ENCLOSED COMBUSTOR

Abstract

An interchangeable enclosed combustor for combustion of vapors includes: an interchangeable multi-paneled, multi-tiered combustor housing having a plurality of panels coupled together in polygonal form and further arranged in multiple tiers of polygonal forms, thereby to form a vertical, columnar, polygonal stack to flame combust combustible vapors; and a burner manifold disposed within the vertical, columnar, polygonal stack to flame combust combustible vapors to reduce toxic emissions. The burner manifold natural draft burners and nozzles are configured to the ratio of air and fuel to mix to achieve stoichiometric combustion and reduce harmful emissions at a rate >98% destruction efficiency and inlet pressure of <1 oz./in2. The burner manifold includes at least one orifice of a predetermined size through which to draw fuel into a plurality of mixing chambers where air is drawn in through multiple stages of air intake ports that are sized based upon fuel type and pressure.

Claims

1. An interchangeable, modular enclosed combustor for enclosed flame combustion of combustible vapors, the enclosed combustor comprising: a first plurality of interchangeable, sectional panels of a first predetermined height configured for coupling one to another to form a first polygonal tier of the first predetermined height; a second plurality of interchangeable, sectional panels of a second predetermined height configured for coupling one to another to form a second polygonal tier of the second predetermined height, wherein the second plurality of panels is disposed on top of the first plurality of panels, vertically extending the enclosed combustor; a plurality of fasteners to couple interchangeably in modular form the second polygonal tier to the first polygonal tier; wherein the first and second polygonal tiers collectively form a vertical, columnar, polygonal stack within which to flame combust combustible vapors; wherein the enclosed combustor is expandable in diameter through the addition of more panels to extend an outer perimeter of the first and second polygonal tiers; wherein the enclosed combustor is expandable vertically in height by the addition of more polygonal tiers in stacked form; and a burner manifold disposed within the vertical, columnar, polygonal stack to flame combust combustible vapors.

2. The enclosed combustor of claim 1, further comprising: a third plurality of interchangeable, sectional panels of a third predetermined height configured for coupling one to another to form a third polygonal tier of the third predetermined height, wherein the third plurality of panels is disposed on top of the second plurality of panels, vertically extending the enclosed combustor; and a plurality of fasteners to couple interchangeably in modular form the third polygonal tier to the second polygonal tier.

3. The enclosed combustor of claim 2, further comprising: a fourth plurality of interchangeable, sectional panels of a fourth predetermined height configured for coupling one to another to form a fourth polygonal tier of the fourth predetermined height, wherein the fourth plurality of panels is disposed on top of the third plurality of panels, vertically extending the enclosed combustor; and a plurality of fasteners to couple interchangeably in modular form the fourth polygonal tier to the third polygonal tier.

4. The enclosed combustor of claim 1, wherein the first plurality of interchangeable, sectional panels of a first predetermined height configured for coupling one to another to form a first polygonal tier of the first predetermined height comprises vented panels.

5. The enclosed combustor of claim 1, wherein the first plurality of interchangeable, sectional panels and the second plurality of interchangeable, sectional panels comprise a number of panels that varies based upon an application of the enclosed combustor and capacity requirements.

6. The enclosed combustor of claim 1, wherein the first plurality of interchangeable, sectional panels and the second plurality of interchangeable, sectional panels comprise interchangeable, lightweight stainless-steel panels that are precision cut for accuracy and repeatability and formed to add strength and rigidity.

7. The enclosed combustor of claim 1, further comprising: a burner management system to control a gas train and the burner manifold.

8. The enclosed combustor of claim 1, wherein the burner manifold disposed within the vertical, columnar, polygonal stack to flame combust combustible vapors further comprises a plurality of burners and nozzles; wherein the burner manifold comprises natural draft burners and is configured to mix air with fuel through a natural draft; and wherein the nozzles are configured to allow a correct ratio of air and fuel to mix to achieve stoichiometric combustion.

