial output gases produced by a factory or other industrial plant or the like. 
       2. Description of the Related Art 
       [0003]    Factories and other industrial centers and operations typically produce various gaseous emissions as byproducts of their processes. As time has progressed it has become widely recognized that many, if not most, of these gases are harmful to the environment, and regulations have been implemented to require that such output be minimized or at least controlled. 
         [0004]    As factories and industrial operations produce a wide variety of goods, the chemical compositions of their emissions vary widely as well. Nonetheless, it can be safely stated that the majority of such emissions comprise particulate matter mixed with other chemicals that remain in a gaseous state at ambient temperatures. Even operations that produce relatively “clean” atmospheric emissions will often produce excessive amounts of steam as a byproduct of their cooling needs. As a result, it has proven difficult to produce a system that is capable of decontaminating both particulate and gaseous output from various industrial facilities. 
         [0005]    Thus, a system for decontaminating industrial output gases solving the aforementioned problems is desired. 
       SUMMARY OF THE INVENTION 
       [0006]    The system for decontaminating industrial output gases may be constructed immediately adjacent to a factory that develops such gases, or may be located at some distance therefrom. The system comprises multiple embodiments for processing particulate matter in gaseous industrial emissions and/or vaporous emissions. 
         [0007]    One embodiment comprises a complex of alternating active and inactive planar filter elements, a wash system for the inactive filter elements, and a collection basin for particulates washed from the filter elements. A plurality of fans draws the gases through the filter elements, and the resulting particulate-free gases are delivered by the fans to a gas classification plant for separating the remaining gaseous compounds and/or elements from one another. Another embodiment incorporates all of the above components, and includes an incinerator for burning any released gases from the classification plant. The resulting oxidized gases are recirculated through the system. 
         [0008]    Yet another embodiment is adapted for processing the steam byproduct produced from so-called “clean” industrial processes, e.g., due to the cooling needs of nuclear power plants. As there are no particulates in such output, this embodiment deletes the filter apparatus and substitutes a cooling system for the steam output. This can be quite valuable in arid areas where the steam may be recaptured as useful water, e.g., for recirculation through the cooling system of the plant, rather than being released into the atmosphere. 
         [0009]    These and other features of the present invention will become readily apparent upon further review of the following specification and drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a top perspective view of a first embodiment of a system for decontaminating industrial output gases according to the present invention, illustrating its general features. 
           [0011]      FIG. 2  is a detailed perspective view of the particulate filtration component of the system for decontaminating industrial output gases according to the present invention, showing the outlet plenum partially broken away to illustrate various details of the system. 
           [0012]      FIG. 3  is a detailed perspective view of the fan component of the system for decontaminating industrial output gases according to the present invention, showing the fan housings partially broken away to illustrate various details of the system. 
           [0013]      FIG. 4  is a perspective view of an alternative embodiment of a system for decontaminating industrial output gases according to the present invention, illustrating a subsystem for burning off combustible gases and recirculating the resulting gases through the system. 
           [0014]      FIG. 5  is a top plan view of another alternative embodiment of a system for decontaminating industrial output gases according to the present invention, illustrating a cooling system for industrial steam output. 
       
    
    
       [0015]    Similar reference characters denote corresponding features consistently throughout the attached drawings. 
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0016]    The system for decontaminating industrial output gases includes several major subsystems for removing particulates from various gases and for classifying or separating the remaining gases into their separate elements or compounds, as appropriate. The system may include a subsystem for burning off remaining combustible gases and recycling the resulting products. 
         [0017]      FIG. 1  of the drawings provides a general perspective view of all of the subsystems incorporated into a first embodiment of the system for decontaminating industrial output gases, generally designated as system  10 . Gases produced by an industrial factory or plant P are delivered to the system  10  by a gas input flue  12  to a filter input plenum  14  at the upstream or inlet end  16  of a filter housing  18 , shown in broken lines in  FIG. 1  in order to show a first plurality of filters  20   a,    20   c,  and  20   e  therein. Alternatively, the system  10  may be located closer to the factory or plant P, and the gas input flue  12  may be shortened accordingly, or the system  10  may be constructed immediately adjacent to the factory or plant P so that output gases pass directly to the system  10  with no intervening flue. 
         [0018]      FIG. 2  of the drawings provides a more detailed view of the filter housing  18  in its entirety, which has six generally planar filters  20   a  through  20   f.  The orientation of the filter housing  18  and associated components is turned approximately 90° counterclockwise from the orientation shown in  FIG. 1 . The industrial output gases flow from the gas input flue  12 , through the input plenum  14  (shown in  FIG. 1 ) and through the length  22  of the filter housing  18  from its inlet end  16  to its opposite outlet end  24  and out through the outlet plenum  26 . The outlet plenum  26  may include a plurality of concentric, funnel-like guides  26   a,    26   b,    26   c  therein to reduce turbulent flow from the filter housing. 
