Dual Fuel Fluid Heating Systems and Methods

Abstract

A fluid heating system is disclosed. The fluid heating system may include a first valve and a second valve configured to selectively control a supply of a first fuel source and second fuel source respectively. The fluid heating system may further include an air inlet configured to receive ambient air in the fluid heating system. The fluid heating system may further include a controller configured to determine whether the fluid heating system is using the first fuel source and/or the second fuel source. The controller may be further configured to determine an optimal opening area of an air inlet of the fluid heating system based on the determination of whether the fluid heating system is using the first fuel source and/or the second fuel source, and cause to adjust an opening area of the air inlet based on the optimal opening area.

Claims

1. A fluid heating system comprising: a first valve configured to selectively control a supply of a first fuel source; a second valve configured to selectively control a supply of a second fuel source; an air inlet configured to receive ambient air in the fluid heating system; and a controller configured to: determine whether the fluid heating system is using the first fuel source and/or the second fuel source; determine, based on whether the fluid heating system is using the first fuel source and/or the second fuel source, an optimal opening area of the air inlet of the fluid heating system; and cause, based on the optimal opening area, an opening area of the air inlet to adjust based on the optimal opening area.

2. The fluid heating system of claim 1, wherein the first fuel source is biogas.

3. The fluid heating system of claim 1, wherein the second fuel source is natural gas.

4. The fluid heating system of claim 1, wherein the fluid heating system comprises a gas burner.

5. The fluid heating system of claim 1 further comprising a damper configured to control an intake of ambient air in the fluid heating system, via the air inlet, for combustion of the first fuel source and/or the second fuel source, wherein the air inlet is part of the damper.

6. The fluid heating system of claim 5, wherein the damper comprises an air moving screen configured to control the intake of ambient air in the fluid heating system.

7. The fluid heating system of claim 6, wherein the air moving screen is configured to move between a first position and a second position to change the opening area of the air inlet, and wherein the air moving screen is configured to reduce the opening area when the air moving screen is in the first position as compared to the second position.

8. The fluid heating system of claim 7, wherein the controller is configured to cause adjustment of the opening area by causing the air moving screen to move between the first position and the second position based on determining the optimal opening area.

9. The fluid heating system of claim 8 further comprising an actuation mechanism configured to move the air moving screen between the first position and the second position.

10. The fluid heating system of claim 9, wherein the actuation mechanism comprises electromagnetic coils and a magnetic rod.

11. The fluid heating system of claim 10, wherein the air moving screen is attached to the magnetic rod.

12. The fluid heating system of claim 9 further comprising a locking unit configured to lock the air locking screen at the first position or the second position.

13. The fluid heating system of claim 1, wherein the controller is further configured to: obtain a desired fuel source parameter; obtain a real-time fuel source parameter associated with the first fuel source and/or the second fuel source; and select the first fuel source and/or the second fuel source to heat a fluid based on the desired fuel source parameter and the real-time fuel source parameter.

14. The fluid heating system of claim 13, wherein the desired fuel source parameter comprises a desired fuel supply pressure or a desired methane content, and wherein the real-time fuel source parameter comprises a real-time fuel supply pressure or a real-time methane content.

15. The fluid heating system of claim 14 further comprising a detection unit configured to monitor the real-time fuel supply pressure and the real-time methane content of the first fuel source and the second fuel source, wherein the controller is configured to obtain the real-time fuel supply pressure or the real-time methane content from the detection unit.

16. The fluid heating system of claim 14, wherein the controller is further configured to: select the first fuel source to heat the fluid when the real-time fuel supply pressure of the first fuel source is greater than or equal to the desired fuel supply pressure; and select the second fuel source to heat the fluid when the real-time fuel supply pressure of the first fuel source is less than the desired fuel supply pressure.

17. The fluid heating system of claim 14, wherein the controller is further configured to: select the first fuel source to heat the fluid when the real-time methane content in the first fuel source is greater than or equal to the desired methane content; and select both the first fuel source and the second fuel source to heat the fluid when the real-time methane content in the first fuel source is less than the desired methane content.

18. The fluid heating system of claim 17, wherein the controller is further configured to select a ratio of the first fuel source and the second fuel source based on the real-time methane content in the first fuel source, the real-time methane content in the second fuel source, and the desired methane content when the controller selects both the first fuel source and the second fuel source to heat the fluid.

19. A method to heat a fluid with a fluid heating system, the method comprising: determining, by a controller, that the fluid heating system is using a first fuel source and/or a second fuel source; determining, by the controller and based on the fluid heating system using the first fuel source and/or the second fuel source, an optimal opening area of an air inlet of the fluid heating system; and adjusting, by the controller and based on the optimal opening area, an opening area of the air inlet.

20. A non-transitory computer-readable storage medium having instructions stored thereupon which, when executed by a processor, cause the processor to: determine whether a fluid heating system is using a first fuel source and/or a second fuel source; determine an optimal opening area of an air inlet of the fluid heating system based on the fluid heating system using the first fuel source and/or the second fuel source; and cause an opening area of the air inlet to adjust based on the optimal opening area.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The detailed description is set forth with reference to the accompanying drawings. The use of the same reference numerals may indicate similar or identical items. Various embodiments may utilize elements and/or components other than those illustrated in the drawings, and some elements and/or components may not be present in various embodiments. Elements and/or components in the figures are not necessarily drawn to scale. Throughout this disclosure, depending on the context, singular and plural terminology may be used interchangeably.

[0006] FIG. 1 depicts an example fluid heating system in accordance with one or more embodiments of the present disclosure.

[0007] FIGS. 2A and 2B depict an example damper of a fluid heating system in accordance with one or more embodiments of the present disclosure.

