EMISSION REDUCTION SYSTEM

Abstract

A system for emission reduction may include a housing defining a housing interior, a gas inlet configured to receive gas, a first emission reduction module comprising a first catalytic heater, and internal tubing disposed in the housing interior and configured to transport and control the gas to the first catalytic heater of the first emission reduction module.

Claims

1. A system for emission reduction, the system comprising: a housing defining a housing interior; and a gas inlet configured to receive gas; a first emission reduction module comprising a first catalytic heater; and internal tubing disposed in the housing interior and configured to transport and control the gas to the first catalytic heater of the first emission reduction module.

2. The system of claim 1, further comprising a second emission reduction module comprising a second catalytic heater; wherein the internal tubing is configured to transport and control the gas to the second catalytic heater of the second emission reduction module.

3. The system of claim 1, wherein the first catalytic heater is inclined relative to a vertical direction at a first predetermined inclination angle.

4. The system of claim 3, wherein the second catalytic heater is inclined relative to a vertical direction at a second predetermined inclination angle.

5. The system of claim 4, wherein the first predetermined inclination angle is equal to the second predetermined inclination angle.

6. The system of claim 3, wherein the first predetermined inclination angle is greater than 0 degrees and less than or equal to 45 degrees.

7. The system of claim 3, wherein the first predetermined inclination angle is 15 degrees.

8. The system of claim 2, wherein the first catalytic heater and the second catalytic heater face each other within the housing.

9. The system of claim 2, wherein the first catalytic heater and the second catalytic heater are inclined toward each other.

10. The system of claim 2, further comprising a thermal energy conversion module provided within the housing in proximity to the first catalytic heater.

11. The system of claim 10, wherein the thermal energy conversion module is provided between the first catalytic heater and the second catalytic heater.

12. The system of claim 11, wherein: the thermal energy conversion module is disposed at an approximate center of the housing; and the first catalytic heater and the second catalytic heater are symmetrically disposed about the thermal energy conversion module.

13. The system of claim 10, wherein the heat exchanger is a glycol heat exchanger.

14. The system of claim 1, further comprising an air inlet vent provided on a bottom surface of the housing.

15. The system of claim 1, further comprising an exhaust module at a top surface of the housing.

16. A system for emission reduction, the system comprising: a first emission reduction module comprising a first catalytic heater; a second emission reduction module comprising a second catalytic heater; and a thermal energy conversion module provided between the first catalytic heater and the second catalytic heater; wherein the first catalytic heater is inclined relative to a vertical direction at a first predetermined inclination angle; and the second catalytic heater is inclined relative to a vertical direction at a second predetermined inclination angle.

17. The system of claim 16, wherein the first predetermined inclination angle is equal to the second predetermined inclination angle.

18. The system of claim 17, wherein: the first emission reduction module, the second emission reduction module, and the thermal energy conversion module are provided within a housing; the thermal energy conversion module is disposed at an approximate center of the housing; and the first catalytic heater and the second catalytic heater are symmetrically disposed about the thermal energy conversion module.

19. A method of reducing emissions, the method comprising: providing a system comprising: a housing defining a housing interior; a gas inlet configured to receive gas; a first emission reduction module comprising a first catalytic heater; internal tubing disposed in the housing interior and configured to transport and control the gas to the first catalytic heater of the first emission reduction module; and a thermal energy conversion module provided within the housing in proximity to the first catalytic heater; transferring heat energy from the first catalytic heater to the thermal energy conversion module; and using the heat energy transferred to the thermal energy conversion module to perform a task.

20. The method of claim 19, further comprising: providing a second catalytic heater such that the thermal energy conversion module is between the first catalytic heater and the second catalytic heater; and transferring heat energy from the second catalytic heater to the thermal energy conversion module.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0013] A more particular description will be rendered by reference to exemplary embodiments that are illustrated in the accompanying figures. Understanding that these drawings depict exemplary embodiments and do not limit the scope of this disclosure, the exemplary embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0014] FIG. 1 is a perspective view of an emission reduction system according to an exemplary embodiment.

[0015] FIG. 2 is a perspective view of an emission reduction system according to an exemplary embodiment.

[0016] FIG. 3 is a front view of an emission reduction system according to an exemplary embodiment.

[0017] FIG. 4 is a left side view of an emission reduction system according to an exemplary embodiment.

[0018] FIG. 5 is a rear view of an emission reduction system according to an exemplary embodiment.

[0019] FIG. 6 is a top view of an emission reduction system according to an exemplary embodiment.

