U.S. patent application number 10/703544 was filed with the patent office on 2004-08-26 for unitary base and integral housing for chemical equipment.
This patent application is currently assigned to H2GEN INNOVATIONS, INC.. Invention is credited to Davis, Chris A., Gremonprez, Dan E., Lim, Kim Hong, Lomax, Franklin D. JR., Waide, Stephen W..
Application Number | 20040164217 10/703544 |
Document ID | / |
Family ID | 32312954 |
Filed Date | 2004-08-26 |
United States Patent
Application |
20040164217 |
Kind Code |
A1 |
Lomax, Franklin D. JR. ; et
al. |
August 26, 2004 |
Unitary base and integral housing for chemical equipment
Abstract
An apparatus for structural support of process equipment
including a unitary structural base. The structural base includes a
first surface having a mounting recess shaped to receive a first
equipment component and a second surface located on the opposite
side of the first surface and having a stiffening rib shaped to
provide structural support. The structural base also includes a
side surface located between the first and second surface and
including an aperture shaped to receive a lifting component.
Inventors: |
Lomax, Franklin D. JR.;
(Arlington, VA) ; Lim, Kim Hong; (Annandale,
VA) ; Waide, Stephen W.; (Arlington, VA) ;
Davis, Chris A.; (West Bend, WI) ; Gremonprez, Dan
E.; (West Bend, WI) |
Correspondence
Address: |
OBLON, SPIVAK, MCCLELLAND, MAIER & NEUSTADT, P.C.
1940 DUKE STREET
ALEXANDRIA
VA
22314
US
|
Assignee: |
H2GEN INNOVATIONS, INC.
Alexandria
VA
|
Family ID: |
32312954 |
Appl. No.: |
10/703544 |
Filed: |
November 10, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60425260 |
Nov 12, 2002 |
|
|
|
Current U.S.
Class: |
248/346.01 |
Current CPC
Class: |
B01J 2219/00087
20130101; B01J 19/0053 20130101; B01J 2219/00022 20130101; F16M
1/00 20130101 |
Class at
Publication: |
248/346.01 |
International
Class: |
B65D 019/00; A47G
029/00; A47B 091/00 |
Claims
What is claimed is:
1. An apparatus for structural support of process equipment,
comprising: a unitary structural base including, a first surface
including a mounting recess shaped to receive a first equipment
component, a second surface located on an opposite side of the
structural base from the first surface and including a stiffening
rib shaped to provide structural support, and a side surface
located between the first and second surface and including an
aperture shaped to receive a lifting component.
2. The apparatus of claim 1, further comprising a removable
component carrier shaped to receive a second equipment component,
wherein the first surface includes an aperture shaped to receive
the component carrier.
3. The apparatus of claim 1, wherein the first surface includes at
least one component mounting hole configured to interface with the
first equipment component.
4. The apparatus of claim 1, wherein the side surface is
curved.
5. The apparatus of claim 1, wherein the structural base is made of
at least one of a metal, a reinforced ceramic, and a polymer.
6. The apparatus of claim 1, further comprising a ducting baffle
attached to the structural base.
7. The apparatus of claim 6, further comprising a heat exchanger
supported by the ducting baffle.
8. The apparatus of claim 1, further comprising a duct inlet
attached to the structural base.
9. The apparatus of claim 8, further comprising a filter supported
by the duct inlet.
10. The apparatus of claim 1, further comprising a housing attached
to the structural base.
11. The apparatus of claim 10, wherein the structural base includes
an integral sealing element that seals an interface between the
structural base and the housing.
12. The apparatus of claim 10, further comprising a structural
frame attached to the structural base, wherein the housing is
attached to the structural frame.
13. The apparatus of claim 10, wherein the housing includes
multiple external panels.
14. The apparatus of claim 10, wherein at least one of the external
panels is curved.
15. The apparatus of claim 10, wherein at least one of the external
panels includes a stiffening element.
16. The apparatus of claim 13, wherein a first one of the external
panels includes an integral ventilation inlet louver.
17. The apparatus of claim 16, wherein a second one of the external
panels includes an integral exhaust louver.
18. The apparatus of claim 17, wherein the ventilation inlet louver
is positioned on the first one of the external panels at least 18
inches above the second surface of the structural base.