[0008] FIG. 3 depicts a block diagram of a controller in accordance with one or more embodiments of the present disclosure.

[0009] FIG. 4 depicts a flow diagram of an example first method to control a fluid heating system in accordance with one or more embodiments of the present disclosure.

[0010] FIG. 5 depicts a flow diagram of an example second method to control a fluid heating system in accordance with one or more embodiments of the present disclosure.

DETAILED DESCRIPTION

[0011] The present disclosure is directed towards dual fuel fluid heating systems and methods that may be heat a fluid such as water based on a first fuel source and a second fuel source. The first fuel source may supply a first fuel such as biogas and the second fuel source may supply a second fuel such as natural gas or any other gas. The system may heat the water using only biogas, only natural gas, or a mixture of biogas and natural gas.

[0012] The system may include a heating element that may be configured to heat water in the system. In an exemplary embodiment, the heating element may be a gas burner that may receive a mixture of fuel (the first fuel and/or the second fuel) and air (e.g., ambient air), combust the fuel and air mixture, and produce heat to heat the water in the system (e.g., combustion gasses may flow through a heat exchanger in thermal communication with the water in the system for transferring heat from the combustion gasses to the water).

[0013] The system may further include a damper that may control intake of air for combustion of the first fuel and/or the second fuel. In some aspects, the damper may allow relatively less air to enter in the damper when the gas burner may be operating using the first fuel as compared to the second fuel (as biogas requires relatively less air/oxygen for combustion). The damper may further receive fuel from the first fuel source and/or the second fuel source, mix the fuel and the air, and supply the fuel air mixture to the gas burner.

[0014] In some aspects, the damper may include an air moving screen that may move between a first position and a second position (e.g., up and down) to change the amount of intake air. In some aspects, a top end of the air moving screen may be attached to the gas burner (e.g., a bottom end of the gas burner), and a bottom end of the air moving screen is attached to a rod (e.g., a movable magnetic rod). The air moving screen may move by pushing or pulling the bottom end of the air moving screen in a longitudinal direction. The air moving screen may include an air inlet having one or more orifices that may allow entry of air inside the damper. When the air moving screen moves between the first position and the second position, an opening area associated with the air inlet (or the orifices) may change, thereby changing the amount of intake air. For example, when the bottom end of the air moving screen is pulled in a downward direction (e.g., by pulling the movable magnetic rod), the opening area of the air inlet may increase, thereby allowing more air to enter in the damper. Similarly, when the bottom end of the air moving screen is pushed in an upward direction (e.g., by pushing the movable magnetic rod), the opening area of the air inlet may decrease, thereby allowing less air to enter in the damper.

[0015] In some aspects, the system may further include an actuation mechanism configured to actuate movement of the air moving screen, to regulate the amount of intake air. In some aspects, the actuation mechanism may include electromagnetic coil(s) and the movable magnetic rod. When the electromagnetic coil(s) are actuated/energized, the electromagnetic coils may pull the movable magnetic rod in the downward direction, thereby pulling the bottom end of the air moving screen in the downward direction. In certain aspects, the actuation mechanism is a solenoid. In some aspects, the actuation mechanism may be energized based on inputs from a controller. In some aspects, the actuation mechanism may include a linear actuator, screw actuator, or any other mechanism for vertically displacing the air moving screen.

[0016] In some aspects, the controller may determine whether the gas burner may be operating using the first fuel and/or second fuel and may determine an optimal opening area of the air inlet based on the determination of whether the gas burner may be operating using the first fuel and/or the second fuel. Responsive to the determination of the optimal opening area, the control may cause to adjust the opening area based on the optimal opening area. In some aspects, the controller may transmit a command/actuation signal to the actuation mechanism to adjust the opening area of the air inlet.

[0017] In further aspects, the controller may select a fuel type to heat the water in the system. In some aspects, the controller may receive inputs from a detection unit and may select the fuel type based on the inputs from the detection unit. In an exemplary aspect, the detection unit may monitor fuel source parameters for the first fuel source and the second fuel source. The fuel source parameters may be, for example, fuel supply pressure and methane content. The controller may obtain inputs on the fuel source parameters from the detection unit and may select the fuel type based on the inputs. For example, the controller may select biogas when the supply pressure of biogas may be greater than a first threshold value. On the other hand, when the supply pressure of biogas may be less than the first threshold value, the controller may shut-off the supply of biogas and may select natural gas to heat the water in the system. In another example, the controller may determine methane content in biogas. When the methane content in biogas may be less than a second threshold value, the controller may add natural gas in biogas and the mixture may be used to heat water in the system.

[0018] The present disclosure is directed to a fluid heating system that may enable heating of water using biogas. When there is shortage of biogas or when the methane content in biogas may be less, the system allows use of other gases, such as natural gas, to heat water in the system. The system further allows use of multiple fuel sources (such as biogas and natural gas) in the same system, as the system automatically controls the amount of intake air required for combustion.

[0019] Although certain examples of the disclosed technology are explained in detail herein, it is to be understood that other examples, embodiments, and implementations of the disclosed technology are contemplated. Accordingly, it is not intended that the disclosed technology is limited in its scope to the details of construction and arrangement of components expressly set forth in the following description or illustrated in the drawings. The disclosed technology can be implemented in a variety of examples and can be practiced or carried out in various ways. In particular, the presently disclosed subject matter is described in the context of being a system and method for heating water using multiple heating sources. The present disclosure, however, is not so limited, and can be applicable in other contexts. The present disclosure, for example and not limiting, can include other water heater systems such as boilers, pool heaters, industrial water heaters, and other water heater systems configured to heat water. Furthermore, the present disclosure can include other fluid heating systems configured to heat a fluid other than water, such as process fluid heaters used in industrial applications. More so, the heating systems disclosed herein may be used to heat other gasses and fluids, such as air in HVAC systems or the like. Such implementations and applications are contemplated within the scope of the present disclosure. Accordingly, when the present disclosure is described in the context of being a system and method for heating water with multiple heating sources, it will be understood that other implementations can take the place of those referred to.