[0020] FIG. 7 is a bottom view of an emission reduction system according to an exemplary embodiment.

[0021] FIG. 8 is a cross-section view of the emission reduction system of FIG. 4 along line A-A.

[0022] FIG. 9 is a cross-section view of the emission reduction system of FIG. 5 along line B-B.

[0023] FIG. 10 is a perspective view of an emission reduction system according to an exemplary embodiment.

[0024] FIG. 11A is a top view of a thermal energy conversion module according to an exemplary embodiment.

[0025] FIG. 11B is a side view of a thermal energy conversion module according to an exemplary embodiment.

[0026] FIG. 11C is a rear view of a thermal energy conversion module according to an exemplary embodiment.

[0027] FIG. 12 is a perspective view of an emission reduction system according to an exemplary embodiment.

[0028] FIG. 13A is a top view of a target plate cartridge according to an exemplary embodiment.

[0029] FIG. 13B is a side view of a target plate cartridge according to an exemplary embodiment.

[0030] FIG. 13C is a rear view of a target plate cartridge according to an exemplary embodiment.

[0031] FIG. 14 is a flowchart illustrating a method of reducing emissions according to an exemplary embodiment.

[0032] FIG. 15 is a schematic diagram illustrating operation of a first emission reduction module and a second emission reduction module according to an exemplary embodiment.

[0033] Various features, aspects, and advantages of the exemplary embodiments will become more apparent from the following detailed description, along with the accompanying drawings in which like numerals represent like components throughout the figures and detailed description. The various described features are not necessarily drawn to scale in the drawings but are drawn to aid in understanding the features of the exemplary embodiments.

[0034] The headings used herein are for organizational purposes only and are not meant to limit the scope of the disclosure or the claims. To facilitate understanding, reference numerals have been used, where possible, to designate like elements common to the figures.

DETAILED DESCRIPTION

[0035] Reference will now be made in detail to various exemplary embodiments. Each example is provided by way of explanation and is not meant as a limitation and does not constitute a definition of all possible embodiments. It is understood that reference to a particular exemplary embodiment of, e.g., a structure, assembly, component, configuration, method, etc. includes exemplary embodiments of, e.g., the associated features, subcomponents, method steps, etc. forming a part of the exemplary embodiment.

[0036] FIG. 1 through FIG. 10 illustrate one possible embodiment of a system for an emission reduction system 102. The emission reduction system 102 may include a housing 104 that defines a housing interior 118. The housing 104 may be supported by one or more legs 120. The housing 104 may further include power cord brackets 110 provided on an exterior of the housing 104 for storing power cords.

[0037] An exhaust module 106 may be provided on a top surface of the housing 104 and be configured to both release exhaust gas and protect the housing interior 118 from precipitation, dirt, and/or debris. The exhaust module 106 may include an exhaust thermometer 108 configured to measure a temperature of the exhaust gas. Additionally, the emission reduction system 102 may include further instrumentation and/or displays, such as a gas flow meter (not shown) coupled to an intake of the housing 104 and configured to display the amount of methane or other gases that have been processed. This information may be useful for documenting mitigation for carbon credit markets or for monitoring performance of the device. The displays on the emission reduction system 102 may be configured for real-time flow monitoring and/or batch data related to the amount of gas processed in a particular time period (e.g., per day, per week, per month, etc.). The emission reduction system 102 may further include communications modules configured to transmit data and/or receive instructions via wireless or wired communication.

[0038] The emission reduction system 102 may include a gas inlet 124 configured to receive gas such as methane from a wellhead or other sources that may vent methane to the atmosphere. The gas inlet 124 may be connected to internal tubing 126 provided within the housing interior 118. The term internal tubing 126 may be used to collectively refer to tubing, pipes, valves, connectors or other similar hardware used for transporting and controlling the gas.

[0039] The emission reduction system 102 may further include a first emission reduction module 122a and a second emission reduction module 122b, the details of which are described below. The emission reduction system 102 may also include thermal energy conversion module such as a heat exchanger cartridge 112 having a heat exchanger inlet 114 and a heat exchanger outlet 116. In alternative embodiments, the thermal energy conversion module may be a thermo-electric generator or an air-to-air heat exchanger.

[0040] As seen in FIG. 2, the emission reduction system 102 may further include removable panels 202 on the side of the housing 104. Access doors 204 may be provided in the removable panels 202 or other panels of the housing 104 to allow access to internal components.