19. The apparatus of claim 17, wherein the exhaust louver is
positioned near a top edge of the second one of the external
panels.
20. The apparatus of claim 13, wherein at least one of the external
panels includes a material that at least one of flame retardant and
static-dissipative.
21. A method of making an apparatus for structural support of
process equipment, comprising: forming a unitary structural base in
a first near-net shape process, wherein the unitary structural base
includes, a first surface including a mounting recess shaped to
receive a first equipment component, a second surface located on
the opposite side of the first surface and including a stiffening
rib shaped to provide structural support, and a side surface
located between the first and second surface and including an
aperture shaped to receive a lifting component.
22. The method of claim 21, further comprising: forming the
structural base by casting, forging, powder metallurgy, or
molding.
23. The method of claim 21, wherein the structural base is made of
at least one of a metal, a reinforced ceramic, or a polymer.
24. The method of claim 21, further comprising: attaching a housing
to the structural base, wherein the housing includes an external
panel.
25. The method of claim 24, further comprising: forming the
external panel in a second near-net shape process.
26. The method of claim 25, further comprising: forming the
external panel by hydroforming, vacuum forming, rotational molding,
hand lay up, spray up, resin transfer molding, or compression
injection molding.
27. The method of claim 24, wherein the external panel is made of a
material that is at least one of flame retardant and
static-dissipative.
28. The method of claim 24, further comprising: adding to the
external panel a material that is at least one of flame retardant
and static-dissipative.
29. A method of assembling and maintaining chemical process
equipment, comprising: providing a unitary structural base;
positioning a first chemical process component in an integral
component mounting recess of the structural base; and enclosing the
first process equipment by attaching a housing to the structural
base around the first equipment component.
30. The method of claim 29, further comprising: positioning a
second chemical process component in a removable component carrier;
attaching the component carrier to an integral aperture of the
structural base; removing the component carrier from the aperture
to repair or replace the second chemical process component.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a housing system for
chemical equipment.
[0003] 2. Discussion of the Background
[0004] Chemical processing equipment is generally assembled into
complex systems with a large number of valving connections between
individual elements with varying functions and attributes. Examples
include pressure vessels, compressors, pumps, mixers, chemical
reactors, burners, etc. Traditionally, one or more components of
the complex system, often referred to as the plant, are delivered
to the site of the plant and assembled in situ with independent
fluid connections, mechanical supports, weather protection, fire
protection, ventilation systems, etc. This method has been employed
for many years, and is especially well-adapted to physically-large
equipment which must be fabricated on site. For small chemical
equipment, this method is far less desirable, as the time and
expense required to erect the components in the field can
significantly impair the economics of the system.
[0005] Consequently, small subsystems of existing chemical plants
are often fabricated at a remote facility, then shipped to the site
for final integration. This practice, known as shop fabrication,
has been used to reduce the time required to assemble subsystems of
plants. Generally, individual "skids," fabricated manually from
structural metal shapes by welding, bolting and similar methods are
provided for complete subsystems such as electrical control,
compression, pumping, pressure swing adsorption and other
processes. For very small plants, complete processes have even been
packaged on skids of this type, offering significant advantages
over site-erection in terms of reduced assembly time, improved work
quality, and reduced worker exposure to the elements on site.
Particular examples of plants of this type are compact hydrogen
generation plants, pressure-swing adsorption plants for air
separation, and water treatment plants.
[0006] Traditional skid construction has many serious drawbacks
though. First, the skid is constructed from many structural
elements, requiring a great deal of careful manual labor for
assembly. Subsequent to this assembly, the individual functional
elements of the plant are integrated to the skid with additional
labor required to locate and drill mounting holes, attach
fasteners, and the like.
[0007] Provision of an outer housing can be difficult, as the
dimensional tolerances of such structures can be rather poor,
causing problems with fit-up of the housing elements. Many skids
are thus left without any weather protection. Even if a cover is
fitted, it is generally difficult to make this cover
aesthetically-pleasing, due to the limited variety of shapes which
can be fabricated using a metal structural frame without
substantial outlay of precision labor or large investments in
tooling. This is a marked disadvantage if the equipment is to be
sited near public areas where aesthetic concerns may be of enormous
importance.