[0020] Although the term water is used throughout this specification, it is to be understood that other fluids may take the place of the term water as used herein. Therefore, although described as a water heating system, it is to be understood that the system and methods described herein can apply to fluids other than water. Further, it is also to be understood that the term water can replace the term fluid as used herein unless the context clearly dictates otherwise.

[0021] Turning now to the drawings, FIG. 1 depicts an example water heating system 100 (or fluid heating system) in accordance with one or more embodiments of the present disclosure. The water heating system 100 (hereinafter referred to as system 100) may heat water to be used in residential, commercial, and/or industrial applications. In an exemplary aspect, the system 100 may be used in a residential or home set-up and may provide heated water to be used in kitchen, washroom, shower, etc. In certain embodiments, the system 100 may be a tankless water heating system that may include an instant heating tankless water heater 105 (or a water heater 105) connected with an inlet valve and an outlet valve (not shown). A tankless water heater is a water heater that instantly (e.g., within a short time duration in a range of 10 to 30 seconds) heats water as the water flows through the tankless water heater, and water is not required to be stored in the tankless water heater. In various implementations, heating elements within a tankless water heater are activated when there is a flow of water detected flowing through the tankless water heater (e.g., a hot water demand event such as a hot water fixture opening). This is in contrast to a storage tank water heater that operates heating elements without a flow to maintain the water stored therein at a set point temperature. While tankless water heaters may include heating chambers where water is heated, the volume of such chambers is 10% or less of a typical storage tank water heater. For example, a volume of a heating chamber in a tankless water heater may be 5 gallons or less, 3 gallons or less, 1 gallon or less, or half a gallon or less. This is in contrast to a storage tank water heater with volumes of hot water of 28 to 90 gallons or more. In various implementations, a tankless water heater may include a small buffer tank for maintaining a small volume of hot water (e.g., 0.5-5 gallons or less). Although the present disclosure describes the system 100 as tankless water heating system, the present disclosure may be used for any gas appliance such as storage tank water heater, furnace in an air handler, boilers, etc.

[0022] In some aspects, the water heater 105 may receive a supply of water (e.g., cold water supply from a utility or the like) via the inlet valve and may output heated water via the outlet valve. In certain embodiments, the water heater 105 may be a gas tankless water heater that may be of any suitable size, shape, or configuration. In alternative aspects, the system 100 may include a water tank (not shown) that may be configured to store water. The water tank may be of any suitable size, shape, or configuration. The water tank may receive cold water from a water supply (e.g., from a utility or the like), via the inlet valve, store the received water and output heated water via the outlet valve.

[0023] The system 100 (e.g., the water heater 105) may include a heating element 110 that may heat the water in the water heater 105. The heating element 110 may include, but is not limited to, a gas burner (herein after referred as gas burner 110). In some aspects, the system 100 may include more than one heating element that may be of different types. For example, the system 100 may include an electric heating element, heat pump element (e.g., condenser), solar heating element (e.g., recirculation loop) or any other type of heating element used in conjunction with the gas burner 110. Any suitable heating element or combination of one or more heating elements may be used herein.

[0024] The gas burner 110 may be configured to receive a mixture of fuel and ambient air (or oxygen, hereinafter referred to as air), combust the fuel and air mixture, and produce heat to heat the water in the water heater 105. The gas burner 110 may be any type of gas burner capable of burning a mixture of fuel and air to produce heat for heating water. For example, and not limiting, the gas burner 110 may be an atmospheric burner, an induced draft burner, a power burner, or any other type of burner suitable for the application. Furthermore, the gas burner 110 may be configured to burn any type of fuel suitable for the application. For example and not limiting, the gas burner 110 may be configured to burn natural gas, propane, butane, coal gas, water gas, methane, biogas, producer gas, syngas, wood gas, blast furnace gas, acetylene, gasoline, or any other suitable type of fuel for the application. The gas burner 110 may include an igniter configured to ignite the mixture of fuel and air to create a flame in the gas burner 110.

[0025] The system 100 may further include a plurality of fuel sources to heat the fluid (or water) in the water heater 105. The plurality of fuel sources may include, but is not limited to, a first fuel source 115 and a second fuel source 120. In certain embodiments, the first fuel source 115 may be associated with a first fuel such as biogas, and the second fuel source 120 may be associated with a second fuel such as natural gas, propane, butane, coal gas, water gas, methane, biogas, producer gas, syngas, wood gas, blast furnace gas, acetylene, gasoline, or any other gas. Additional fuel sources may be used herein. Any suitable combination and count of fuel sources may be used herein. In some aspects, the first fuel source 115 and the second fuel source 120 may be used independently or simultaneously to heat the water (e.g., based on inputs from a controller 125, described in detail later below).

[0026] In some aspects, the system 100 may further include a first valve 130 and a second valve 135. The first valve 130 may be configured to direct the first fuel (e.g., biogas) from the first fuel source 115 towards the gas burner 110, and the second valve 135 may be configured to direct the second fuel (e.g., natural gas or any other gas) from the second fuel source 120 towards the gas burner 110. The first valve 130 and the second valve 135 may be configured to control/regulate flow of fuels from the first fuel source 115 and/or the second fuel source 120 towards the gas burner 110.