9. The enclosed combustor of claim 1, wherein the first plurality of interchangeable, sectional panels and the second plurality of interchangeable, sectional panels comprise laser-cut, stainless steel panels thereby to provide a precise, rigid, and lightweight structure.

10. The enclosed combustor of claim 1, wherein the burner manifold further comprises at least one orifice of a predetermined size through which to draw fuel into a plurality of mixing chambers where air is drawn in through multiple stages of air intake ports that are sized based upon fuel type and pressure.

11. The enclosed combustor of claim 1, wherein the burner manifold further comprises a plurality of natural draft burners that are spaced in a predetermined pattern thereby to eliminate air starvation.

12. An interchangeable enclosed combustor for enclosed flame combustion of combustible vapors, the enclosed combustor comprising: an interchangeable multi-paneled, multitiered combustor housing comprising a plurality of panels coupled together and arranged in a polygonal form and further arranged in multiple tiers of polygonal forms, thereby to form a vertical, columnar, polygonal stack to flame combust combustible vapors; and a burner manifold disposed within the vertical, columnar, polygonal stack to flame combust combustible vapors within the housing and to reduce toxic emissions.

13. The enclosed combustor of claim 12, wherein the burner manifold further comprises a plurality of burners and nozzles; and wherein the burner manifold is configured to mix air with fuel through a natural draft.

14. The enclosed combustor of claim 13, wherein the nozzles are configured to allow a correct ratio of air and fuel to mix to achieve stoichiometric combustion.

15. The enclosed combustor of claim 12, wherein the burner manifold and nozzles are configured to allow a correct ratio of air and fuel to mix to achieve stoichiometric combustion.

16. The enclosed combustor of claim 12, wherein the wherein the burner manifold and nozzles are configured to the ratio of air and fuel to mix to achieve stoichiometric combustion and reduce harmful emissions at a rate >98% destruction efficiency and inlet pressure of <1 oz/in2.

17. The enclosed combustor of claim 12, wherein the burner manifold further comprises at least one orifice of a predetermined size through which to draw fuel into a plurality of mixing chambers where air is drawn in through multiple stages of air intake ports that are sized based upon fuel type and pressure.

18. The enclosed combustor of claim 12, wherein the burner manifold further comprises a plurality of natural draft burners that are spaced in a predetermined pattern thereby to eliminate air starvation.

19. An interchangeable, modular enclosed combustor for enclosed flame combustion of combustible vapors, the enclosed combustor comprising: a first plurality of interchangeable, sectional panels of a first predetermined height configured for coupling one to another to form a first polygonal tier of the first predetermined height; a second plurality of interchangeable, sectional panels of a second predetermined height configured for coupling one to another to form a second polygonal tier of the second predetermined height, wherein the second plurality of panels is disposed on top of the first plurality of panels, vertically extending the enclosed combustor; a plurality of fasteners to couple interchangeably in modular form the second polygonal tier to the first polygonal tier; a third plurality of interchangeable, sectional panels of a third predetermined height configured for coupling one to another to form a third polygonal tier of the third predetermined height, wherein the third plurality of panels is disposed on top of the second plurality of panels, vertically extending the enclosed combustor; and a plurality of fasteners to couple interchangeably in modular form the third polygonal tier to the second polygonal tier. wherein the first, second, and third polygonal tiers collectively form a vertical, columnar, polygonal stack within which to flame combust combustible vapors; wherein the enclosed combustor is expandable in diameter through the additional of more panels to extend an outer perimeter of the first and second polygonal tiers; wherein the enclosed combustor is expandable vertically in height by the addition of more polygonal tiers in stacked form; a burner manifold disposed within the vertical, columnar, polygonal stack to flame combust combustible vapors within the housing and to reduce toxic emissions; wherein the burner manifold further comprises a plurality of natural draft burners and nozzles that are spaced in a predetermined pattern thereby to eliminate air starvation; and wherein the burner manifold and nozzles are configured to allow a correct ratio of air and fuel to mix to achieve stoichiometric combustion.