[0008] Of equal importance is the issue of protection of the
skid-mounted equipment during transit. Traditional skids may
provide lifting points, but they are not generally designed to
discourage improper load application during shipping. Further, they
do not provide any mechanical barrier against damage to the plant
and its associated plumbing and wiring interconnects, which are
generally susceptible to damage during handling, for example, by
impact from a fork truck tine. It is also exceedingly difficult to
provide a skid manufactured from individual structural components
which is proof against shipping shock which is also light in
weight. This results in either relatively massive skids designed to
withstand shock loadings, or in less-substantial skids which run
the risk of plant damage in transit.
[0009] Another drawback of traditional skids is related to
serviceability of the plant components. Existing skids mount each
component for full service while attached to the skid itself. This
can present a serious difficulty in packaging a plant in a compact
fashion for ease of shipment, small installed footprint and
aesthetic appeal.
SUMMARY OF THE INVENTION
[0010] Accordingly, the present invention advantageously provides
an improved mechanical apparatus for structural support of chemical
process equipment.
[0011] The present invention further advantageously provides means
for lifting the chemical process equipment, which prevents improper
handling that may lead to damage or create a safety hazard.
[0012] The present invention also advantageously provides a
structural support system substantially lighter than related art
apparatuses for equivalent mechanical strength and rigidity.
[0013] Additionally, the present invention provides means to
facilitate removal of entire process units as modules for service
and/or shipment.
[0014] Additionally, the present invention provides an improved
mechanical apparatus for the external housing of chemical process
equipment.
[0015] Additionally, the present invention provides a housing that
provides protection of the chemical plant during shipment.
[0016] Additionally, the present invention provides a housing that
provides protection of the chemical plant from fire hazards.
[0017] Additionally, the present invention provides a housing that
provides noise attenuation.
[0018] Additionally, the present invention provides a housing that
provides controlled ventilation.
[0019] Additionally, the present invention provides a housing that
provides control of electromagnetic interference.
[0020] The present invention further provides ready means of
interconnection between the structural support and housing
apparatus of the present invention.
[0021] The present invention further provides a housing that can
serve to support some or all of the components of the chemical
plant.
[0022] The present invention provides an assembled housing and a
structural support that facilitate implementation of
aesthetically-pleasing shapes.
[0023] The present invention substantially reduces the assembly
time for a packaged chemical plant.
[0024] Additionally, the present invention provides a hydrogen
generating plant packaged within an improved housing and support
system of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] A more complete appreciation of the invention and many of
the attendant advantages thereof will become readily apparent with
reference to the following detailed description, particularly when
considered in conjunction with the accompanying drawings, in
which:
[0026] FIG. 1 depicts a unitary structural base of the present
invention with a modular subassembly carrier;
[0027] FIG. 2 depicts an underside of the preferred lightweight
unitary base with stiffening ribs and essentially uniform wall
thickness;
[0028] FIG. 3 depict the unitary structural base of the present
invention with a system of preferred internal support
structures;
[0029] FIG. 4 depicts the improved structural base with internal
support structures and attached outer housing system; and
[0030] FIG. 5A depicts a front, right, top perspective view of a
preferred embodiment of the external housing, and FIG. 5B depicts a
rear, left, top perspective view of the housing of FIG. 5A.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Embodiments of the present invention will be described
hereinafter with reference to the accompanying drawings. In the
following description, the constituent elements having
substantially the same function and arrangement are denoted by the
same reference numerals, and repetitive descriptions will be made
only when necessary.
[0032] FIG. 1 depicts a unitary structural base 1 of the present
invention. The base 1 includes forklift tineways 2, which are
positioned to provide a secure and stable lifting point. As shown
in FIG. 1, each tineway 2 includes an aperture located on a side
surface of the base 1. Each aperture is shaped to receive a lifting
component, such as a forklift tine. These tineways 2 are preferably
positioned such that the center of gravity of the packaged process
plant is between the tineways 2 and near the forklift toward the
rear of the unitary base. The unitary base is provided with a large
number of component mounting holes 3 and internal support mounting
holes 4. The base may be provided with any number of component
mounting recesses 5, as well as provisions for leveling feet 6. It
may also preferably be provided with a raised sealing feature 7,
which can be used to locate and seal the housing panels 101, 102
(shown in FIG. 4) to the unitary base.
