CATALYTIC COOKSTOVE WITH PASSIVE CONTROL OF DRAFT AND METHOD OF USE

Abstract

A catalytic cookstove, for use in cooking, heating, and lighting, is disclosed for reducing particulate matter and carbon monoxide emissions. A non-platinum group metal catalyst promotes oxidation of particulate matter and carbon monoxide to produce carbon dioxide. Additionally, a passive damper automatically adjusts the fuel-to-air ratio based upon the size of fuel fed to the stove to ensure catalyst light off.

Claims

1. A solid-fuel burning stove comprising: a stove body defining a combustion chamber; the stove body comprising an inlet adapted to receive solid fuel, the inlet being disposed substantially at a base of the combustion chamber and the inlet defining a passage for the intake of air and fuel into the chimney; and a catalyst coated substrate comprising a PGM-free, catalytic compound and adapted to permit the flow of exhaust gases therethrough and to expose the catalytic compound to the exhaust gases, the catalyst coated substrate being disposed substantially across the width of the combustion chamber.

2. The solid fuel burning stove of claim 1 further comprising a passive damper disposed within the inlet, the damper adapted to at least partially block the flow of air into the chimney; wherein the damper is adapted to transition from a first position to a second position upon impingement thereon by solid fuel received into the inlet.

3. The solid fuel burning stove of claim 1 further comprising a support disposed on the stove body above the exhaust conduit, the support adapted to receive a cooking vessel.

4. The solid fuel burning stove of claim 2 wherein: the passive damper is comprised of a plate suspended from a hinge, the hinge being disposed along the top of the inlet; the hinge and plate are adapted to enable the plate to swing from a substantially vertical position to an angled position; and the plate blocks a greater proportion of the inlet passage in the vertical position than in the angled position.

5. The solid fuel burning stove of claim 4 wherein the plate is perforated.

6. The solid fuel burning stove of claim 2 wherein the passive damper comprises a substantially flexible curtain suspended from the top of the inlet, the curtain being adapted to swing from the top of the inlet.

7. The solid fuel burning stove of claim 2 wherein the passive damper comprises one or more substantially flexible fire-resistant strands, the one or more strands being adapted to swing from the top of the inlet.

8. The solid fuel burning stove of claim 1 further comprising a rack disposed within the inlet, the rack adapted to support solid fuel above the floor of the inlet and to permit the flow of air below the solid fuel.

9. The solid fuel burning stove of claim 1 wherein the catalytic compound comprises a non-platinum group metal.

10. The solid fuel burning stove of claim 9 wherein the catalytic compound comprises potassium.

11. The solid fuel burning stove of claim 10 wherein the catalytic compound comprises potassium titanate.

12. The solid fuel burning stove of claim 11 wherein the catalytic compound comprises K.sub.2Ti.sub.2O.sub.5.

13. The solid fuel burning stove of claim 12 wherein the catalytic compound is doped with cobalt or copper.

14. The solid fuel burning stove of claim 9 wherein the catalytic compound comprises a non-platinum group metal oxide containing one or more metals selected from the group of non-platinum group metals comprising potassium, manganese, strontium, titanium, copper, cobalt, calcium, silicon, and cerium.

15. The solid fuel burning stove of claim 1 wherein said catalyst coated substrate comprises a substrate supporting the catalytic compound.

16. The solid fuel burning stove of claim 15 wherein the substrate is a refractory ceramic.

17. The solid fuel burning stove of claim 15 wherein the substrate comprises a metal.

18. The solid fuel burning stove of claim 17 wherein the substrate comprises an iron-chromium-aluminum alloy.

19. The solid fuel burning stove of claim 15 wherein the substrate is a honeycomb monolith, a spiral monolith, a mesh, a series of meshes, a plurality of beads of any shape, raschig rings, or a combination thereof.