         [0019]    The filter housing  18  includes lateral passages or slots therein transverse to its length  22  for accepting the filters. Three of the filters are positioned within the filter housing  18  at any given time. The remaining three filters are removed from the housing  18  for cleaning. The three filters comprising each of the filter groups, i.e., the first plurality of filters  20   a,    20   c,    20   e  and the second plurality of filters  20   b,    20   d,    20   f,  are progressively arranged according to filtration capacity. The first or upstream filters  20   a  and  20   b  of each set have a coarse filtration medium, the second filters  20   c  and  20   d  have a medium filtration medium, and the final filters  20   e  and  20   f  have a fine filtration medium. It will be seen that more or fewer than three filters may be included in each group or set. 
         [0020]    In the example illustrated in  FIG. 2 , a first plurality of filters  20   a,    20   c,  and  20   e  are disposed laterally within the filter housing  18 , i.e., with their planes transverse to the length  22  of the housing  18 , and serve in an active capacity to filter particulates from the gases flowing through the filter housing  18 . The remaining second plurality of filters  20   b,    20   d,  and  20   f  are positioned external to the filter housing  18 , where they are positioned for cleaning. The second plurality of filters  20   b,    20   d,  and  20   f  are interchanged periodically with the first plurality of filters  20   a,    20   c,  and  20   e,  the first plurality of filters  20   a,    20   c,  and  20   e  being cleaned while the second plurality of filters  20   b,    20   d,  and  20   f  is serve actively in the filter housing  18 . This arrangement allows the filter subsystem to function substantially continuously. The various filters  20   a  through  20   f  translate laterally from the filter housing  18  in lateral tracks or channels  28  that extend from the side of the housing  18 . The filters  20   a  through  20   f  are provided with conventional wheels or rollers or the like (not shown), which may be motorized to provide for automatic operation. 
         [0021]    The filter cleaning system comprises a plurality of vertical standpipes  30  adjacent each of the tracks or channels  28 . Each standpipe  30  includes a plurality of filter wash nozzles  32  projecting therefrom, each nozzle  32  having a rotary brush  34  extending concentrically therefrom. The nozzles  32  serve to flush particulates from the filters being cleaned, while the brushes  34  provide a physical scrubbing action on the filters. The brushes  34  are driven by a motorized chain drive system or other conventional drive means. A backsplash guard is disposed opposite each row of standpipes  30 , i.e., each standpipe row is disposed between its backsplash guard and corresponding filter. A spillway  36  extends from the distal or outboard ends of the filter channels or tracks  28  to direct the expended filter wash water to an adjacent catch basin  38 . 
         [0022]    Once the gases have been drawn through the filters in the filter housing  18 , they are substantially free of particulate matter. The fans of the system  10  are located downstream from the filters  20   a  through  20   f  to assure that the fans are not contaminated with particulate matter carried by the gases during the operation of the fans.  FIG. 3  provides a detailed illustration of the fans that draw the gases through the filter housing  18  and deliver the gases to other subsystems for further processing. After passing through the filters in the filter housing  18 , the gas flows out of the housing  18  and through the outlet plenum  26  to an outlet flue  40 , from which it flows to divider pipes  42   a  and  42   b  that direct the two gas streams to corresponding valve assemblies  44   a  and  44   b.  The gas flow is then further divided by a fan inlet pipes  46   a  and  46   b  extending from each valve assembly  44   a,    44   b.  The fan inlet pipes  46   a,    46   b  connect to corresponding fan housings  48   a,    48   b.  The fan housings  48   a,    48   b  are substantially completely enclosed, except for their fluid communication with the fan inlet pipes  46   a,    46   b  and corresponding outlet pipes, described further below. However, the front panels of the enclosures or housings  48   a,    48   b  are shown broken away in  FIG. 3  to illustrate the fans  50   a  and  50   b  therein. While only a single fan is required to draw the gas through the filter housing  18 , preferably two such fans  50   a  and  50   b  are provided for redundancy. Thus, the present system  10  may operate substantially continuously so that either fan  50   a  or  50   b  may be shut down when required for maintenance or repair. The fans  50   a  and  50   b  may be of two different types, as illustrated in the example of  FIG. 3 , or may be of identical configuration.  109221  The gas flow control valve assemblies  44   a,    44   b  each comprise an enclosure containing a vertically hinged flapper valve therein, e.g., the valve  52  of the left side valve assembly  44   a,  shown partially broken away in  FIG. 3 . When the right hand fan  50   b  is in operation, the left hand fan  50   a  is shut down. Along with drawing the gases from the filter outlet flue  40  through the fan  50   b,  the fan  50   b  will also tend to draw air from the left-hand fan housing  48   a  through the left-hand inlet pipes  46   a.  This reverse flow draws the flapper valve  52  closed across the end of the divider pipe  42   a  where it connects to the valve assembly  44   a , thereby shutting off airflow from the first fan housing  48   a.  This position of the flapper valve  52  is shown in solid lines in the broken away valve housing  44   a  in  FIG. 3. 100231  Conversely, when the left side fan  50   a  is in operation and the right side fan  50   b  is idle, gas flow will be drawn through the first or left side divider  42   a  and through the first or left side valve assembly  44   a.  The direction of gas flow during this operation will push the flapper valve  52  open to allow the gas to be drawn through the first or left side fan  50   a.  This open valve position is shown in broken lines in the valve housing  44   a  of  FIG. 3 . It will be seen that the flapper valve within the opposite right side valve housing  44   b  will be positioned opposite the flapper valve in the first or left side valve housing  44   a  at all times during fan operation, i.e., the right side valve will be closed when the left side valve is open, and the right side valve will be open when the left side valve is closed. 