[0033] It is most advantageous to provide a removable carrier 9 for
any component which may require periodic maintenance or
replacement. The carrier 9 is integrated into mating aperture 10
and is preferably attached via fastener holes 11 which are provided
in the carrier 9 and around the mating aperture 10. Secure
fastening between these elements can be highly desirable to add
stiffness and strength to the assembled elements to protect against
damage during transport. Alternatively, some particularly fragile
equipment or equipment which generates substantial vibration may be
mounted using a removable carrier 9 which is isolated structurally
from the unitary base by vibration isolation means to provide
protection against shock and/or vibration being transmitted to the
equipment during shipment or operation. Examples of preferred
vibration isolation means are vibration-damping polymer sheet or
combinations of springs and damping elements.
[0034] Both the unitary base 1 and the carrier 9 may be
advantageously formed in a near net shape process such as casting,
forging, powder metallurgy or molding. Sand casting is an
especially-preferred method of manufacture for metal construction.
They may be manufactured from metals or reinforced ceramics or
polymers. Preferred materials combine high strength and stiffness,
low density, corrosion resistance and low cost.
Especially-preferred materials include alloys based on aluminum,
magnesium or fiber-reinforced polymers. For process equipment which
presents a fire hazard, aluminum-alloys are preferred. For process
equipment handling materials which attack metals, such as strong
acids, fiber-reinforced polymers are preferred.
[0035] Although many component mounting features may be formed in
the initial casting or molding process, tolerance limitations may
require secondary machining to provide finished features with close
tolerances. Computer Numeric Controlled (CNC) secondary operations
can provide feature placement to very tight tolerances, and are
especially preferred for providing threaded attachment holes 3, 4,
6 and 11, mounting pad surfaces 14, and outer panel sealing
surfaces 7.
[0036] The unitary base 1, when manufactured using near net-shape
processes, has the distinct advantage over structural skids of the
related art in that the shape of the perimeter of the unitary base
1 may have essentially any shape, and is not restricted to
polygonal shapes such as rectangles. In particular, curved sections
18 in the outer perimeter and compound curved sections 19 may be
easily formed. These features can serve structural purposes, such
as preventing snagging the exterior of the process plant during
transport, or can serve purely aesthetic purposes. The latter is of
especial performance in applications where process equipment is to
be sited near public places, where aesthetic considerations may be
crucial to obtaining permission to install the system.
[0037] FIG. 2 depicts the underside of the unitary base 1 of the
present invention. Although casting and molding can be used to form
essentially solid bases with recesses and features provided as
noted in FIG. 1, this practice undesirably increases the weight and
material cost of the assembled process plant. The increased weight
can further exacerbate handling of the plant, increasing the
probability of damage during shipment. Preferably, the unitary base
is provided with stiffening ribs 20. These ribs may be
strategically-located to reinforce areas around particularly heavy
components. Further, the tineways 2 also serve as stiffening
features. It should be noted that in sand cast construction of the
unitary base, core support points 21 may be added to reduce the
probability of defective castings being manufactured. In the
preferred embodiment, the unitary base 1 is configured such that
the wall thickness is essentially uniform throughout the part, with
increases and decreases in thickness occurring gradually in order
to promote ease of manufacture through molding or casting.
[0038] FIG. 3 depicts the unitary base 1 with attached structural
frames 31. These frames are provided with mounting points 32 for
outer side panels and holes 33 for attaching the roof panel 201
(FIG. 5A). The structural frames 31 are also provided with a large
number of component support holes 35. All of these features are
most preferably provided using computer numeric controlled (CNC)
methods such as laser cutting, or punch press work. This allows
these features to precisely match the mating holes provided in the
unitary base 1, the housing panels 101, 102, and in the supported
components themselves.
