Heater with replaceable cartridge
10018305 ยท 2018-07-10
Assignee
Inventors
Cpc classification
Y10T137/6443
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F17C2225/0123
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17C2223/033
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17C7/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17C2227/0302
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17C2201/054
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17C2270/0134
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23D2203/107
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23C2900/13001
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23D2900/00003
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17C2201/0114
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17C2203/0617
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23D2213/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17C2205/018
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17C2205/0379
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17C2260/053
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y10T29/4973
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F17C2225/035
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17C2221/035
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17C2227/0386
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23C13/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17C2270/0745
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23D14/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17C2201/035
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F17C7/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23C13/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A catalytic tank heater includes a removably attached catalytic heater cartridge having catalytic material. The heater is attached to an LPG tank to position the catalytic heater cartridge to face the tank. The catalytic heater cartridge covers a plenum chamber of the catalytic tank heater. A fuel distribution header and heating element are positioned within the plenum chamber and are controlled to initiate combustion of the catalytic material to heat the tank. Vapor from the tank is provided as fuel to the catalytic tank heater, and is regulated to increase heat output as tank pressure drops. The catalytic heater cartridge can be replaced with a new cartridge while at the location of the tank on a property.
Claims
1. A system, comprising: catalytic heater housing having an open space defining a plenum chamber, a first side panel, and a second side panel; a fuel supply line coupled to the catalytic heater housing and configured to deliver fuel to the plenum chamber from a fuel supply; an insulation layer positioned within the catalytic heater housing; a heating element positioned within the insulation layer extending along a length in a direction from the first side panel to the second side panel and being adjacent the plenum chamber; at least one catalytic heater cartridge containing a layer of catalyst material, the at least one catalytic heater cartridge being positioned adjacent the insulation layer and the heating element and removably attached to the catalytic heater housing to be removed without removing the insulation layer and the heating element, and the at least one catalytic heater cartridge covering the plenum chamber with a gas-tight seal to provide a substantially gas-tight seal to the plenum chamber within the catalytic heater housing; and wherein the insulation layer and the catalytic heating cartridge extend from the first side panel to the second side panel.
2. The system of claim 1, further comprising a fuel distribution header positioned in the plenum chamber and configured to deliver fuel to the plenum chamber from the fuel supply.
3. The system of claim 1, further comprising a sealing perimeter portion extending along a perimeter of the plenum chamber, wherein the at least one catalytic heater cartridge is biased to the sealing perimeter portion to provide the substantially gas-tight seal to the plenum chamber.
4. The system of claim 1, wherein the catalytic heater housing includes at least one attachment device to removably attach the at least one catalytic heater cartridge to the catalytic heater housing.
5. The system of claim 1, wherein the catalytic heater housing is configured to be coupled to a storage tank with the at least one catalytic heater cartridge facing the storage tank and spaced therefrom a distance sufficient to permit passage of air between the catalytic heater cartridge and the storage tank.
6. The system of claim 1, wherein the heating element is an electric heating element configured to heat the catalyst layer and initiate combustion when fuel is supplied to the plenum chamber.
7. The system of claim 5, wherein the catalytic heater housing includes a cabinet to substantially enclose a space between the at least one catalytic heater cartridge and a wall of the storage tank when coupled thereto.
8. The system of claim 1, further comprising a gas valve having a main fuel inlet coupled to the fuel supply line and configured to regulate a volume of fuel passing through the gas valve to the plenum chamber.
9. The system of claim 8, wherein the gas valve includes a main fuel outlet coupled to one end of a fuel distribution header and a pilot fuel outlet coupled to the other end of the fuel distribution header, wherein the fuel distribution header is positioned in the plenum chamber.
10. The system of claim 1, wherein the catalytic heater housing includes a thermoelectric element configured to produce an electrical potential while a heat differential is present across the thermoelectric element, and wherein operation of a gas valve is powered by the electrical potential produced by the thermoelectric element.
11. A system, comprising: a cylindrical storage tank configured to receive contents under pressure; a catalytic tank heater having an open space defining a plenum chamber, a first side panel, and a second side panel, and having an electric heating element positioned within an insulation layer that is located within or adjacent the plenum chamber; a main fuel inlet configured to deliver fuel to the plenum chamber; a replaceable catalytic heater cartridge having a catalyst layer, the cartridge removably coupled to the catalytic tank heater and covering the plenum chamber, the cartridge facing the storage tank and spaced therefrom a distance sufficient to permit passage of air between the cartridge and the storage tank, and sufficiently close that substantially any heat radiated outward from a face of the cartridge impinges on a wall of the storage tank, the cartridge configured to be removed from the catalytic tank heater and replaced with a replacement catalytic heater cartridge without removing the insulation layer and the electric heating element of the catalytic tank heater from the storage tank; and wherein the insulation layer and the catalytic heating cartridge extend from the first side panel to the second side panel while the electric heating element extends along a length in a direction from the first side panel to the second side panel.