[0041] As seen in FIG. 7, the housing 104 may include an air inlet vent 704 provided on a bottom panel 702 of the housing 104. The air inlet vent 704 is configured to allow fresh air 1506 to enter the housing interior 118 (see also FIG. 15). The housing 104 may further include one or more door vents 706 provided on the bottom panel 702. As seen in FIG. 7, FIG. 8, and FIG. 15, fresh air 1506 may be drawn in through the air inlet vent 704 and or the door vents 706 via convection as exhaust gas 1508 exits emission reduction system 102 via the exhaust module 106.

[0042] As further seen in FIG. 8, the exhaust module 106 is shown as a cross-section view cut through line A-A from FIG. 4. The exhaust module 106 may include an exhaust cover 802 and one or more exhaust outlets 804. The exhaust gas 1508 may exit the emission reduction system 102 via the exhaust outlets 804.

[0043] As further seen in FIG. 8, the first emission reduction module 122a may include a first mounting bracket 806a and a first catalytic heater 808a mounted on the first mounting bracket 806a. Similarly, the second emission reduction module 122b may include a second mounting bracket 806b and a second catalytic heater 808b mounted on the second mounting bracket 806b. The internal tubing 126 may be configured to supply vented gas to the first catalytic heater 808a and the 808b for treatment and methane abatement. After passing through the first catalytic heater 808a and/or the second catalytic heater 808b, the treated gas exits towards the center of the housing 104 and will then be drawn up through the exhaust module 106 through convection as exhaust gas 1508. For example, the exhaust gas 1508 is heated by the 808a and/or the 808b, which causes the exhaust gas 1508 to rise and exit through the exhaust module 106. The exit of the exhaust gas 1508 through the exhaust module 106 creates a localized lower pressure within the emission reduction system 102, which causes fresh air 1506 to be drawn into the emission reduction system 102 through the air inlet vent 704 and/or the door vent 706 to equalize the pressure. Additional details of the structure and function of a catalytic heater such as the first catalytic heater 808a and the second catalytic heater 808b can be found in U.S. Pat. No. 10,577,883 issued to Etter Engineering Company, Inc., which is hereby incorporated by reference in its entirety.

[0044] FIG. 15 is a schematic diagram illustrating the operation of the first emission reduction module 122a and the second emission reduction module 122b according to an exemplary embodiment. The first emission reduction module 122a may include a first gas connection 1502a and the second emission reduction module 122b may include a second gas connection 1502b. The first gas connection 1502a and the second gas connection 1502b may supply methane gas or other gas to the first emission reduction module 122a and the second emission reduction module 122b respectively. In an exemplary embodiment, the first gas connection 1502a and the second gas connection 1502b may supply gas via the internal tubing 126 described above. The first emission reduction module 122a may further include a first perforated plate 1504a and the first catalytic heater 808a. The second emission reduction module 122b may include a second perforated plate 1504b and the second catalytic heater 808b. Further details of the first perforated plate 1504a and the second perforated plate 1504b are described below.

[0045] While the discussion below will refer to the first emission reduction module 122a and its components, it will be understood that the description will apply equally to the second emission reduction module 122b and its components. Vented gas may be brought from the source through the internal tubing 126 to the first gas connection 1502a. The vented gas may flow into the first emission reduction module 122a where it is evenly disbursed across the first catalytic heater 808a, which may include, for instance, a platinum based catalytic pad. Through an exothermic chemical reaction, the vented gas is oxidized with the fresh air 1506 present at the face of the first catalytic heater 808a resulting in the release of exhaust gas 1508 while outputting heat as infrared energy. In other words, the platinum catalyst causes the oxidation of methane into carbon dioxide and water vapor at lower temperatures. For example, the presence of the platinum catalyst may facilitate a flameless, non-burning oxidation of methane gas in a temperature range of 400-900 degrees Fahrenheit. The carbon dioxide and water vapor, indicated as exhaust gas 1508 in FIG. 15, may vent through the exhaust module 106 via convection. The heat energy 1510 generated by the exothermic catalytic reaction may be radiated to the heat exchanger cartridge 112, where it may be used to perform other tasks, such as heating surfaces to melt snow and ice, providing heat to other equipment, or other suitable uses.