20. The solid fuel burning stove of claim 1 wherein the catalyst coated substrate has a void fraction greater than 65%.

21. The solid fuel burning stove of claim 1 wherein the catalyst coated substrate has a thickness of less than 1.5 inches.

22. The solid fuel burning stove of claim 1 wherein the catalyst coated substrate has an average channel diameter in the range of 0.1 inches to 0.3 inches.

23. The solid fuel burning stove of claim 1 wherein the catalyst coated substrate is disposed in a location exposed to flames when the solid fuel burning stove is operated.

24. A method for using the solid fuel burning stove of claim 1 comprising the steps of: placing an amount of solid fuel in the inlet; impinging on the damper with the amount of solid fuel, causing the damper to transition from the first position to the second position; and igniting the solid fuel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] FIG. 1 is an isometric view of a small solid-fuel cookstove in accordance with one embodiment of the present invention.

[0025] FIG. 2 is a cross-sectional isometric view of the internal components of the small solid-fuel cookstove in accordance with the same embodiment of the present invention.

[0026] FIGS. 3A and 3B are cross-sectional side views of the small solid-fuel cookstove in accordance with the same embodiment of the present invention being fed a small amount of solid fuel (FIG. 3A) a large amount of solid fuel (FIG. 3B).

DETAILED DESCRIPTION OF THE DRAWINGS

[0027] Now referring to FIG. 1, an embodiment of a catalytic cookstove 11 in accordance with the present invention is shown with a fuel feed inlet 12 capable of accommodating both small and large pieces of solid fuel. At the top of the catalytic cookstove 11, a pot support 13 may be affixed to the top of the stove body 14. Pot support 13 may be removably affixed to stove body 14. The method by which the pot support 13 is affixed to a stove body 14 can take many forms, including but not limited to, using rivets, screws, bolts, high-temperature adhesives, or metal joining. Pot support 13 may also simply sit atop stove body 14 and not be affixed thereto. The pot support 13 includes one or more protruding structures 15, upon which a cooking vessel rests. The protruding structures 15 extend above the rest of the pot support 13 to allow hot gases to exit the cookstove 11 and transfer heat to a cooking vessel. The pot support 13 can accommodate a wide range of cooking vessels, including, but not limited to pots, pans, skillets, comals, woks, Dutch ovens, and tea pots. The pot support 13 can also support a grill grate for grilling meats and vegetables.

[0028] During use fuel is fed through the fuel feed inlet 12 and may rest on a fuel rack 16. A fire is ignited within the cookstove 11 and the fire is fed by the operator pushing additional fuel through the fuel feed inlet 12. If the cookstove is equipped with a fuel rack, as fuel is fed to the fire, it sits on the fuel rack 16, rather than the base of the cookstove 11. The fuel can be any solid fuel such as wood, charcoal, pellets, dung, agricultural residues and the like. In addition to fuel, the fire also requires oxygen to remain lit. Oxygen is supplied by air that flows into the cookstove 11 through the fuel feed inlet 12. Air flow is driven by the cookstove's 11 draft, which is a pressure differential that induces air flow and is caused by the elevated fire temperature. When used, the fuel rack 16 allows for air to flow under and through the solid fuel rather than around or above the solid fuel. The fuel rack 16 can be affixed to the catalytic cookstove 11 or it can be a separate and distinct component. The fuel rack 16 can take many forms, including but not limited to a wire rack, a solid plate, a perforated plate, or a set of rungs. The fuel rack 16 also allows ash and small coals to fall to the bottom of the cookstove 11. This prevents the fire from being choked as ash accumulates. In one embodiment of the present invention, the ash falls into a removable ash pan to allow for easy ash disposal. As air flows through the cookstove 11, the air heats up to form a hot flue gas that travels vertically from the combustion chamber up and out of the catalytic cookstove 11 via buoyancy driven flow. Heat transfer from the hot flue gases produced by such a fire is the primary mechanism by which a cooking vessel (not shown) is heated.