12. The system of claim 11 wherein the electric heating element is configured to heat the catalyst layer to initiate combustion when fuel is supplied to the plenum chamber.
13. The system of claim 11, further comprising a sealing perimeter portion defined by a perimeter of the plenum chamber, the replaceable catalytic heater cartridge biased to the sealing perimeter portion to provide a substantially gas-tight seal to the plenum chamber.
14. The system of claim 11, further comprising a fuel distribution header positioned in the plenum chamber and having a main fuel supply port and a pilot fuel supply port, both coupled to the main fuel inlet to deliver fuel to the fuel distribution header.
15. The system of claim 11, wherein the replaceable catalytic heater cartridge includes a perimeter frame having a pair of grids defining a catalyst area, wherein the catalyst layer is positioned within the catalyst area.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
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DETAILED DESCRIPTION
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(11) With the known systems shown in
(12) These cumbersome and complicated procedures of these existing systems are required for at least two reasons. First, the catalyst layer 132 is quite difficult to handle because it is comprised of fibrous refractory material that is loose, pliable, soft and friable. The catalyst layers are typically comprised of a woven ceramic fiber pad that is treated with chemicals that attach to the fibers, such as platinum and palladium, which act as catalysts for the reaction between a combustion gas and oxygen. When such material is contaminated, it requires replacement by uncontaminated catalyst material, which requires servicing by skilled technicians at the manufacturer's factory or at a different servicing location. The second reason existing systems are cumbersome and complicated is because of the configuration of the existing heater system 104 and its heater element 106. As shown in
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(14) For purposes of illustration, the replaceable catalytic cartridge 208 is shown as a shadow box positioned within the cabinet 212. According to one method of operation, when the replaceable catalytic cartridge 208 requires replacement, a service technician or customer can simply remove the catalytic tank heater 206 from the tank 202 and replace the used replaceable catalytic cartridge 208 with a new replaceable catalytic cartridge. Alternatively, the service technician can disconnect only the top side walls 216 from the straps 210, open the cabinet 212, replace the cartridge 208 and reconnect the top side walls 216 to the straps 210; complete removal of the cabinet 212 is not required. The catalytic tank heater 206 can then be reattached to the tank 202 without the need to remove the catalytic tank heater 206 from the location of the tank 202 for servicing, as discussed above regarding the existing systems of
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(16) According to one method of operation, the tank 202 supplies vaporized gas to the load as required, according to known processes, absorbing heat from its environment to boil the liquefied gas as it is drawn. As long as the gas pressure remains above a selected threshold, the pressure at the control terminal 229 of the second regulator valve 224 is sufficient to hold the valve closed. However, in the event the pressure drops below the threshold, the valve 224 opens and catalytic tank heater 206 is activated to produce radiant heat by catalytic oxidation of the gas. As pressure drops in the tank 202, the reduction of pressure, as transmitted by the feedback line 227 to the control terminal 229 of the second regulator valve 224, opens the valve further, increasing the gas flow to the catalytic tank heater 206, and thereby increasing the amount of heat produced. As heat from the catalytic tank heater 206 is absorbed by the tank 202, it is conducted to the interior of the tank, and transferred to the liquefied gas inside, warming the gas and increasing the equilibrium temperature, resulting in an increased rate of boiling, thereby increasing tank pressure. The increased tank pressure is fed back, via the feedback line 227, to the second regulator valve 224, which reduces gas flow as the pressure rises, thereby regulating the tank pressure.
(17) An optional alternate fuel source 234 is shown, coupled to the first regulator valve 222 via alternate gas supply line 236a, shown in dotted lines. In the case where a storage tank is used to store liquefied gas that is not appropriate for use in a catalytic heater system, such as, e.g., anhydrous ammonia, vapor from the storage tank cannot be used to operate the catalytic tank heater 206. In such a case, the feedback line 227 is coupled directly to the outlet 230 of the tank 202, and the alternate supply line 236b replaces the line 236a of the supply line 228. The heater control circuit 220 operates substantially as described above to control the catalytic tank heater 206 to warm the tank 202, but draws fuel from the alternate fuel source 234. Additional heater control circuits are described in the '363 application, which include features that may be used with the features of the present disclosure, such as with respect to the features pertaining to FIGS. 7, 11, 16, and 19 of the '363 application, for example. It will be appreciated that some or all of the features and embodiments disclosed in the '363 application may be utilized with the components of the present disclosure, particularly as pertaining to operation with the catalytic tank heater 206 and replaceable catalytic cartridge 208 of the present disclosure.