[0046] The first catalytic heater 808a and the second catalytic heater 808b may be arranged to face each other in the housing interior 118. In an exemplary embodiment, the first catalytic heater 808a and the second catalytic heater 808b may be mounted substantially vertically. In another exemplary embodiment, the first catalytic heater 808a and the second catalytic heater 808b may be inclined with respect to a vertical direction 812 at a predetermined inclination angle 810. The first catalytic heater 808a and the second catalytic heater 808b may be inclined at the same inclination angle 810, or the first catalytic heater 808a and the second catalytic heater 808b may have different inclination angles 810. In an exemplary embodiment, the inclination angle 810 may be greater than 0 degrees and less than or equal to 45 degrees. In a further exemplary embodiment, the inclination angle 810 may be in a range from 10 degrees to 20 degrees. In a further exemplary embodiment, the inclination angle 810 may be 15 degrees. It will also be understood that in an exemplary embodiment, the inclination angle may be equal to 0 degrees, i.e., the first catalytic heater 808a and the second catalytic heater 808b may be substantially vertical. The inclination angle 810 may be adjusted to improve efficiency of the first catalytic heater 808a and the second catalytic heater 808b. Additionally, the inclination angle 810 may also help to protect the first catalytic heater 808a and the second catalytic heater 808b from any stray water or debris that may enter the housing interior 118. Additionally, a drip lip (not shown) may be provided at a top side of the first catalytic heater 808a and the 808b so that any water that does happen to get into the housing interior 118 will drip down the center of the housing interior 118 without contacting the first catalytic heater 808a or the second catalytic heater 808b.

[0047] The embodiment described above includes two catalytic heaters, but it will be understood that the disclosure is not limited to this embodiment. For example, a housing 104 may be provided having a single first mounting bracket 806a and a single first catalytic heater 808a. In this embodiment, a smaller housing 104 may be used to provide additional flexibility in placement, and/or the side of the housing 104 where the second mounting bracket 806b was mounted may have a solid wall without a cut-out or be provided with a filler panel.

[0048] As noted above, the emission reduction system 102 may further include a heat exchanger cartridge 112. FIG. 10, FIG. 11A, FIG. 11B, and FIG. 11C show that the heat exchanger cartridge 112 may include a heat exchanger inlet 114, a first heat exchanger compartment 814, a second heat exchanger compartment 816, and a heat exchanger outlet 116. The heat exchanger inlet 114 may supply a temperature control fluid to the first heat exchanger compartment 814 and the second heat exchanger compartment 816. The heat exchanger inlet 114 may be connected to a pumping system and/or reservoir outside of the emission reduction system 102. In the first heat exchanger compartment 814 and the second heat exchanger compartment 816, the temperature control fluid may absorb excess heat generated by the first catalytic heater 808a and the second catalytic heater 808b. In other words, heat energy is transferred from the first catalytic heater 808a and/or the second catalytic heater 808b to the first heat exchanger compartment 814 and/or the second heat exchanger compartment 816. Then heated temperature control fluid can exit the heat exchanger cartridge 112 via the heat exchanger outlet 116. The heated temperature control fluid leaving the heat exchanger outlet 116 can be used to supply energy for performing a task, such as heating surfaces to melt snow and ice, providing heat to other equipment, or other suitable uses. Ultimately, the temperature control fluid can be recirculated back through the system after the task has been performed and the temperature control fluid returns to its original temperature.

[0049] In an exemplary embodiment, the temperature control fluid may be glycol. In an alternative embodiment, the temperature control fluid may be a mixture of glycol and water. In an alternative embodiment, the temperature control fluid may be water if ambient temperature allows. It will be understood that the temperature control fluid is not limited to these embodiments, and that any suitable heat transfer fluid may be used in the heat exchanger cartridge 112.

[0050] While the Figures show a first heat exchanger compartment 814 and a second heat exchanger compartment 816, it will be understood that the disclosure is not limited to this configuration. For example, there may be a single heat exchanger compartment or more than two heat exchanger compartments. Additionally, in an embodiment with multiple heat exchanger compartments, the heat exchanger compartments may be arranged serially or in parallel.

[0051] As an alternative to the heat exchanger cartridge 112, the housing 104 may be equipped with other types of heat recovery devices provided between the first catalytic heater 808a and the second catalytic heater 808b. For example, the housing 104 may include a thermos-electric generator or an air-to-air heat exchanger. A thermoelectric generator may use the excess heat energy from the first catalytic heater 808a and the second catalytic heater 808b to generate electricity for powering other equipment or devices.