[0039] Compared to related art skids which are assembled from
standard structural shapes such as square or round tubes or
L-shaped structural members, the structural frames 31 of the
present invention are preferably formed from plate or sheet metal,
or by molding of fiber-reinforced polymers. This allows the shape
of the subframes to be optimized for strength and stiffness, while
minimizing weight and cost. It is particularly preferred to utilize
components, ducting features, and supporting panels to create box
structures. For example, internal ducting baffle 36 may be joined
to the forward structural supports by fasteners, as well as to the
electrical enclosure 37. The structural supports may also be joined
to duct inlet 38, which may also be joined directly to the unitary
base 1. The resulting structural shape is not only extremely strong
and stiff, and much more resistant to damage due to shock loading
due to shipping and handling, but is also highly functional. The
duct inlet 38 is provided with means to support filters 39 as well
as directing the flow of ventilating air to the plant and providing
structural support. The ducting baffle 36 is provided with features
to support a heat exchanger 40 and to attach an access panel 41
which may be used during maintenance to access internal components
inside the plant. All of these functions may advantageously be
served by a much reduced set of componentry compared to process
plants mounted on skids of the related art.
[0040] FIG. 4 depicts the unitary base 1 and structural subframes
of the present invention with external panels 101, 102, and 206
attached. The external panels are preferably provided with
attachment features 110, which are placed precisely to match the
mounting means 45 provided on the structural subframes 31 (shown in
FIG. 4). The external panels may be attached by bolts, screws,
pins, or any other means of attachment apparent to one skilled in
the art. The joints between the external panels, and between the
panels and the unitary base may advantageously be provided with
weather sealing means such as weather-stripping, caulk or any other
means apparent to one skilled in the art. To facilitate proper
sealing, the external panels may be provided with sealing features
111, which may take the form of overlapping seams, or shiplaps.
These features have the especial advantage of providing an
aesthetically-pleasing seal implementation where the sealing
material is not readily visible.
[0041] The external panels of the present invention can serve many
purposes. If they are rigidly mounted to at least one of the
subframes 31 and the unitary base 1, they can serve as load-bearing
members of the assembly. This is especially advantageous if the
panels are provided with stiffening features 112 or curvature 113.
These features advantageously increase the stiffness of the
external panels relative to that of planar panels as practiced with
polygonal skids of the related art. These combination of
high-stiffness external panels and correspondingly high stiffness
subframes 31 and unitary base 1 can result in significant increase
in the durability of the housing assembly and thus to its
resistance to damage due to imposed loads, such as shock loads
during shipping. Alternatively, one or more sides of the enclosure
may be combined to form larger housing systems, which may cover
two, three or more sides of the process plant. Such combination of
panels advantageously reduces assembly labor, increases strength
and stiffness, and reduces the number of weather seals required.
However, the tooling required to form such combined panels may be
very expensive, and the combined panels may restrict maintenance
access, such that neither method is preferred.
[0042] The external panels of the present invention may be made of
any material. Preferably, the panels are made of material which
offers one or more of the following attributes: ease of
formability; low flame spread; low smoke generation; good sound
attenuation; high strength; high stiffness; high toughness; and low
density. Most preferably, the panels may be made from fiber or
particle reinforced thermoset or thermoplastic polymer resin.
Resins which include fire-retardant compounds are
especially-preferred. An example of an especially-preferred
material is glass fiber reinforced polyesther resin with flame
retardant additives. Fire retardancy may advantageously be obtained
by providing panels with a layered construction including one or
more layers which are essentially incombustible or of very limited
combustibility. Examples include the use of fire-retardant polymer
foams, glass or mineral fiber batting or board, or powdered ceramic
material. A surprising advantage of providing this fire-retardant
layer is the concurrent reduction in acoustical transmission in a
properly selected enclosure panel. The acoustic attenuation
properties of the composite may be modified by varying the
thickness, porosity, and density of the insulative material to
selectively reduce acoustic transmission in one or more frequency
ranges.
[0043] In chemical process equipment which handles flammable
materials, it is especially advantageous to provide materials which
have static-dissipative properties to prevent the accumulation of
static electric charge. This is especially important to provide
protection against lightening strike. This may be accomplished by
providing enclosure panels made from metals, or by providing
non-metallic materials which employ a static-dissipative means.