[0029] FIG. 2 shows a cross sectional isometric view of the internal components of the catalytic cookstove 11. The stove combustion chamber 21 occupies the center of the catalytic cookstove 11 and extends vertically. Air enters the stove through the fuel feed inlet 12 where it passes under and around the fuel rack 16 (when so equipped). The air is then heated by a fire located at the central base of the cookstove 11 and passes vertically up through the stove combustion chamber 21 and through a catalyst coated substrate 22 which is comprised of a substrate that provides an overarching structure and a catalytic compound that is coated on the surface of the substrate. Extending beyond the catalyst coated substrate 22, is the exhaust conduit 26 which directs combustion gases and unreacted air out of the stove. The volumetric flow rate and velocity of air through the stove is driven by a draft caused by the temperature difference between the fire and the ambient. Obstructions and constrictions increase the pressure drop through the cookstove 11 and can hinder overall airflow by reducing the stove draft. Based on these constraints, it is important that the catalyst coated substrate 22 have a geometry sufficient to allow a proper stove draft. The substrate of the catalyst coated substrate 22 is coated with an oxidation catalyst and is suspended within the stove combustion chamber 21 and above the fire. In one embodiment of the present invention, the stove combustion chamber narrows above the catalyst coated substrate 22 to ensure air velocity through the stove combustion chamber 21 remains constant.

[0030] During operation, a fire is located at the central base of the cookstove 11 and the fire is fed by combustion of a solid fuel. Complete combustion of the fuel would produce only carbon dioxide, water, and heat. However, because combustion requires oxygen to be readily accessible and well mixed with the fuel, combustion is rarely complete. This results in additional, partially oxidized products that are harmful to human health, and include carbon monoxide, particulate matter, and partially oxidized organics. Upon leaving the fire, partially oxidized products quickly cool to a temperature where unassisted oxidation to carbon dioxide is no longer possible. As the partially oxidized products travel up through the stove combustion chamber 21, they come into contact with the catalyst coated substrate 22, which is coated with an oxidation catalyst. In one embodiment of the present invention, the oxidation catalyst is potassium-based. The catalyst effectively reduces the temperature at which oxidation occurs. Therefore, the catalyst facilitates the oxidation of carbon monoxide, particulate matter, and partially oxidized organics to carbon dioxide.

[0031] Insulation 23 is optionally located between the stove combustion chamber 21 and the stove body 14. Insulation 23 can be any refractory material with insulating properties and is used to improve thermal efficiency. A passive damper 24 is attached to a hinge-like mechanism 25 and suspended at the top of the fuel feed inlet 12. The passive damper 24 is able to rotate around an axis defined by the hinge-like mechanism 25 when impinged by solid fuel. The rotational nature of the passive damper 24 allows the catalytic cookstove 11 to accommodate a range of solid fuel sizes. In alternative embodiments, the damper may comprise a flexible curtain or shroud-like barrier composed of flexible, vertically hanging, fire resistant strands.

[0032] FIG. 3A and 3B show the catalytic cookstove 11 accommodating different sizes or quantities of fuel. FIG. 3A shows the catalytic cookstove 11 being fed with a small amount of solid fuel. In this scenario, the passive damper 24 remains in a vertical resting position. The passive damper 24 then acts to obstruct the free flow of air into the stove and prevent the air-to-fuel ratio from becoming excessively fuel lean. By maintaining the air-to-fuel ratio within an acceptable range, the passive damper 24 ensures the catalytic cookstove 11 operates efficiently.

[0033] FIG. 3B shows a second scenario where the catalytic cookstove 11 is fed with a large amount of solid fuel. In this scenario, the passive damper 24 rotates around the hinge-like mechanism 25 and towards the back of the catalytic cookstove 11 to accommodate the passage of the larger fuel through the fuel feed inlet 12. The cross-section that was occupied by the passive damper 24 is now partially occupied by the fuel, and therefore the air-to-fuel ratio remains within the acceptable range and the catalytic cookstove 11 is able to operate efficiently. As the fuel burns down and its size is reduced, the passive damper 24 swings down to meet the reduced size fuel and thus self-adjusts the air to fuel ratio.