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(19) In some aspects, the catalytic heater cartridge 208 covers the plenum chamber 240 to provide a substantially gas-tight seal to the plenum chamber (
(20) In some aspects, to remove a used catalytic heater cartridge 208, a person removes the fasteners 259 and L-brackets 258, then moves the second portion 256 of the cartridge 208 in a direction away from the heater 206, and then slides the first portion 250 out of the flange 252. When the used catalytic heater cartridge 208 is detached, the heating element and other components of the heater can be more easily serviced and/or replaced than with existing systems. To attach a new cartridge to the catalytic tank heater 206, the person can slide the first portion 250 into the flange 252 and then secure the second portion 256 with the L-brackets 258 and fasteners 259. Replacing the used catalytic heater cartridge 208 can be accomplished without completely removing the catalytic tank heater 206 from tank 202 (perhaps by disengaging only one of the straps 210). More importantly, replacing the used catalytic heater cartridge 208 can be accomplished without removing the catalytic tank heater 206 from the location where the tank 202 is situated. This provides all the advantages discussed above regarding the replaceability of the catalytic heater cartridge 208 from catalytic tank heater 206, all while servicing the system on-site.
(21) It will be appreciated that the catalytic heater cartridge 208 can be attached and removed from the catalytic tank heater 206 by other means and mechanisms, such as with other fasteners. The catalytic heater cartridge 208 may also be slidably engaged to the catalytic tank heater 206, such as a cassette. Accordingly, it is possible that it is not required to detach the catalytic tank heater 206 from the tank 202 because the catalytic heater cartridge 208 may simply slide into place from any position around the perimeter of the catalytic tank heater 206.
(22) In some aspects, a heating device 261 having a heating element 260 is coupled to the cabinet 212. The heating element 260 is positioned at least partially or wholly within the plenum chamber 240 and is configured to heat and initiate combustion in the catalyst layer 242 when fuel is supplied to the plenum chamber 240. The heating element 260 may be an electric heating element having terminals 262 connected to a power source. At least a portion of the heating element 260 may extend through a gas-permeable diffusion and insulation layer 264 contained in the plenum chamber 240 (
(23) As the temperature of the catalyst layer 242 reaches a selected threshold by conductive heat supplied by the heating element 260, gas is provided to the plenum chamber 240 via the fuel distribution header 266. The gas rises through the insulation layer 264 and to the heated catalyst layer 242 for combustion. The catalyst layer 242 is permeable to air, permitting air to pass into it, or as needed, through it to combust or react with the fuel provide from the plenum chamber. Once the heat output by the system is self-sustaining, electric power to the heating element 260 may be turned off or shut down so that no electrical component is active within the plenum chamber 240. The heat produced by the combustion of gas and oxygen, as facilitated by the catalyst material coating in the catalyst layer 242, is then transmitted by radiation to the wall 203 of the tank 202 to heat the LPG contained therein. The above heating operation may be accomplished and controlled by the control circuit 220 of
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(25) As best shown in
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(28) Depending upon the heating requirements of the system (as further described above), the gas valve 274 may be regulated by the heater control 220 to provide a selected volume of gas to the plenum chamber 240 only via the pilot fuel line 278. As such, catalytic combustion may be initiated by the gas provided by the pilot fuel line 278 and the heat provided by the heating element 260. Once combustion or reaction is initiated and if the heater control 220 determines that the pressure level in the tank 202 is below the threshold value, the gas valve 274 may be regulated to provide gas to the plenum chamber 240 via the main fuel supply line 276 to the fuel distribution header 266. At such time, gas may continue to be provided to the plenum chamber 240 via the pilot fuel line 278 concurrently with the main fuel line 276, although not required.
(29) As shown best in
(30) A thermoelectric device 286 may be coupled to the back panel 215 of the inner cabinet 213. Operation of thermoelectric devices are well known, and are commonly used to perform various functions, according to thermoelectric principles. The thermoelectric device 286 may generate electricity to power components of the system, such as the control circuit 220 and the gas valve 274, using waste heat produced by the catalytic tank heater 206, commonly known as the Seebeck principle. The thermoelectric device 286 may have the same or similar configuration as the thermoelectric device shown in
(31) The various embodiments described above can be combined to provide further embodiments. The U.S. patent application referred to in this specification and/or listed in the Application Data Sheet is incorporated herein by reference, in its entirety. Aspects of the embodiments can be modified, if necessary to employ concepts of the various patents, applications and publications to provide yet further embodiments.
(32) These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.