[0027] In some aspects, the first valve 130 and the second valve 135, for example and not limiting, may be or include a solenoid operated valve configured to open or close based on a control signal obtained from the controller 125. Furthermore, the first valve 130 and the second valve 135 may be a normally-closed valve (or may have a default closed state) such that the first valve 130 and the second valve 135 may be capable of preventing the flow of respective fuels toward the gas burner 110 when the valves may be deenergized. In some aspects, the first valve 130 and the second valve 135, for example and not limiting, may be a needle valve or other valve that adjusts a degree to which the valve is open or closed (e.g., from 0% to 100% in predetermined increments, such as 1%, 3%, 5%, or 10% increments or fractions thereof).

[0028] The first fuel and the second fuel may be mixed together in any ratio in a mixing chamber 140, and the mixture of the fuels may be fed to the gas burner 110 to combust and heat the water. The mixing chamber 140 may be configured to receive the first fuel and the second fuel via the first valve 130 and the second valve 135 respectively in a specific ratio (that may be based on the signals obtained from the controller 125), mix the fuels, and direct the mixture towards the gas burner 110. The gas burner 110 may be configured to receive the first fuel and/or second fuel (from the first fuel source 115 and the second fuel source 120, respectively) and the air, combust the fuel and air mixture, and produce heat to heat water in the water heater 105 (or otherwise heat a process fluid for performing a heat exchange).

[0029] The system 100 may further include a damper 145 that may be configured to receive the fuel supply from the first fuel source 115 and/or the second fuel source 120, via the first valve 130, the second valve 135, and the mixing chamber 140. For example, the damper 145 may receive only the first fuel, only the second fuel, or a mixture of the first fuel and the second fuel. The damper 145 may be further configured to receive the air and may allow mixing of the fuel with the air. The damper 145 may be further configured to supply the fuel-air mixture to the gas burner 110 for combustion.

[0030] In some aspects, the damper 145 may control an intake of air in the system 100 for combustion of the first fuel and/or the second fuel. In an exemplary embodiment, the damper 145 may include an air inlet (shown as air inlet 212 in FIGS. 2A and 2B) through which the damper 145 may receive the air. The damper 145 may be configured to control an opening area of the air inlet to control the intake of the air, based on inputs obtained from the controller 125. For example, the damper 145 may decrease the opening area when the gas burner 110 may be operating using biogas (or the first fuel) and may increase the opening area when the gas burner 110 may be operating using natural gas (or the second fuel). This is due to the reason that biogas requires relatively less amount of air/oxygen for combustion, as compared to natural gas. The structural details of the damper 145 are described later below in conjunction with FIGS. 2A and 2B.

[0031] In further aspects, the system 100 may include the controller 125 and a detection unit (shown as detection unit 320 in FIG. 3), which may be communicatively coupled to each other. The controller 125 may be configured to obtain inputs from the detection unit and may control system operation based on the inputs obtained from the detection unit. The detection unit may include one or more sensors that may be configured to detect one or more real-time fuel source parameters associated with the first fuel source and/or the second fuel source. The real-time fuel source parameter may include a real-time fuel supply pressure and/or a real-time methane content (e.g., methane content in biogas, natural gas, or the mixture of biogas and natural gas). In addition, the detection unit may be configured to detect whether the gas burner 110 may be operating using the first fuel source 115 and/or the second fuel source 120. Further, the detection unit may be configured to detect a real-time opening area of the air inlet. Furthermore, the detection unit may be configured to detect a real-time water temperature in the water heater 105 (e.g., a temperature of water flowing out of the water heater 105). For implementations other than water heaters, the detection unit may be configured to detect a real-time temperature of a process fluid output from a heat exchanger in fluid communication with the gas burner 110.

[0032] A person ordinarily skilled in the art may appreciate that the detection unit may include additional sensors or components configured to detect other operational parameters associated with the system 100, which may enable efficient working of the system 100. Examples of such additional sensors or components include, but are not limited to, a pressure sensor, a scale, a voltmeter, an ammeter, a power meter, an ohmmeter, environment condition sensors including ambient air temperature sensor, humidity sensors, and/or the like.

[0033] In some aspects, the controller 125 may be communicatively coupled to the water heater 105, the gas burner 110, the first valve 130, the second valve 135, the mixing chamber 140, and the damper 145 to control system operation. In some aspects, the controller 125 may be configured to determine whether the gas burner 110 may be operating using the first fuel source 115 and/or the second fuel source 120, based on inputs obtained from the detection unit. The controller 125 may be further configured to determine or select an optimal opening area of the air inlet based on the determination of whether the gas burner 110 is using the first fuel source 115 and/or the second fuel source 120. The controller 125 may be further configured to cause the damper 145 to adjust the opening area based on the determination/selection of the opening area. For example, the controller 125 may transmit a command signal or an actuation signal to the damper 145 to adjust the opening area of the air inlet, responsive to determining an optimal opening area based on the fuel being used by the gas burner 110. In further aspects, the controller 125 may select the first fuel source 115 and/or the second fuel source 120 to heat water in the water heater 105 based on inputs obtained from the detection unit. For example, the controller 125 may cause only the first fuel, only the second fuel, or a mixture of the first fuel and the second fuel to enter in the damper 145, by controlling the first valve 130 and the second valve 135. The controller 125 may additionally select a ratio of the first fuel and the second fuel and may control the mixing of the fuels in the mixing chamber 140. The details of the controller 125 are described below in conjunction with FIGS. 3-5.

[0034] FIGS. 2A and 2B depict an example damper 200 of the fluid heating system 100 in accordance with one or more embodiments of the present disclosure. The damper 200 may be same as the damper 145 described above in conjunction with FIG. 1.