[0034] While we have shown and described several embodiments in accordance with our invention, it should be understood that the same is susceptible to further changes and modifications without departing from the scope of our invention. Therefore, we do not want to be limited to the details shown and described herein but intend to cover all such changes and modifications as are encompassed by the scope of the appended claims.

EXAMPLES

[0035] The following examples are intended to be illustrative of the present invention and to teach one of ordinary skill how to make and use the invention. These examples are not intended to limit the invention or its protection in any way.

Example 1

Particulate Matter Emissions from a Catalytic Cookstove

[0036] The present invention was tested in a laboratory setting to demonstrate a reduction in particulate matter and carbon monoxide emissions. Tests were conducted using an abbreviated version of the Water Boil Test (WBT) Version 4.2.2 developed by the International Organization for Standardization (ISO) as an International Workshop Agreement (IWA). The WBT consists of three different stages (cold start, hot start, and simmer phase) that approximate different cooking phases. Each WBT involved measuring stove emissions, heat addition to the water, and fuel consumption. Starting with a cold stove and 5 liters of water in an aluminum pot, a fire was lit and maintained to bring the water to its boiling temperature Immediately following the cold start, the fire was extinguished, fresh water was placed in the pot, and a new fire was kindled. The new pot of water was once again brought to a boil, ending the hot-start phase of the WBT. When the hot start was finished, the pot of water was held within 6 C. of the boiling temperature for a total of 45 minutes; this stage of the WBT was considered the simmer phase. During the WBT a dedicated hood exhaust system was used to collect stove emissions for measurement. Concentrations of particle mass, particle number, carbon monoxide, carbon dioxide, total hydrocarbons, and nitrogen oxides were measured throughout the WBT.

[0037] Four stove configurations were tested using the WBT: 1) a baseline stove, 2) a stove with a non-catalytic 0.5-inch monolith, 3) a stove with a catalytic 0.5-inch monolith, and 4) a stove with restricted airflow and a catalytic 0.5-inch monolith. The catalyst used here was potassium titanate (specifically, K.sub.2Ti.sub.2O.sub.5). Compared to the baseline stove, a stove incorporating a non-catalytic monolith increased particulate matter emissions by 16%. Coating the same monolith with catalyst reduced particulate matter emissions by 12% compared to the baseline stove. Furthermore, restricting air flow into the stove in conjunction with a catalytic monolith reduced particulate matter emissions by 36% compared to the baseline stove. These results demonstrated the effectiveness of incorporating a potassium-based catalyst within a cookstove.

Example 2

Carbon Monoxide Oxidation

[0038] The carbon monoxide oxidation activity of K.sub.2Ti.sub.2O.sub.5 was determined using a small packed bed reactor. A known amount of carbon monoxide in air (100 ppm, by volume) was flown through a small tubular reactor without catalyst as a baseline and packed with catalyst. Without a catalyst, carbon monoxide remained unreacted up to 700 C. Packing the reactor with K.sub.2Ti.sub.2O.sub.5 caused carbon monoxide to be oxidized as low as 500 C. (4% conversion) with conversion reaching 45% at 700 C. Doping K.sub.2Ti.sub.2O.sub.5 with copper or cobalt significantly lowered the temperature for which carbon monoxide oxidation began and improved carbon monoxide conversion. After doping with either copper or cobalt, carbon monoxide oxidation was observed as low as 300 C. (10-20% conversion), and by 700 C. carbon monoxide conversion was approximately 90% for each metal doped catalyst. Based on these results, doping K.sub.2Ti.sub.2O.sub.5 with copper or cobalt can reduce carbon monoxide stove emissions and increase carbon monoxide conversion upward of 55% to 90%.