Examples of such means are providing the electrically
non-conductive material with a conductive filler, such as carbon or
aluminum powder or fibers. Alternatively, static dissipative
coatings may be used. It is particularly advantageous to provide a
static dissipative means which also serves as a shield against the
propagation of electromagnetic noise. This protection may be
against noise radiating from sources outside the enclosure, such as
radio transmitters, high frequency power supplies, or the like, or
against electromagnetic emissions from inside the enclosure such as
high-voltage spark igniters for burners. An example of an
especially-preferred means for static dissipation and electromagnet
noise protection is a copper wire mesh which is assembled to the
enclosure panels, and may be manufactured into the panels.
[0044] The external enclosure of the present invention may be
manufactured using a variety of methods. It is especially-desirable
to employ methods which can produce components with the desirable
features described herein without requiring extremely costly and
complicated tooling, or inordinate expenditure of manual labor for
subsequent finishing and/or assembly of the panels. It is also
desirable to employ a method of manufacture which can yield nearly
net shape components such as hydroforming of metals, vacuum forming
of thermoplastic polymer, or rotational molding of thermoplastic
polymer. For the preferred, reinforced polymer materials, means
such as hand lay up, spray up, resin transfer molding, or
compression injection molding may be advantageously employed. Spray
up of reinforced polymers is especially preferred. It is especially
preferable to provide an excellent surface finish to the external
surfaces of the enclosure. A preferred technique for providing the
desired degree of surface finish is the use of a gel coat, which
preferably contains pigment, luminescent fillers, or other
appearance-enhancing means. Other methods for obtaining the desired
surface finish include painting, powder coating, and electroless
plating, which can also provide the static dissipative means to the
components.
[0045] FIGS. 5A and 5B depict a preferred embodiment of the
assembled enclosure system of the present invention. The enclosure
is provided with a front panel 101, with an integral ventilation
inlet louver 200. This front panel 101 is provided with attachment
means 110 (shown in FIG. 4) which facilitate easy removal for
maintenance purposes. The sealing shiplap 111 (shown in FIG. 4) is
overlapped by the edge of the top panel 201, and is provided with a
compliant sealing material in order to provide a substantially
weather-tight seal between the panels. The bottom edge of the panel
101 is provided with a hidden elastic seal which seals the region
between the sealing feature 7 of the unitary base 1. Similar hidden
seals are preferably provided between each panel which abuts the
unitary base and the base sealing feature 7. These sealing features
may be made externally visible if desired for special aesthetic
reasons.
[0046] The back of the enclosure may advantageously be provided
with an exhaust louver 204. In the preferred embodiment of the
present invention, a rear access panel 205 is provided which can be
separately removed to provide ease of maintenance. A fixed panel
206 is also illustrated which is used to permit permanent
attachment of utility interconnections 207. The location of the
access panels and ventilation louvers is dictated by the concerns
for the chemical process equipment in question. For process
equipment employed in the vicinity of heavier than air flammable
vapors, the height of ventilation inlet louver 200 is most
preferably at least 18 inches above ground level to protect against
the ingestion of such vapors with the ventilation air. For process
equipment generating a heated product gas stream, the exhaust
louver 204 is preferably sited near the top of the enclosure to
ensure rapid dispersal of any heated exhaust and/or any noxious
exhaust products. This arrangement of inlet and exhaust louvers is
particularly preferred for hydrogen generation equipment. The
enclosure of the present invention may most advantageously be
employed as a ventilation ductwork to direct ventilation air over
the chemical process equipment packaged within. This is
particularly preferable when the process equipment presents a risk
of leaking flammable or hazardous vapors. Forced ventilation is
especially preferred for hydrogen generation plants housed within
the enclosure of the present invention.
[0047] It is clear from the preceding description that the
integrated structural housing of the present invention can provide
an extremely high strength and stiffness by integrating a system
including a unitary base with internal structural elements which
preferably combine structural features with other functions such as
internal flow ducting, and a system of outer enclosure panels which
are themselves load-bearing, high-stiffness components.
[0048] It should be noted that the exemplary embodiments depicted
and described herein set forth the preferred embodiments of the
present invention, and are not meant to limit the scope of the
claims hereto in any way.
[0049] Numerous modifications and variations of the present
invention are possible in light of the above teachings. It is
therefore to be understood that, within the scope of the appended
claims, the invention may be practiced otherwise than as
specifically described herein.
* * * * *