20. The interchangeable, modular enclosed combustor of claim 19, wherein the burner manifold of natural draft burners and nozzles are configured to the ratio of air and fuel to mix to achieve stoichiometric combustion and reduce harmful emissions at a rate >98% destruction efficiency and inlet pressure of <1 oz./in2; and wherein the burner manifold further comprises at least one orifice of a predetermined size through which to draw fuel into a plurality of mixing chambers where air is drawn in through multiple stages of air intake ports that are sized based upon fuel type and pressure.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] The technology described herein is illustrated with reference to the various drawings, in which like reference numbers denote like device components and/or method steps, respectively, and in which:

[0042] FIG. 1 is a front perspective view of an enclosed combustor, illustrating, in particular, the portable, interchangeable, modular design of the enclosed combustor that enables the entire assembly to be easily expanded or downsized as needed for a particular application, with a multi-panel, multi-tier assembly design, according to an embodiment of the technology described herein;

[0043] FIG. 2 is an exploded view of the enclosed combustor depicted in FIG. 1, further illustrating the burner manifold contain within, according to an embodiment of the technology described herein;

[0044] FIG. 3 is a close-up view of the enclosed combustor depicted in FIG. 1, further illustrating the fasteners with which to couple the multiple panels and multiple tiers of panels together, that enables the entire assembly to be easily expanded or downsized as needed for a particular application, according to an embodiment of the technology described herein;

[0045] FIG. 4 is a front perspective view of a burner manifold having a multiplicity of burners, illustrating, in particular, the gas orifice and the multi-stage air intake ports located on the individual mixing chambers, according to an embodiment of the technology described herein;

[0046] FIG. 5 is a front perspective view of the burner manifold, illustrating a close-up view of the multiple burners, the gas orifice and the multi-stage air intake ports located on the individual mixing chambers, according to an embodiment of the technology described herein;

[0047] FIG. 6 is a front perspective view of the enclosed combustor depicted in FIG. 1, further illustrating a close-up of the lower tiers of panels in the multi-panel, multi-tier assembly; and

[0048] FIG. 7 is a front perspective view of the enclosed combustor depicted in FIG. 1, further illustrating a close-up of the upper tiers of panels in the multi-panel, multi-tier assembly.

DETAILED DESCRIPTION OF THE INVENTION

[0049] Before describing the disclosed embodiments of this technology in detail, it is to be understood that the technology is not limited in its application to the details of the particular arrangement shown here since the technology described is capable of other embodiments. In addition, the terminology used herein is for the purpose of description and not of limitation.

[0050] In various exemplary embodiments, the technology described herein provides an improved, low-cost enclosed combustor to destruct vapors that are harmful to the environment such as hydrocarbons. Additionally, the technology described herein provides an interchangeable, modular panel structure for the enclosed combustor and to a burner manifold and nozzles to regulate the ratio of air and gas to achieve stoichiometric combustion.

[0051] Known manufacturers of enclosed combustion devices include Flare Industries, ABUTEC, Zeeco, and Cimarron Energy. There are numerous deficiencies and shortcomings in these known devices, systems, and methods that are utilized to reduce emissions such as hydrocarbons. By way of example, these devices cannot change capacity, and require heavy equipment and specialized teams to install and start them up. Also, by way of example, a major issue is the cost and time it takes install one of these enclosed combustion systems. The current combustors are typically shipped on large flatbed trucks to remote locations in multiple large pieces that require a crane and an operator to offload. These large pieces require several men and heavy equipment to set in place. Due to the remote locations of the typical installation the cost for labor and heavy equipment is at a premium. Thus, there are numerous deficiencies and shortcomings in these known devices, systems, and methods.