[0035] As described above, the damper 200 may be configured to receive the first fuel and/or the second fuel. In some aspects, the damper 200 may receive the fuel from a bottom portion of the damper 200, as shown in FIGS. 2A and 2B. The damper 200 may be further configured to receive air from a top portion of the damper 200, mix the fuel and the air in the top portion, and supply the fuel-air mixture to the gas burner 110.

[0036] In some aspects, the damper 200 may be a cylindrical body that may include a plurality of components including, but not limited to, an air moving screen 202, an actuation mechanism (including one or more electromagnetic coils 204 and a magnetic rod 206), a power source 208, and/or the like. In other aspects, the damper 200 may of any other shape, e.g., cuboidal, conical, etc.

[0037] In some aspects, the air moving screen 202 may be a hollow cylindrical screen (or be of any other shape complementary to the shape of the damper 200) having a top end 210a and a bottom end 210b. The top end 210a may be attached to the gas burner 110 (e.g., bottom end of the gas burner 110) or located in proximity to the gas burner 110. The bottom end 210b may be attached to the magnetic rod 206. In some aspects, the air moving screen 202 may be made of any material. In an exemplary aspect, the air moving screen 202 may be made of non-magnetic material. In addition, the air moving screen 202 may be made of lightweight material such as aluminum, steel, or any other similar material.

[0038] The air moving screen 202 may include an air inlet 212 that may be configured to control an intake of air in the damper 200 from outside, as shown in FIGS. 2A and 2B. In an exemplary aspect, the air moving screen 202 may include a mesh structure configured to intake air from outside. The air inlet 212 may include one or more orifices (or through-holes) that may be disposed at the air moving screen 202 at a predetermined location. In some aspects, air may enter into the damper 200 from all around the air moving screen 202, via the air inlet 212 (or the orifices). In addition, the air moving screen 202 may receive the first fuel and/or the second fuel, mix the fuel with the air, and supply the mixture of the fuel and air to the gas burner 110.

[0039] In some aspects, the air moving screen 202 may be configured to compress and expand (e.g., by moving longitudinally or by moving up and down) to control the intake of the air inside the damper 200. Specifically, the air moving screen 202 may move between a first position (or a fully compressed position) and a second position (or a fully expanded position) to change the opening area of the inlet (e.g., to control the intake of air inside the damper 200). In some aspects, the first position may be a fully compressed position in which the air moving screen 202 may block inflow of air or intake minimum amount of air inside the damper 200, as shown in FIG. 2A. The second position may be a fully expanded position in which the air moving screen 202 may intake maximum amount of air in the damper 200, as shown in FIG. 2B. Thus, the air moving screen 202 reduces the opening area when the air moving screen 202 may be in the first position as compared to the second position. Likewise, the air moving screen 202 increases the opening area when the air moving screen 202 is in the second position as compared to the first position. While described as being in the first position or second position above, in some aspects, the air moving screen 202 may be positioned at any intermediate position between the first position and the second position.

[0040] The movement of the air moving screen 202 may change the opening area of the air inlet 212 (or opening area of the orifices), thereby changing the amount of intake air. When the air moving screen 202 may be pulled in a downward direction (e.g., by moving the magnetic rod 206 towards the fixed bottom portion of the damper 200, as described below), the air moving screen 202 may expand and the opening area of the air inlet 212 may increase, thereby allowing more amount of air to enter in the damper 200. Similarly, when the air moving screen 202 may be pushed in the upwards direction (e.g., by moving the magnetic rod 206 towards the fixed top portion and away from the fixed bottom portion of the damper 200, as described below), the air moving screen 202 may compress and the opening area may decrease, thereby allowing no/less air to enter in the damper 200. The damper 145 may intake relatively less air (e.g., based on the inputs obtained from the controller 125) when the gas burner 110 may be operating on biogas, as compared to natural gas, as biogas requires less air for burning/combustion.

[0041] In some aspects, the air moving screen 202 may be configured to move between the first position and the second position via the actuation mechanism. The actuation mechanism may be configured to obtain the command signal or the actuation signal from the controller 125 and may move the air moving screen 202 between the first position and the second position based on the command signal or the actuation signal (e.g., to change the opening area of the air inlet 212).

[0042] In some aspects, the controller 125 may determine whether the system 100 (e.g., the gas burner 110) may be operating using only the first fuel source 115, only the second fuel source 120, or both the first fuel source 115 and the second fuel source 120 and may determine or select an optimal opening area of the air inlet 212 based on the fuel being used (i.e., based on the fuel type). As an example, the controller 125 may select a relatively smaller opening area of the air inlet 212 when the gas burner 110 may be operating on biogas, as compared to the opening area when natural gas may be used. The controller 125 may send the command/actuation signal to the actuation mechanism to move the air moving screen 202 at a desired level based on the selection/determination of the opening area and the real-time position of the air moving screen 202.

[0043] In further aspects, the controller 125 may select the opening area of the air inlet 212 based on the methane content in the fuel. For example, when the gas burner 110 may be operating using the mixture of the first fuel and the second fuel, the controller 125 may determine a methane content in the mixture of the first fuel and the second fuel, select the opening area based on the methane content, and may transmit the actuation signal based on the selection of the opening area.

[0044] In certain embodiments, the actuation mechanism may include the electromagnetic coils 204 that may be configured to receive actuation signal from the controller 125 and may pull the magnetic rod 206 downwards (e.g., towards the bottom portion of the damper 200) based on the actuation signal. Stated another way, the electromagnetic coils 204 may pull the magnetic rod 206 when the electromagnetic coils 204 are energized. When the electromagnetic coils 204 are energized (e.g., when the electromagnetic coils 204 receive electric current from the controller 125), the electromagnetic coils 204 may generate magnetic fields that may interact with the magnetic rod 206 to pull the magnetic rod 206 in the downward direction. Since the magnetic rod 206 is attached to the bottom end 210b of the air moving screen 202, the air moving screen 202 (e.g., the bottom end 210b) may be pulled in the downward direction (e.g., towards the second position), thereby increasing the opening area of the air inlet 212 and allowing more amount of air to enter in the damper 200.