[0052] In some embodiments, a user may not wish to use a heat exchanger cartridge 112 in the emission reduction system 102. In these situations, the heat exchanger cartridge 112 may be replaced with a target plate cartridge 1202, as seen in FIG. 12, FIG. 13A, FIG. 13B, and FIG. 13C. The target plate cartridge 1202 may include a target plate 1204, and a plurality of target plate holes 1206 may be provided in the target plate 1204. The target plate cartridge 1202 helps to compartmentalize the heat for the first catalytic heater 808a and the second catalytic heater 808b while still facilitating air flow through the emission reduction system 102.

[0053] FIG. 14 is a flowchart showing an exemplary embodiment of a method 1402 of reducing emissions. In block 1404, a first catalytic heater may be provided. The first catalytic heater of block 1404 may be similar to the first catalytic heater 808a described above. In block 1406, a second catalytic heater may be provided. The second catalytic heater of block 1406 may be similar to the second catalytic heater 808b described above.

[0054] In block 1408, a thermal energy conversion module may be positioned proximate to the first catalytic heater and the second catalytic heater. The thermal energy conversion module of block 1408 may be similar to the heat exchanger cartridge 112 described above. In an exemplary embodiment, the thermal energy conversion module may be positioned between the first catalytic heater and the second catalytic heater.

[0055] In block 1410, heat energy may be transferred from the first catalytic heater and/or the second catalytic heater to the thermal energy conversion module. In block 1412, the heat transferred to the thermal energy conversion module may be used to perform a task, such as heating surfaces to melt snow and ice, providing heat to other equipment, or other suitable uses. In an alternative embodiment, the thermal energy conversion module in method 1402 may be another type of heat recovery devices, such as a thermo-electric generator or an air to air heat exchanger as described above.

[0056] This disclosure, in various embodiments, configurations and aspects, includes components, methods, processes, systems, and/or apparatuses as depicted and described herein, including various embodiments, sub-combinations, and subsets thereof. This disclosure contemplates, in various embodiments, configurations and aspects, the actual or optional use or inclusion of, e.g., components or processes as may be well-known or understood in the art and consistent with this disclosure though not depicted and/or described herein.

[0057] The phrases at least one, one or more, and and/or are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions at least one of A, B and C, at least one of A, B, or C, one or more of A, B, and C, one or more of A, B, or C and A, B, and/or C means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

[0058] In this specification and the claims that follow, reference will be made to a number of terms that have the following meanings. The terms a (or an) and the refer to one or more of that entity, thereby including plural referents unless the context clearly dictates otherwise. As such, the terms a (or an), one or more and at least one can be used interchangeably herein. Furthermore, references to one embodiment, some embodiments, an embodiment and the like are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term such as about is not to be limited to the precise value specified. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Terms such as first, second, upper, lower etc. are used to identify one element from another, and unless otherwise specified are not meant to refer to a particular order or number of elements.

[0059] As used herein, the terms may and may be indicate a possibility of an occurrence within a set of circumstances; a possession of a specified property, characteristic or function; and/or qualify another verb by expressing one or more of an ability, capability, or possibility associated with the qualified verb. Accordingly, usage of may and may be indicates that a modified term is apparently appropriate, capable, or suitable for an indicated capacity, function, or usage, while considering that in some circumstances the modified term may sometimes not be appropriate, capable, or suitable. For example, in some circumstances an event or capacity can be expected, while in other circumstances the event or capacity cannot occur-this distinction is captured by the terms may and may be.

[0060] As used in the claims, the word comprises and its grammatical variants logically also subtend and include phrases of varying and differing extent such as for example, but not limited thereto, consisting essentially of and consisting of. Where necessary, ranges have been supplied, and those ranges are inclusive of all sub-ranges therebetween. It is to be expected that the appended claims should cover variations in the ranges except where this disclosure makes clear the use of a particular range in certain embodiments.

[0061] The terms determine, calculate and compute, and variations thereof, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation or technique.

[0062] This disclosure is presented for purposes of illustration and description. This disclosure is not limited to the form or forms disclosed herein. In the Detailed Description of this disclosure, for example, various features of some exemplary embodiments are grouped together to representatively describe those and other contemplated embodiments, configurations, and aspects, to the extent that including in this disclosure a description of every potential embodiment, variant, and combination of features is not feasible. Thus, the features of the disclosed embodiments, configurations, and aspects may be combined in alternate embodiments, configurations, and aspects not expressly discussed above. For example, the features recited in the following claims lie in less than all features of a single disclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this disclosure.

[0063] Advances in science and technology may provide variations that are not necessarily express in the terminology of this disclosure although the claims would not necessarily exclude these variations.