[0052] The technology disclosed herein has a unique construction design, is lower cost, lightweight, efficient, with interchangeable panels and burners for varying the capacity and is easily installed by two technicians with basic hand tools. For example, the system is made of several interchangeable, lightweight stainless-steel panels that are precision cut for accuracy and repeatability and formed to add strength and rigidity. These panels, along with the gas train, burner manifold, and burner management system (items required to be a complete combustor system) are shipped in a crate that can be delivered in the back of a standard full-size pickup truck. The lightweight panels can be handled by two men and the entire system can be assembled in about one hour with hand tools.

[0053] Also, by way of example, another issue that is a common concern among current enclosed combustion systems is their efficiency. The Environmental Protection Agency (EPA) ruling NSPS OOOO & OOOOa 60.5413(d) requires that and emissions control device must be tested using Propylene gas. Propylene is used due to its nature of being heavier than air and very difficult to destruct through a natural draft combustion at low inlet pressures. The majority of the applications where these combustion devices are used are low pressures typically <2-4 oz./in2. The majority of the combustors on the market today have difficulty completely destructing this gas at this low-pressure range. This is witnessed by dark smoke exiting the outlet of the combustion stack.

[0054] The technology disclosed herein is designed with combustion efficiency as a top priority. This technology uses a burner manifold with multiple natural draft burners. Each individual burner on the manifold was engineered to draw in the proper amount of air to mix with fuel to provide stoichiometric combustion.

[0055] Referring now to the Figures, the technology described herein provides an interchangeable, modular enclosed combustor 100 for enclosed flame combustion of combustible vapors.

[0056] The enclosed combustor 100 includes a first plurality of interchangeable, sectional panels 108. The first plurality of interchangeable, sectional panels 116 (vented) are of a first predetermined height configured for coupling one to another to form a first polygonal tier 108 of the first predetermined height.

[0057] As depicted in the Figures the panels 116 of the first polygonal tier 108 are vented with a plurality of vents 118. Depending on the application, panels 110 that do not include vents are utilized.

[0058] The enclosed combustor 100 includes a second plurality of interchangeable, sectional panels 110. The second plurality of interchangeable, sectional panels 110 are of a second predetermined height configured for coupling one to another to form a second polygonal tier 106 of the second predetermined height.

[0059] The second plurality of panels, the second polygonal tier 106, is disposed on top of the first plurality of panels, the first polygonal tier 108. This modular, interchangeable assembly vertically extends the enclosed combustor 100. The tiers 108, 106, 104, 102 can include rims or lips formed in the panels 110, 116, such as 112 on both lower and upper powers that provide an area to contact the next adjacent tier for securing tiers together. Additional corner supports, such as 120, can be utilized to secure tiers together and to secure the lowest tier 108 to a base surface. Panels 110, 116 may also include one or more handles 114.

[0060] A plurality of fasteners 200 are used to couple interchangeably in modular form the second polygonal tier 106 to the first polygonal tier 108. The first and second polygonal tiers 108, 106 collectively form a vertical, columnar, polygonal stack within which to flame combust combustible vapors.

[0061] The enclosed combustor 100 is expandable in diameter through the addition of more panels to extend an outer perimeter of the first and second polygonal tiers 108, 106, and any subsequently added tiers.

[0062] The enclosed combustor 100 is expandable vertically in height by the addition of more polygonal tiers 108, 106, and subsequent stacks tiers, in stacked form.

[0063] The enclosed combustor 100 includes a burner manifold 300 disposed within the vertical, columnar, polygonal stack to flame combust combustible vapors.

[0064] In at least one embodiment of the interchangeable, modular enclosed combustor 100, the enclosed combustor also includes a third plurality of interchangeable, sectional panels of a third predetermined height configured for coupling one to another to form a third polygonal tier 104 of the third predetermined height. The third plurality of panels is disposed on top of the second plurality of panels, vertically extending the enclosed combustor 100. A plurality of fasteners is used to couple interchangeably in modular form the third polygonal tier to the second polygonal tier.