         [0023]    After being drawn through the filter subsystem by one of the fans  50   a  or  50   b,  the gases flow into corresponding fan housing outlet pipes  54   a  or  54   b  extending from their respective fan housings  48   a  or  48   b,  either outlet pipe manifold  54   a  extending from the first or left side fan housing  48   a  or outlet pipe manifold  54   b  extending from the second or right side fan housing  48   b,  depending upon which of the two fans  50   a  or  50   b  is in operation. The gases flow through the operative manifold  54   a  or  54   b  to corresponding connector pipes  56   a  or  56   b , which connect the two manifolds  54   a,    54   b  to a single gas classification collector pipe or flue  58 . The collector pipe  58  ducts the gases to a gas classification plant subsystem  60 , shown generally in  FIG. 1 , where the various gases (e.g., CO 2 , NO 2 , gaseous hydrocarbons, ammonia, etc.) are separated or classified into their respective compounds and/or elements. This may be accomplished by known and conventional means, e.g., cryogenic separation, molecular membranes, etc. These principles are known and used commercially, and need not be expanded upon in detail here. 
         [0024]    At this point, the gases will have been purified and separated into their constituent elements or compounds, as appropriate to the gases produced. However, some industrial factories and plants may produce certain gases that may be combusted, e.g., gaseous hydrocarbons and the like. Accordingly, the present system for decontaminating industrial output gases may include a gas burnoff and recirculation system, generally as illustrated in  FIG. 4  of the drawings. A gas burnoff delivery flue or pipe  62  delivers the gases from the classification plant subsystem  60  to a burnoff site  64 . The remaining gases are burned at the burnoff site  64 , and any residual gases are then captured by a hood  64  and recirculated back to the gas input flue  12  ( FIG. 1 ) by a return or recirculation flue  66  to be drawn back through the filter subsystem by the fan subsystem for further processing. 
         [0025]      FIG. 5  of the drawings provides a top plan view of an alternative embodiment of the system in which the output gases are cooled, rather than being filtered. This system is particularly suitable for installation with industrial plants having cooling towers that otherwise release large quantities of steam into the atmosphere. While the steam may generally be relatively pure in its composition, the water vapor contained in the steam may be useful if condensed back to its liquid state, particularly in arid areas of the world. 
         [0026]    Accordingly, the embodiment of  FIG. 5  replaces the filter subsystem illustrated in  FIGS. 1 and 2  with a gas cooling subsystem. The industrial output gases are delivered to the cooling subsystem by the gas input flue  12 , also shown in  FIGS. 1 and 2 . The flue  12  is connected to the inlet end of a gas cooling duct  68  installed in a cooling basin or tank  70 . A canopy  72  (shown in broken lines in  FIG. 5 ) may be provided to reduce solar heating of the duct  68  and water in the cooling basin  70 . The cooling duct  68  has an output end  74  that connects to the outlet flue  40 . A liquid recirculation line  76  may be provided to extend from the outlet end  74  of the gas cooling duct  68  back to the gas input flue  12  or to some other point for collection. 
         [0027]    The cooled gas then flows from the output end  74  of the cooling duct  68 , through the divider pipes  42   a,    42   b,  the two flapper valve assemblies  44   a,    44   b,  the fan housing inlet pipes or manifolds  46   a,    46   b,  and the fan housings  48   a,    48   b,  where the cooled gases are drawn through the system by either of the fans  50   a  or  50   b  (shown in  FIG. 3 ). The cooled gases then flow through the corresponding fan outlet pipe or manifold  54   a  or  54   b  to the corresponding connector pipe  56   a  or  56   b  to the collector pipe  58 , generally as shown in  FIG. 3  of the drawings. The cooled gas then flows to the classification plant subsystem  60  for further processing, if necessary. In the event of pure steam (or other pure gas) being released to pass through the system, the classification plant  60  is not required. 
         [0028]    The present system for decontaminating industrial output gases in any of its various embodiments also includes an operating or control system for the overall plant or system. This is illustrated in Fig. l of the drawings, which shows a control room or facility  78  communicating with the various subsystems of the overall system. A filter control system cable  80   a  extends from the control center  78  to the filter housing and subsystem  18 , and a fan control system cable  80   b  extends from the control center or facility  78  to the fans  50   a  and  50   b  in their housings  48   a  and  48   b.  A third control cable  80   c  extends from the control room or facility  78  to the gas classification plant  60 . The control system provides completely automated or manual control over all of the various subsystems of the complete system  10 . 
         [0029]    It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.