[0045] In some aspects, the damper 200 may further include a locking unit or latching mechanism (not shown) that may be configured to lock the air moving screen 202 in the first position and/or the second position. For example, the locking unit may lock the air moving screen 202 in the downward position (e.g., after pulling the air moving screen 202 downward) till the natural gas is used in the gas burner 110, so that the magnets in the magnetic rod 206 do not have to keep pulling down the air moving screen 202 (thereby saving energy). In further aspects, the damper 200 may include a spring 214 that may be configured to push the air moving screen 202 back to its default position (or the first position) when no/less air is needed. For example, when the air moving screen 202 (or the magnetic rod 206) moves downwards, the spring 214 may be compressed and may expand back to move/push the air moving screen 202 in the upward direction when no/less air is needed.

[0046] In some aspects, the electromagnetic coils 204 may be connected to the power source 208 to operate (e.g., to actuate to move the air moving screen 202). The power source 208 may include, but is not limited to, a battery, a supercapacitor, and/or the like. In some aspects, the power source 208 may store electrical energy from a pilot's thermocouple. The pilot's thermocouple may be any conventional pilot's thermocouple that may be used in the system 100. In some aspects, the power source 208 may be operated/actuated by the controller 125, and/or may be supplied via the controller 125.

[0047] Although the present disclosure describes the use of electromagnetic coils 204 and the magnetic rod 206 as the actuation mechanism, the present disclosure may use any other actuation means to move the air moving screen 202, without departing from the scope of the present disclosure. For example, other actuation mechanisms may include a linear actuator, screw actuator, or any other mechanism for vertically displacing the air moving screen 202.

[0048] FIG. 3 depicts a block diagram of a controller 300 in accordance with one or more embodiments of the present disclosure. The controller 300 may be same as the controller 125 described in conjunction with FIG. 1. The controller 300 may include a plurality of components, including, but not limited to, a communication interface 305, a processor 310, and memory 315. The controller 300 may be a computing device configured to receive data, determine actions based on the received data, and output a control signal instructing one or more system components to perform one or more actions. As discussed above, the controller 300 may be a part of the water heating system 100, and the controller 300 may be in communication with at least some of the system components.

[0049] In some aspects, the controller 300 may be configured to send and receive wireless or wired signals, and the signals may be analog or digital signals. The wireless signals may include Bluetooth, BLE, WiFi, ZigBee, infrared, microwave radio, laser, or any other type of wireless communication signals as may be suitable for a particular system application. The hard-wired signals can include communication signals between any directly wired connections between the controller 300 and other system components. For example, the controller 300 can have a hard-wired 24 Volts Direct Current (VDC) connection to the sensors/components described above in conjunction with FIG. 1.

[0050] Alternatively, the controller 300 may communicate with the sensors/components installed in the water heating system 100 via a digital connection. The digital connection can include a connection such as an Ethernet or a serial connection and can utilize any suitable communication protocol for the system application, such as Modbus, fieldbus, PROFIBUS, SafetyBus, Ethernet/IP, and/or the like. Furthermore, the controller 300 can utilize a combination of wireless, hard-wired, and analog or digital communication signals to communicate with and control the various system components. The above configurations are given merely as non-limiting examples and the actual configuration can vary depending on the particular system application.

[0051] In certain embodiments, the controller 300 may be configured to communicate, via the communication interface 305, with a detection unit 320 that may be part of the water heating system 100. The detection unit 320 may include a plurality of sensors including, but not limited to, a fuel type sensor 325, a fuel parameter sensor 330, an opening area sensor 335, a temperature sensor 340, and/or the like. The fuel type sensor 325 may detect whether the gas burner 110 may be operating using the first fuel and/or the second fuel (e.g., by detecting the state of the first valve 130 and/or the second valve 135).

[0052] The fuel parameter sensor 330 may detect/monitor one or more real-time fuel source parameters associated with the first fuel source 115 and/or the second fuel source 120. The real-time fuel source parameter may include a real-time fuel supply pressure and/or a real-time methane content (e.g., fuel source parameter in biogas, natural gas, or the mixture of biogas and natural gas). In some aspects, the fuel parameter sensor 330 may include flow sensor(s) that may detect a flow of fuel (including flow rate/fuel supply pressure) from the first fuel source 115 and/or the second fuel source 120 (via the first valve 130 and/or the second valve 135) and a gas analyzer configured to detect a percentage of methane in the fuel (e.g., methane content in biogas, methane content in natural gas, or methane content in the mixture of biogas and natural gas). If it is desirable to measure the rate of fluid flow, the flow sensor may be a flow meter or another type of rate-measuring flow sensor. For example, the flow sensor may be a differential pressure flow meter, a positive displacement flow meter, a velocity flow meter, a mass flow meter, an open channel flow meter, or any other type of flow meter configured to measure a fluid flow rate. The type of flow sensor used may depend on the type of fluid being measured, its temperature, pressure, viscosity, conductivity, corrosiveness, cleanliness, and other properties of the fluid in the system 100.

[0053] The opening area sensor 335 may detect a real-time opening area of the air inlet 212 or the position of the air moving screen 202. The temperature sensor 340 may detect a real-time water temperature in the water heater 105. The temperature sensor 340 may be or include a thermocouple, a resistor temperature detector, a thermistor, an infrared sensor, a semiconductor, or any other type of sensor which would be appropriate for a given use or application. One skilled in the art will appreciate that the type, location, and number of temperature sensors can vary depending on the application.