[0065] In at least one embodiment of the interchangeable, modular enclosed combustor, the enclosed combustor also includes a fourth plurality of interchangeable, sectional panels of a fourth predetermined height configured for coupling one to another to form a fourth polygonal tier 102 of the fourth predetermined height. The fourth plurality of panels is disposed on top of the third plurality of panels, vertically extending the enclosed combustor 100. A plurality of fasteners is used to couple interchangeably in modular form the fourth polygonal tier to the third polygonal tier.

[0066] In at least one embodiment of the interchangeable, modular enclosed combustor 100, the first plurality of interchangeable, sectional panels of a first predetermined height configured for coupling one to another to form a first polygonal tier of the first predetermined height comprises vented panels 118.

[0067] In at least one embodiment of the interchangeable, modular enclosed combustor 100, the first plurality of interchangeable, sectional panels and the second plurality of interchangeable, sectional panels comprise a number of panels that varies based upon an application of the enclosed combustor and capacity requirements.

[0068] In at least one embodiment of the interchangeable, modular enclosed combustor 100, the first plurality of interchangeable, sectional panels and the second plurality of interchangeable, sectional panels comprise interchangeable, lightweight stainless-steel panels that are precision cut for accuracy and repeatability and formed to add strength and rigidity.

[0069] In at least one embodiment of the interchangeable, modular enclosed combustor 100, the enclosed combustor further includes a burner management system to control a gas train and the burner manifold.

[0070] In at least one embodiment of the interchangeable, modular enclosed combustor 100, the burner manifold 300 disposed within the vertical, columnar, polygonal stack to flame combust combustible vapors further comprises a plurality of burners and air nozzles 302 and gas nozzles 306. The burner manifold 300 comprises natural draft burners and is configured to mix air with fuel through a natural draft. The air and gas nozzles 302, 306 are configured to allow a correct ratio of air and fuel to mix to achieve stoichiometric combustion.

[0071] In at least one embodiment of the interchangeable, modular enclosed combustor 100, the first plurality of interchangeable, sectional panels and the second plurality of interchangeable, sectional panels comprise laser-cut, stainless steel panels thereby to provide a precise, rigid, and lightweight structure.

[0072] In at least one embodiment of the interchangeable, modular enclosed combustor, the burner manifold further comprises at least one gas orifice 310 of a predetermined size through which to draw fuel into a plurality of mixing chambers where air is drawn in through multiple stages of air intake ports (for example, and not of limitation, primary air intake(s) 308 and secondary air intake(s) 304) that are sized based upon fuel type and pressure.

[0073] In at least one embodiment of the interchangeable, modular enclosed combustor 100, the burner manifold 300 further comprises a plurality of natural draft burners that are spaced in a predetermined pattern thereby to eliminate air starvation.

[0074] In at least one embodiment of the interchangeable, modular enclosed combustor 100, the burner manifold and nozzles are configured to allow a correct ratio of air and fuel to mix to achieve stoichiometric combustion. The burner manifold and nozzles are configured to the ratio of air and fuel to mix to achieve stoichiometric combustion and reduce harmful emissions at a rate >98% destruction efficiency and inlet pressure of <1 oz./in2.

[0075] In at least one embodiment of the interchangeable, modular enclosed combustor 100, the burner manifold further comprises at least one orifice of a predetermined size through which to draw fuel into a plurality of mixing chambers where air is drawn in through multiple stages of air intake ports that are sized based upon fuel type and pressure.

[0076] In at least one embodiment of the interchangeable, modular enclosed combustor 100, the burner manifold 300 further comprises a plurality of natural draft burners that are spaced in a predetermined pattern thereby to eliminate air starvation. By way of example, it is beneficial to have the burners close together, but if they are too close, air starvation can occur. This can be observed, for example, by the flame, such as a low blue flame preferred over a large yellow flame. These indications of flame color and flame size aid on the determination of the ideal spacing.

[0077] Although this technology has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples can perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the invention and are intended to be covered by the following claims.