[0054] The memory 315 may be configured to store a program and/or instructions associated with the functions and methods described herein. The processor 310 may be configured to execute the program and/or instructions stored in the memory 315. The memory 315 can include one or more suitable types of memory (e.g., volatile or non-volatile memory, random access memory (RAM), read only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), magnetic disks, optical disks, floppy disks, hard disks, removable cartridges, flash memory, a redundant array of independent disks (RAID), and the like) for storing files including the operating system, application programs (including, for example, a web browser application, a widget or gadget engine, and or other applications, as necessary), executable instructions and data. One, some, or all of the processing techniques or methods described herein can be implemented as a combination of executable instructions and data within the memory 315.

[0055] The communication interface 305 may be configured to send or receive communication signals between the various system components. The communication interface 305 can include hardware, firmware, and/or software that allows the processor 310 to communicate with the other components via wired or wireless networks, whether local or wide area, private or public, as known in the art. The communication interface 305 can also provide access to a cellular network, the Internet, a local area network, or another wide-area network as suitable for the particular system application.

[0056] In some aspects, the controller 300 may be configured to obtain inputs from the detection unit 320 and control system operation based on the obtained inputs. In some aspects, the controller 300 may determine or select an optimal opening area of the air inlet 212 (or the position of the air moving screen 202) based on the determination whether the gas burner 110 may be operating using the first fuel and/or the second fuel. The controller 300 may be configured to cause the damper 200 to adjust the opening area based on the determination/selection of the opening area (or the position of the air moving screen 202). In addition, the controller 300 may select the first fuel source 115 and/or the second fuel source 120 to operate the system 100. The details of the system operation may be understood in conjunction with example methods described in conjunction with FIGS. 4 and 5.

[0057] FIG. 4 depicts a flow diagram of an example first method 400 to control the fluid heating system 100 in accordance with one or more embodiments of the present disclosure. FIG. 4 may be described with continued reference to prior figures, including FIGS. 1-3. The following process is exemplary and not confined to the steps described hereafter. Moreover, alternative embodiments may include more or less steps than are shown or described herein and may include these steps in a different order than the order described in the following example embodiments.

[0058] The method 400 starts at step 402. At step 404, the method 400 may include obtaining, by the controller 300, desired fuel source parameters. The desired fuel source parameters may include a desired fuel supply pressure or a desired methane content that may be pre-stored in the memory 315. In some aspects, the controller 300 may obtain the desired fuel source parameters from a user. In further aspects, the controller 300 may derive the desired fuel source parameters based on user inputs (e.g., derived from a required water output temperature and/or a real-time water temperature flowing out of the water heater 105).

[0059] At step 406, the method 400 may include obtaining, by the controller 300, a real-time fuel source parameter associated with at least one of the first fuel source 115 or the second fuel source 120. The real-time fuel source parameter may include a real-time fuel supply pressure or a real-time methane content. In some aspects, the controller 300 may obtain the real-time fuel source parameters from the detection unit 320 (e.g., from the fuel parameter sensor 330).

[0060] At step 408, the method 400 may include selecting, by the controller 300, at least one of the first fuel source 115 or the second fuel source 120 based on the desired fuel source parameter and the real-time fuel source parameter. In some aspects, the controller 300 may compare the desired fuel source parameter with the real-time fuel source parameter and select at least one of the first fuel source 115 or the second fuel source 120 based on the comparison. For example, the controller 300 may select only biogas, only natural gas, or a mixture of biogas and natural gas based on the comparison.

[0061] As an example, the controller 300 may determine the real-time fuel supply pressure of biogas (e.g., using flow sensors) and compare the real-time fuel supply pressure of biogas with the desired supply pressure of biogas required to heat the water at the desired temperature (that may be based on user's requirement of water output temperature and the real-time water temperature detected by the temperature sensor 340). When the real-time fuel supply pressure of biogas may be equal to or greater than the desired fuel supply pressure of biogas, the controller 300 may select biogas to heat the water. Stated another way, the controller 300 may continue to heat water in the water heater 105 (or other process fluid) using biogas when the real-time fuel supply pressure of biogas may be equal to or greater than the desired fuel supply pressure of biogas.

[0062] On the other hand, when the real-time fuel supply pressure of biogas may be less than the desired supply pressure of biogas, the controller 300 may select natural gas to heat the water in the water heater 105. In some aspects, responsive to the selection of the natural gas, the controller 300 may continue to monitor the real-time fuel supply pressure of biogas, via the detection unit 320. When the controller 300 determines that the real-time fuel supply pressure of biogas to be equal to or greater than the desired fuel supply pressure of biogas, the controller 300 may switch the selection back from natural gas to biogas.

[0063] In another example, the controller 300 may determine the real-time methane content of biogas (e.g., using gas analyzer) and compare the real-time methane content of biogas with the desired methane content of biogas required to heat the water at the desired temperature. When the real-time methane content of biogas may be equal to or greater than the desired methane content of biogas, the controller 300 may continue to use biogas to heat water in the water heater 105. Stated another way, the controller 300 may select the first fuel source 115 to heat water in the water heater 105 when the real-time methane content of biogas may be equal to or greater than the desired methane content of biogas.

[0064] On the other hand, when the real-time methane content of biogas may be less than the desired methane content of biogas, the controller 300 may add natural gas to biogas to heat the water in the water heater 105 (even if the supply pressure of biogas may be greater than the desired supply pressure of biogas), to maintain the methane content in fuel. Stated another way, the controller 300 may select both the natural gas and the biogas to heat water when the real-time methane content of biogas may be less than the desired methane content of biogas. In this case, the controller 300 may be further configured to determine or select a ratio of the first fuel/biogas and the second fuel/natural gas based on the real-time methane content in biogas, real-time methane content in natural gas, and the desired methane content in fuel, when the controller 300 selects both the biogas and the natural gas to heat the fluid. In some aspects, responsive to the selection of both the biogas and the natural gas, the controller 300 may continue to monitor the real-time methane content in biogas, via the detection unit 320. When the controller 300 determines that the real-time methane content biogas may be equal to or greater than the desired methane content, the controller 300 may switch the selection back to only the biogas.

[0065] At step 410, the method 400 may include performing, by the controller 300, a predefined action. The predefined action may include causing opening/closing of the first valve 130 and/or the second valve 135 based on the selection of the first fuel source 115 and/or the second fuel source 120. For example, the controller 300 may open the first valve 130 to allow the first fuel (e.g., biogas) to flow inside the damper 200 and may close/shut-off the second valve 135 to prevent supply of second fuel (e.g., natural gas) when the controller 300 selects the first fuel source 115 at the step 408. Similarly, the controller 300 may close/shut-off the first valve 130 and may open the second valve 135 when the controller 300 selects the second fuel source 120 at the step 408. In addition, the controller 300 may partially open both the first valve 130 and the second valve 135 when the controller 300 selects both the fuel sources. In such a scenario, the controller 300 may open the first valve 130 and the second valve 135 based on the ratio of the first fluid and the second fluid determined/selected by the controller 300 at the step 408.

[0066] The method 400 stops at step 412.

[0067] FIG. 5 depicts a flow diagram of an example second method 500 to control the fluid heating system 100 in accordance with one or more embodiments of the present disclosure. FIG. 5 may be described with continued reference to prior figures, including FIGS. 1-4. The following process is exemplary and not confined to the steps described hereafter. Moreover, alternative embodiments may include more or less steps than are shown or described herein and may include these steps in a different order than the order described in the following example embodiments.

[0068] The method 500 starts at step 502. At step 504, the method 500 may include determining, by the controller 300, whether the system 100 is using the first fuel source 115 or the second fuel source 120. The controller 300 may perform the determination based on the inputs obtained from the detection unit 320 (e.g., the fuel type sensor 325 and/or the flow sensors).

[0069] At step 506, the method 500 may include determining/selecting, by the controller 300, an optimal opening area of the air inlet 212 of the system 100 (or the position of the air moving screen 202) based on the determination of whether the system 100 is using the first fuel source 115 or the second fuel source 120. As described above, the controller 300 may select a relatively greater opening area when the gas burner 110 may be using natural gas (or the second fuel), as compared to the opening area when the gas burner 110 may be using biogas (or the first fuel). In some aspects, the controller 300 may select the opening area of the air inlet 212 corresponding to the methane content in the fuel used by the gas burner 110.

[0070] At step 508, the method 500 may include causing, by the controller 300, the damper 200 to adjust the opening area of the air inlet 212 responsive to the determination of the opening area. The controller 300 may cause the adjustment of the opening area by causing the air moving screen 202 to move between the first position and the second position based on the determination of the opening area. The controller 300 may transmit an actuation signal to the damper 200 (e.g., the electromagnetic coils 204) to change the opening area. When the electromagnetic coils 204 receive the actuation signal, the electromagnetic coils 204 may be energized and may pull the magnetic rod 206 towards the bottom portion of the damper 200. Since the magnetic rod 206 is attached to the air moving screen 202, the air moving screen 202 may move as the magnetic rod 206 moves, thereby changing the opening area of the air inlet 212. When the electromagnetic coils 204 are deenergized (e.g., when no/less air is required), the spring 214 may push the magnetic rod 206 and the air moving screen 202 to go back to the original position (e.g., the first position).

[0071] The method 500 stops at step 510.

[0072] In the above disclosure, reference has been made to the accompanying drawings, which form a part hereof, which illustrate specific implementations in which the present disclosure may be practiced. It is understood that other implementations may be utilized, and structural changes may be made without departing from the scope of the present disclosure. References in the specification to one embodiment, an embodiment, an example embodiment, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a feature, structure, or characteristic is described in connection with an embodiment, one skilled in the art will recognize such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

[0073] It should also be understood that the word example as used herein is intended to be non-exclusionary and non-limiting in nature. More particularly, the word example as used herein indicates one among several examples, and it should be understood that no undue emphasis or preference is being directed to the particular example being described.

[0074] With regard to the processes, systems, methods, heuristics, etc. described herein, it should be understood that, although the steps of such processes, etc. have been described as occurring according to a certain ordered sequence, such processes could be practiced with the described steps performed in an order other than the order described herein. It further should be understood that certain steps could be performed simultaneously, that other steps could be added, or that certain steps described herein could be omitted. In other words, the descriptions of processes herein are provided for the purpose of illustrating various embodiments and should in no way be construed so as to limit the claims.

[0075] Accordingly, it is to be understood that the above description is intended to be illustrative and not restrictive. Many embodiments and applications other than the examples provided would be apparent upon reading the above description. The scope should be determined, not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. It is anticipated and intended that future developments will occur in the technologies discussed herein, and that the disclosed systems and methods will be incorporated into such future embodiments. In sum, it should be understood that the application is capable of modification and variation.

[0076] All terms used in the claims are intended to be given their ordinary meanings as understood by those knowledgeable in the technologies described herein unless an explicit indication to the contrary is made herein. In particular, use of the singular articles such as a, the, said, etc., should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary. Conditional language, such as, among others, can, could, might, or may, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments could include, while other embodiments may not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments.