U.S. patent application number 12/464449 was filed with the patent office on 2009-09-10 for powdered fuels and powdered fuel dispersions.
Invention is credited to Edward Bacorn, James K. McKnight, Ken W. White.
Application Number | 20090223612 12/464449 |
Document ID | / |
Family ID | 41052385 |
Filed Date | 2009-09-10 |
United States Patent
Application |
20090223612 |
Kind Code |
A1 |
McKnight; James K. ; et
al. |
September 10, 2009 |
POWDERED FUELS AND POWDERED FUEL DISPERSIONS
Abstract
A powdered fuel includes a powder including a material
consisting of particles having a particle size distribution median
and other statistical characteristics such that less than about 5%
of the particles by weight have a size larger than an explosibility
size limit for the material. The particle size distribution median
and other statistical characteristics are selected based on the use
of the powder as a substantially explosible fuel. In one embodiment
the material is biomass. In other embodiments, the material is a
metal material, a metal alloy, a metal oxide, a plastic material,
or a hydrocarbon-bearing solid. A powdered fuel dispersion includes
an oxidizing gas and a powdered fuel dispersed in the oxidizing gas
at a ratio such that the powdered fuel dispersion is explosible.
Proper control of the moving dispersion produces a stationary
deflagrating wave that substantially consumes the fuel to produce
energy.
Inventors: |
McKnight; James K.; (Ithaca,
NY) ; Bacorn; Edward; (Lansing, NY) ; White;
Ken W.; (Ithaca, NY) |
Correspondence
Address: |
BROWN & MICHAELS, PC;400 M & T BANK BUILDING
118 NORTH TIOGA ST
ITHACA
NY
14850
US
|
Family ID: |
41052385 |
Appl. No.: |
12/464449 |
Filed: |
May 12, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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PCT/US2007/024044 |
Nov 16, 2007 |
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12464449 |
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Current U.S.
Class: |
149/21 ;
149/108.2; 149/109.4; 149/22; 149/29 |
Current CPC
Class: |
C10L 1/322 20130101;
Y02E 50/10 20130101; C10L 5/44 20130101; Y02E 50/30 20130101; C10L
5/366 20130101; C06B 43/00 20130101; C06D 5/10 20130101 |
Class at
Publication: |
149/21 ;
149/108.2; 149/109.4; 149/22; 149/29 |
International
Class: |
C06B 45/02 20060101
C06B045/02; C06B 43/00 20060101 C06B043/00; C06B 47/10 20060101
C06B047/10; C06B 39/00 20060101 C06B039/00 |
Claims
1. A powdered fuel comprising a powder comprising at least one
biomass material, the powder consisting of particles having a
particle size distribution median and other statistical
characteristics such that: less than about 5% of the particles by
weight have a size larger than an explosibility size limit for the
biomass material; wherein the particle size distribution median and
other statistical characteristics are selected based on the use of
the powder as a substantially explosible fuel.
2. The powdered fuel of claim 1, wherein the powder comprises a
first plurality of particles having a first particle size
distribution median and other statistical characteristics and a
second plurality of particles having a second particle size
distribution median and other statistical characteristics different
from the first particle size distribution median and other
statistical characteristics, and wherein the first particle size
distribution median and other statistical characteristics and the
second particle size distribution median and other statistical
characteristics are selected based on the use of the powder as the
substantially explosible fuel.
3. The powdered fuel of claim 2, wherein the second plurality of
particles are a powdered coal material.
4. The powdered fuel of claim 1, wherein the powder is a blended
powdered fuel of two or more materials.
5. The powdered fuel of claim 4, wherein the blended powder has 10%
to 90% coal.
6. The powdered fuel of claim 1, wherein the biomass material is
selected from the group consisting of crops, wastes and residues,
starch crops, grains, rice, barley, rye, oats, soybean, maize and
wheat, sugar cane, sugar, cocoa bean, sugar crops, corn, grasses,
switchgrass, Miscanthus grass, elephant grass, tall fescue, prairie
grass, Reed canarygrass, Giant reed, cotton, seeds and husks,
seaweed, water hyacinth, algae, microalgae, herbaceous and woody
energy crops, wood chips, bamboo, wood, stem wood, cellulose, and
lignin, hardwoods, American sycamore, black locust, eucalyptus,
hybrid poplar, hybrid willow, silver maple, softwoods, cedar, pine,
Monterey pine, fishmeal, fat, whey, agricultural wastes, rice
straw, chaff, wheat straw, sugar cane bagasse, corn stover, corn
stalks, and forestal wastes, sawdust, shavings, lumber wastes, pulp
and pulp waste, mill wastes, thinned woods, brush, municipal and
industrial solid wastes, construction wastes, demolition wood
wastes, urban wood wastes, yard wastes, agricultural residues,
livestock wastes, dry manure solids, poultry wastes, intermediate
enzymatic and acid hydrolysis bio-solid byproducts, waste solids
from biological processes of ethanol fermentation, methane
production and anaerobic digestion.
7. The powdered fuel of claim 1, wherein the powder comprises at
least one material selected from the group consisting of boron,
calcium, phosphorus, magnesium, silicon, sulfur, aluminum, iron,
titanium, tantalum, zirconium, zinc, and compounds and alloys
thereof, bronze, titanium dioxide, coal, ultra clean coal, metal,
plastic, sulfur dust, phosphorus dust, polyester dust, a
hydrocarbon-bearing solid, polypropylene, polystyrene,
acrylonitrile butadiene styrene, polyethylene terephthalate,
polyester, polyamides, polyurethanes, polycarbonate, polyvinylidene
chloride, polyethylene, polymethyl methacrylate,
polytetrafluoroethylene, polyetheretherketone, polyetherimide,
phenolics, urea-formaldehyde, melamine formaldehyde, and polylactic
acid.
8. The powdered fuel of claim 1, wherein: less than about 5% of the
particles by weight have a size larger than or equal to 80 mesh; at
least about 15% of the particles by weight have a size smaller than
200 mesh; and the particle size distribution median and other
statistical characteristics are selected based on the use of the
powder as a substantially explosible fuel.
9. The powdered fuel of claim 8, wherein less than about 5% of the
particles by weight have a size larger than or equal to 200
mesh.
10. The powdered fuel of claim 9, wherein less than about 1% of the
particles by weight have size larger than or equal to 200 mesh.
11. The powdered fuel of claim 9, wherein: at least 50% of the
particles by weight have a size smaller than 325 mesh; at least 15%
of the particles by weight have a size smaller than 400 mesh; and
the particle size distribution median and other statistical
characteristics are selected based on the use of the powder as a
substantially explosible fuel.
12. The powdered fuel of claim 11, wherein at least 70% of the
particles by weight have a size smaller than 325 mesh.
13. The powdered fuel of claim 11, wherein at least 30% of the
particles by weight have a size smaller than 400 mesh.
14. The powdered fuel of claim 8, wherein at least 30% of the
particles by weight have a size smaller than 200 mesh.
15. The powdered fuel of claim 14, wherein at least 30% of the
particles by weight have a size smaller than 325 mesh.
16. The powdered fuel of claim 15, wherein at least 40% of the
particles by weight have a size smaller than 200 mesh.
17. The powdered fuel of claim 8, wherein less than 1% of the
particles by weight have a size larger than or equal to 80
mesh.
18. The powdered fuel of claim 17, wherein substantially all of the
particles have a size smaller than or equal to 80 mesh.
19. The powdered fuel of claim 8, wherein the powder is dispersed
in an oxidizing gas at an explosible ratio of four to fifty grams
of powder to one cubic foot of oxidizing gas.
20. A powdered fuel comprising at least one powdered material, the
powdered material consisting of particles having a particle size
distribution median and other statistical characteristics such
that: less than about 5% of the particles by weight have a size
larger than an explosibility size limit for the powdered material;
wherein the particle size distribution median and other statistical
characteristics are selected based on the use of the powder as a
substantially explosible fuel; and wherein the powdered material is
selected from the group consisting of a metal material, a metal
alloy, a metal compound, a plastic material, and a
hydrocarbon-bearing solid.
21. The powdered fuel of claim 20, wherein: less than about 5% of
the particles by weight have a size larger than or equal to 200
mesh; at least about 25% of the particles by weight have a size
smaller than 325 mesh; and the particle size distribution median
and other statistical characteristics are selected based on the use
of the powder as a substantially explosible fuel.
22. The powdered fuel of claim 21, wherein the powdered material
comprises at least one material selected from the group consisting
of boron, calcium, phosphorus, magnesium, silicon, sulfur,
aluminum, iron, titanium, tantalum, zirconium, zinc, and compounds
and alloys thereof, bronze, titanium dioxide, metal, plastic,
sulfur dust, phosphorus dust, polyester dust, a hydrocarbon-bearing
solid, polypropylene, polystyrene, acrylonitrile butadiene styrene,
polyethylene terephthalate, polyester, polyamides, polyurethanes,
polycarbonate, polyvinylidene chloride, polyethylene, polymethyl
methacrylate, polytetrafluoroethylene, polyetheretherketone,
polyetherimide, phenolics, urea-formaldehyde, melamine
formaldehyde, and polylactic acid.
23. A travelling powdered fuel dispersion comprising: an oxidizing
gas; and a powdered fuel dispersed in the oxidizing gas at an
explosible ratio such that the powdered fuel dispersion is
explosible, the powdered fuel comprising at least one material
comprising a powder consisting of particles having a particle size
distribution median and other statistical characteristics such
that: less than about 5% of the particles by weight have a size
larger than an explosibility size limit for the material; wherein
the particle size distribution median and other statistical
characteristics are selected based on the use of the powder as a
substantially explosible fuel.
24. The powdered fuel dispersion of claim 23, wherein the
explosible ratio is between four and fifty grams of powder to one
cubic foot of oxidizing gas.
25. The powdered fuel dispersion of claim 24, wherein the oxidizing
gas is air.
26. The powdered fuel dispersion of claim 24, wherein: less than
about 5% of the particles by weight have a size larger than or
equal to 80 mesh; at least about 15% of the particles by weight
have a size smaller than 200 mesh; and the particle size
distribution median and other statistical characteristics are
selected based on the use of the powder as a substantially
explosible fuel.
27. The powdered fuel dispersion of claim 26, wherein less than
about 1% of the particles by weight have size larger than or equal
to 200 mesh.
28. The powdered fuel dispersion of claim 26, wherein at least
about 30% of the particles by weight have a size smaller than 325
mesh.
29. The powdered fuel dispersion of claim 26, wherein at least 30%
of the particles by weight have a size smaller than 200 mesh and
the particle size distribution is selected based on the use of the
powder as the substantially explosible fuel.
30. The powdered fuel dispersion of claim 26, wherein the powdered
fuel has a particle size distribution wherein: less than 5% of the
particles by weight have a size larger than or equal to 200 mesh;
at least 50% of the particles by weight have a size smaller than
325 mesh; at least 15% of the particles by weight have a size
smaller than 400 mesh; and the particle size distribution median
and other statistical characteristics are selected based on the use
of the powder as a substantially explosible fuel.
Description
REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation patent application of co-pending PCT
application serial number PCT/US2007/024044, filed Nov. 16, 2007,
entitled "POWDERED FUELS, DISPERSIONS THEREOF, AND COMBUSTION
DEVICES RELATED THERETO", which claims priority to U.S. provisional
patent application Ser. No. 60/859,779, filed Nov. 17, 2006, now
abandoned, U.S. provisional patent application Ser. No. 60/868,408,
filed Dec. 4, 2006, now abandoned, and U.S. provisional patent
application Ser. No. 60/993,221, filed Sep. 10, 2007, now
abandoned. The benefit under 35 USC .sctn. 119(e) of the United
States provisional applications is hereby claimed, and the
aforementioned applications are hereby incorporated herein by
reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention pertains to the field of fuels. More
particularly, the invention pertains to powdered fuels.
[0004] 2. Description of Related Art
[0005] Scientists and engineers have toiled for decades to discover
workable alternatives to petroleum-based fuels. Despite this
prolonged effort, such alternatives have failed to gain commercial
success. However, this failure can hardly be attributed entirely to
economic conditions. Indeed, market conditions have been favorable
to petroleum alternatives, particularly in times of oil shortages
such as during World War II and the 1970's energy crisis.
[0006] The lack of commercial success of alternative fuels may be
explained, at least in part, by the shortcomings of prior systems.
One of the major drawbacks of prior systems and methods of
utilizing alternative fuels is the inability of the systems to
provide the operational benefits of petroleum-based systems. For
example, pellet-burning wood stoves and coal-fed cyclone furnaces
lack the on/off functionality of gas and oil burners. The furnace
will continue to burn the fuel added to the burner chamber until
the fuel is consumed regardless of whether the desired temperature
is reached. Likewise, existing pellet- and powder-based systems
lack the ability to quickly respond to increased performance
demands due to the "ramp up" time required to ignite the newly
added fuel.
[0007] Moreover, the disadvantages of existing alternative fuel
systems can be staggering. These systems often produce pollution
that is worse than that produced by petroleum-based systems. For
example, existing wood boilers produce unpleasant odors and large
particulates that can irritate the lungs and eyes. See, e.g.,
Anahad O'Connor, Wood Boilers Cut Heating Bills. The Rub?
Secondhand Smoke, N.Y. Times, Dec. 18, 2006. Additionally, these
systems may not even produce the proper conditions for efficient
combustion, for example, resulting in excess carbon monoxide
production.
[0008] As the existing technology has been clearly inadequate to
produce an alternative fuel system, there still remains a need for
clean, dependable, and efficient alternate fuels, in addition to
the systems that utilize these alternate fuels.
SUMMARY OF THE INVENTION
[0009] A powdered fuel includes a powder including a material
consisting of particles having a particle size distribution median
and other statistical characteristics such that less than about 5%
of the particles by weight have a size larger than an explosibility
size limit for the material. The particle size distribution median
and other statistical characteristics are selected based on the use
of the powder as a substantially explosible fuel. In one embodiment
the material is biomass. In other embodiments, the material is a
metal material, a metal alloy, a metal oxide, a plastic material,
or a hydrocarbon-bearing solid. A powdered fuel dispersion includes
an oxidizing gas and a powdered fuel dispersed in the oxidizing gas
at a ratio such that the powdered fuel dispersion is explosible.
Proper control of the moving dispersion produces a stationary
deflagrating wave that substantially consumes the fuel to produce
energy.
[0010] In one embodiment, the powdered fuel includes a powder
having a particle size distribution where less than about 5% of the
particles by weight have a size larger than or equal to 200 mesh,
at least about 25% of the particles by weight have a size smaller
than 325 mesh, and the particle size distribution is selected based
on the use of the powder as an explosible fuel.
[0011] In another embodiment, the powdered fuel includes powdered
softwood particles having a particle size distribution where less
than 5% of the particles by weight have a size larger than or equal
to 50 mesh, less than 15% of the particles by weight have a size
larger than or equal to 80 mesh, and at least 20% of the particles
by weight have a size smaller than 200 mesh.
[0012] In another embodiment, the powdered fuel includes powdered
hardwood particles having a particle size distribution where less
than 5% of the particles by weight have a size larger than or equal
to 80 mesh and at least 30% of the particles by weight have a size
smaller than 200 mesh.
[0013] In another embodiment, the powdered fuel includes powdered
grass particles having the particle size distribution where less
than 5% of the particles by weight have a size larger than or equal
to 200 mesh, at least 65% of the particles by weight have a size
smaller than 325 mesh, and at least 25% of the particles by weight
have a size smaller than 400 mesh.
[0014] In yet another embodiment, a powdered fuel dispersion
includes a gas and a powdered fuel dispersed in the gas.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1a shows the relationship between particle combustion
time and particle size.
[0016] FIG. 1b shows the relationship between heat transfer rate
and particle size.
[0017] FIG. 1c shows an exemplary particle size distribution for a
powdered fuel provided herein and a particle size distribution for
existing biomass fuels.
[0018] FIG. 1d shows three exemplary particle size distributions
for powdered fuels provided herein.
[0019] FIG. 2 shows a block diagram depicting a method of operating
a combustion device utilizing powdered fuel.
[0020] FIGS. 3a, 3b, 4, 4a, 5, 5a, 6, and 7 show embodiments of
kits and systems for creating powdered fuel dispersions.
[0021] FIGS. 8a-8h show components and embodiments of exemplary
positive displacement powder dispersion devices including a rotary
disk.
[0022] FIGS. 12, 13a, 13b, and 13c show embodiments of a powdered
fuel engine.
[0023] FIGS. 14a and 14b show additional embodiments of a powdered
fuel engine.
[0024] FIG. 15 shows systems for creating bursts of gas.
[0025] FIG. 16 shows a schematic of a microprocessor for
controlling a powdered fuel combustion device.
[0026] FIGS. 17a and 17b show schematics depicting data flows for
controlling a powdered fuel combustion device.
DETAILED DESCRIPTION OF THE INVENTION
I. Introduction
[0027] The challenges of the prior art demonstrate the need for
systems capable of clean, dependable, and efficient combustion of
powdered fuels.
[0028] As such, the inventions described herein provide for the use
of dispersions of explosible powder mixed with an oxidizing gas to
produce heat or perform work. In certain embodiments of the
invention, the composition of the dispersion is selected to achieve
explosibility for particular applications. In other embodiments,
the dispersion is dispensed through a controlled mechanism to
achieve and maintain a stoichiometric air/fuel ratio mixture that
is in the explosible range. Through the inventions herein, the
physics, thermodynamics, fluid mechanics, and chemistry of a
stationary deflagrating combustion wave are exploited to create a
stationary and sustainable flame front.
[0029] The inventions described herein provide a number of
advantages. The powdered fuel dispersions combust in a manner that
is visually indistinguishable from gaseous and liquid fuels such as
gasoline or propane. This characteristic allows for instant
ignition and sustained burning without the need for a large initial
heat input. Steady-state combustion is reached quickly. Like
existing gaseous and liquid fuels, the flame produced by combustion
of powdered fuel dispersions may be precisely controlled over a
large range of heat outputs by adjusting the flow rate of the
dispersion. The combustion of powdered fuel dispersion is almost
completely soot free and odor free, as well as carbon neutral.
Moreover, the powdered fuel dispersions provided are not limited to
particular combustion applications, allowing the powdered fuel
dispersions to be used with a variety of combustion devices and
allowing a single combustion device to combust powdered fuel
dispersions including a variety of fuels (e.g. hardwood, softwood,
grass, metal, plastic) with little or no modification or adjustment
required.
[0030] A further, important, and unexpected advantage is that this
new form of combustible fluid is much safer than petroleum products
such as oil, gasoline, propane, liquefied petroleum gas, and
methane, i.e., this fuel when spilled or allowed to collect on a
surface will not burn with a flame when touched with a blow torch.
In contrast, spilled petroleum products pose a serious health and
safety hazard.
[0031] The explosibility of powders is affected by, for example,
several factors including the surface area of the powder particles,
the energy content of the powder, the concentration of an oxidizer
such as oxygen in the powder dispersion, the temperature of the
powder and the oxidizer, the heat transfer rate, and the powder
particle size. Generally, smaller particles combust faster than
larger particles, resulting in the flame propagation which
characterizes an explosible dispersion. FIG. 1a depicts the general
relationship between particle size of a powder particle and the
particle combustion time. Dashed line 102 depicts the explosible
limit for the powder--a threshold above which the dispersion is not
explosible. This threshold varies from between individual
dispersions and may vary due to the other noted factors above, even
where the powder is the same between dispersions. For example, with
respect to the concentration of an oxidizer, a first dispersion
including a particular powder may not be explosible where the
dispersion includes air having 20.95% oxygen, while a second
dispersion including the same powder may be explosible where the
dispersion includes pure oxygen. It should be understood that, in
consideration of the disclosure of the present invention, methods
and apparatus for determining the explosible limit of a powder are
described in Wolfgang Bartknecht, Dust Explosions: Course,
Prevention, Protection .sctn. 2.3 (1989).
[0032] As depicted in FIG. 1b, there is a generally inverse
relationship between the heat transfer rate and the particle size.
The heat transfer rate for smaller particles is generally higher
than for larger particles. Again, dashed line 102 depicts the
explosible limit. FIG. 1b provides explanation for the reasons why
fuels composed primarily of large particles; for example, particles
on the order of 500 .mu.m must remain in a furnace for a
significant period of time.
[0033] FIG. 1c generally depicts a difference between the powdered
fuel dispersions provided herein and the powdered coal and biomass
fuels used in existing combustion devices. As is seen, curve 106,
which represents the particle size distribution of conventional
fuels, is shifted to the right of curve 108, representing the
particle size distribution of one embodiment of the powder fuels
disclosed herein. Line 104 represents a median powder particle size
for inventions described herein, which may, in some embodiments, be
between 50 .mu.m and 80 .mu.m.
[0034] As depicted in FIG. 1d, the particle size distributions for
embodiments of the inventions herein may have a variety of
statistical characteristics.
[0035] By selecting powder dispersions where the powder size
distribution has a median represented by line 104, dispersions are
achieved that are explosible regardless of variables such as the
surface area of the powder particles, the energy content of the
powder, the concentration of an oxidizer such as oxygen, the
temperature of the powder and the oxidizer, and the heat transfer
rate, provided that sufficient oxidizing gas is present to qualify
as explosible in nature. Accordingly, embodiments of inventions
herein are capable of deflagrating dispersions of powdered fuel
with little or no adjustment required for various powder
materials.
[0036] Accordingly, in light of the present disclosure, it is now
possible to use physics, thermodynamics, fluid mechanics, and
chemistry to determine the approximate conditions to create the
explosible powder dispersions of the invention.
[0037] However, before further description of the present
invention, and in order that the invention may be more readily
understood, certain terms have been first defined and collected
here for convenience.
II. Definitions
[0038] The term "ash" as used herein describes the incombustible
remains of combustion.
[0039] The term "biomass" as used herein describes any organic
matter available on a renewable, or recurring, basis. Ashraf
Elfasakhany, Modeling of Pulverized Wood Flames 3-4 (2005). Biomass
may include a wide variety of substances including agricultural
residues such as grasses, nut hulls, oat hulls, corn stover, sugar
cane, and wheat straw; energy crops such as grasses including but
not limited to pampas grass, willows, hybrid poplars, maple,
sycamore, switch grass, and other prairie grasses; animal waste
from animals such as fowl, bovine, and horses; sewage sludge; wood
residues (hardwood and/or softwood) from industries such as
logging, milling, woodworking, construction, and manufacturing; and
food products such as sugars and corn starch. See, e.g., id. The
chemical composition of selected types of biomass is described in
Kirsten Hamilton, Feasibility Study Grain-dust Burner (2006),
available at
http://www.esru.strath.ac.uk/Documents/MSc.sub.--2006/hamilton.pdf,
the contents of which are incorporated by reference herein.
[0040] The language "blended powdered fuel" as used herein
describes a powdered fuel that includes two or more distinct
powdered fuels, each of which may vary in particle size or
material/composition.
[0041] The language "BTU content" as used herein describes the
amount of energy (in British Thermal Units) produced when a fuel
combusts.
[0042] The language "closed loop system" as used herein describes a
system in which a result is monitored for deviations from a desired
value and one or more inputs are adjusted to minimize the
deviations.
[0043] The language "combustion device" as used herein includes any
system that burns and/or deflagrates a fuel of any type. Such
combustion devices include internal combustion engines, furnaces,
grain dryers, and generators.
[0044] The term "converting" as used in the language "converting
said energy" is used herein to describe the act of harnessing or
utilizing, for example, said energy, to produce a result, such as
doing work or producing heat. In certain embodiments, the
conversion of the energy may occur through the operation of a
device, as measured by the action of the device, i.e., which will
produce a measurable result.
[0045] The terms "combustion" or "combust(s)" as used herein
(without reference to a type of device, i.e., a combustion device),
describe the act of deflagration. These terms are distinguishable
from the act of simple burning.
[0046] The language "combustion area" as used herein describes a
location where combustion occurs, for example, adjacent to a
nozzle, inside an engine cylinder, etc.
[0047] The language "communicatively coupled" as used herein
describes the ability of two more components to communicate by any
technique and/or apparatus known to those of skill in the art.
[0048] The language "complete combustion" is art-recognized, and is
used to describe a combustion reaction in which the oxidizer
consumes the fuel, producing a limited number of products. As such,
complete combustion of a hydrocarbon in oxygen, yields carbon
dioxide and water. Complete combustion of a hydrocarbon or any fuel
occurring in air, also yields nitrogen.
[0049] The term "controlled", as used in the language "controlled
quantity", describes the characterization of a parameter that is
capable of being modified, e.g., finely or coarsely, through the
use of a feedback loop of information. For example, the language
"controlled quantity" refers to the quantity of a measurement that
is selected based on feedback modification, e.g., a feedback loop
of information.
[0050] The language "controlled stream" is used herein to describe
a movement or stream of particles that may be directly controlled
and modified, e.g., by feedback modification, based on parameters
flow rate, mass transfer rates, power/heat output, temperature
regulation, and the like. The stream may be finely or coarsely
controlled as the particular application may require. Moreover,
devices, such as sensors described herein below, may be used to
provide the data necessary to control or modify the stream. In
particular embodiments, the stream may be controlled for the
purpose of producing consistent explosible powder dispersion.
[0051] The term "coupled" is art-recognized, and is used herein to
describe the connection of two or more components by any technique
and/or apparatus known to those of skill in the art. Coupling may
be direct (two components in physical contact with each other) or
indirect (a first component in physical contact with one or more
components that are in physical contact with a second component).
For example, in the expression, "wherein the nozzle and the
turbulence chamber are coupled by a first conduit", the term
coupled describes the relationship between the nozzle and the
turbulence chamber where a powder dispersion can flow from the
turbulence chamber through the first conduit to the nozzle.
[0052] The term "deagglomeration" is used herein to describe the
act of breaking up or removing large particles included of groups
of smaller particles self-adhering in clumps.
[0053] The term "deflagrating" is art-recognized, and describes
subsonic combustion that usually propagates through thermal
conductivity (e.g., combusting material heats the next layer of
cold material and ignites it). It should be understood that
deflagration is distinguished from detonation in that detonation is
supersonic and propagates through shock compression.
[0054] The term "directing" is used herein to describe the
purposeful or deliberate guidance (e.g., through the use of devices
or connections of components) of a material, such as the explosible
powder dispersion of the invention, to a designated location. This
may be distinguished from material that remains stationary, as in a
dust explosion, which may be defined as deflagrating combustion
wave front propagating through an initially stationary dust/air
mix.
[0055] The term "explosible" as used herein describes a property of
a powder, which, when dispersed under the appropriate conditions as
a powder-gas mixture, is capable of deflagrating flame propagation
after ignition. Explosible powders that form explosible powder
dispersions are capable of flame propagation when mixed with the
appropriate ratio of an oxidizing gas. Numerous explosible powders
(which are distinguishable from ignitable powders) are described in
Table A.1 of Rolf K. Eckhoff, Dust Explosions in the Process
Industry (3d ed. 2003), the contents of which are hereby
incorporated by reference herein.
[0056] The term "gas" and "oxidizing gas" are used interchangeably
herein to describe any substance in the gaseous state of matter,
which contains a minimum amount of an oxidizing gas, e.g., O.sub.2,
to produce an explosible powder dispersion (i.e., even if
insufficient to provide complete combustion). For example, the
compressed gas from the compressed gas source, i.e., used to create
explosible powder dispersions is an oxidizing gas, such as air.
This term is intended to encompass gases of singular composition,
e.g., O.sub.2, and mixtures of gases, such as air. (This is in
contrast to the use of this term as the abbreviated form of the
word gasoline, liquefied petroleum gas, or natural gas.) In certain
embodiments of the invention, a gas may be used to create a
powdered fuel dispersion.
[0057] The language "incomplete combustion" is art-recognized, and
is used to describe a combustion reaction in which the fuel is
incompletely consumed by the combustion. Incomplete combustion will
produce large amounts of byproducts. For example, incomplete
combustion of hydrocarbons may produce carbon monoxide, pure carbon
(soot or ash) and various other compounds such as nitrogen oxides.
In a particularly advantageous embodiment of the invention, the
level of incomplete combustion is reduced.
[0058] The term "mesh" as used herein to describe particle size by
comparison to the open spacing of particle sieves as defined by a
specific standard of mesh. A variety of standards for mesh scales
exist including ISO 565, ISO 3310, and ASTM E 11-70. All mesh sizes
referred to herein are measured using the ASTM E 11-70
standard.
[0059] The language "particle size" as used herein describes the
size of a particle, e.g., in terms of what size mesh screen the
particle will pass through or by metric description of the size
(e.g., in microns). Moreover, certain embodiments of the powdered
fuel are defined, in part, by particle size. Particle size may be
defined by mesh scales, in which larger numbers indicate smaller
particles. As described herein, embodiments of powdered fuel may
have a particle size smaller than or equal to 50 mesh. Powdered
fuel also encompasses powdered fuels with more stringent
requirements, for example, powdered fuels including particles
smaller than approximately 80 mesh, e.g., smaller than
approximately 200 mesh, e.g., 325 mesh, e.g., 400 mesh.
[0060] The language "particle size distribution" as used herein
describes the prevalence of particles of various size ranges, i.e.,
the distribution of the particles of various sizes, within a powder
sample.
[0061] The term "plastic" as used herein describes synthetic or
semisynthetic polymerization products including, but not limited
to, polypropylene, polystyrene, acrylonitrile butadiene styrene
(ABS), polyethylene terephthalate, polyester, polyamides,
polyurethanes, polycarbonate, polyvinylidene chloride,
polyethylene, polymethyl methacrylate, polytetrafluoroethylene
(PTFE), polyetheretherketone (PEEK), polyetherimide, phenolics,
urea-formaldehyde, melamine formaldehyde, and polylactic acid. As
used herein, "plastic" includes the general categories of both
recyclable and non-recyclable plastics.
[0062] The language "positive displacement" is used herein to
describe a technique using devices that move a known volume of
material per unit operation as in per stroke, per index, or even
per unit time. In certain embodiments, positive displacement
devices are useful for accurate metering of fluids and solids.
[0063] The term "powder", as used herein describes a solid compound
composed of a number of fine particles that may flow freely when
shaken or tilted. The powder composition and/or particulate size
(and particulate size distribution) may be selected based on the
application in which the powder is being used. For example, in
certain embodiments the particle size distribution and/or particle
material is purposefully selected based on the desired utility
requiring a particular continuance, e.g., powdered fuel supplied to
a four cycle engine may have a distribution of particles that is
finer than the powdered fuel supplied to a furnace. The powders of
the present invention are at least "substantially explosible", in
that the limited particles in the particle distribution that exceed
the size limitations for explosibility amount to less than would
prevent the powder dispersion from igniting to produce a
sustainable stationary deflagrating combustion wave. In certain
embodiments, the particles in the particle distribution that exceed
the size limitations for explosibility are less than 20% to less
than 0.25%. In a particular embodiment, the particles in the
particle distribution that exceed the size limitations for
explosibility are less than 2%. In another particular embodiment,
there are no particles in the particle distribution that exceed the
size limitations for explosibility.
[0064] The term "powdered" as used herein described a substance
that has been reduced to a powder.
[0065] The language "powdered fuel dispersion" and "powder
dispersion" are used interchangeably herein to describe
substantially uniform mixtures of powdered fuel and an oxidizing
gas, which are selected to be explosible based on the nature of the
powder (e.g., size and/or composition of the constituent particles)
and the ratio of the powder to the oxidizing gas. The explosibility
of the powdered fuel dispersion may be affected by a number of
factors including, for example, the surface area of the powder
particles, the energy content of the powder, the concentration of
an oxidizer such as oxygen in the powder dispersion, the
temperature of the powder and the oxidizer, the heat transfer rate,
and the powder particle size. The language "powdered fuel
dispersion" and "powder dispersion" is also intended to cover those
dispersions that include an imperfectly distributed mixture made
with an imperfect distribution of an explosible powder, provided
that such dispersions are explosible.
[0066] The language "stoichiometric" for example, as used in
relation to the language "stoichiometric combustion" or
"stoichiometric mixture", is used herein to describe the ratio of
the explosible powdered fuel to the oxidizing gas in the powdered
fuel/oxidizing gas mixture, i.e., the powdered fuel dispersion of
the invention, that is suitable to support deflagration and
substantially consume the explosible powder in the mixture or
dispersion. The stoichiometric amount of oxidizing gas necessary to
consume the explosible powder in the combustion area may be
distinguished from the amount of oxidizing gas of the powder
dispersion, which is sufficient to create an explosible mixture yet
is typically lower that the total amount of oxidizing gas that is
ultimate capable of consuming the powder. As such, powders of the
present invention are explosible even without a stoichiometric
amount of an oxidizer.
[0067] The language "substantially consuming" is used herein to
describe level of consumption of the explosible powders of the
invention. A powder of the invention that is substantially consumed
produces less than 5% by weight residue to less than 0.25% by
weight residue. In certain embodiments, substantially consuming is
complete consumption. In certain embodiments, the present invention
is directed to reducing the amount of incomplete combustion, or
production of the consumption residue noted above.
[0068] The language "turbulent combustion" is art-recognized, and
used to describe a combustion characterized by turbulent flows. In
certain embodiments of the invention the deflagrating combustion is
turbulent combustion, which assists in the mixing process between
the fuel and oxidizer.
[0069] The language "ultra clean coal" as used herein describes any
coal having a low ash content by weight, for example, less than
1.00% to less than 0.05%.
[0070] The language "volatile mass" as used herein describes the
mass of the powder fuel particles that includes material or
compounds, such as water, which vaporize or volatilize at or below
the combustion temperature of the powdered fuel.
III. Methods of Utilizing Powdered Fuel
[0071] In one embodiment, the invention provides a method of
producing energy including the steps of mixing a substantially
explosible powder with an oxidizing gas to form an explosible
powder dispersion, directing the explosible powder dispersion in a
controlled stream past an ignition source, and igniting the
explosible powder dispersion to produce a stationary deflagrating
combustion wave. The method thereby substantially consumes the
explosible powder to produce energy, e.g., heat energy or energy
used to perform work. In certain embodiments, the explosible powder
dispersion in the controlled stream may be defined by one or more
selected from the group consisting of: powder fuel energy content,
powder fuel size, oxidizing gas characteristics, and oxidizing gas
temperature. Moreover, the explosible powder may include a material
selected from the group consisting of powdered biomass (e.g.,
powdered hardwood, powdered softwood, powdered grass) powdered
metals, powdered plastics, and any combination thereof. In certain
embodiments the method further includes the step of obtaining the
explosible powder.
[0072] This method may further include the step of converting the
energy produced by/through/in the operation of a device. Such a
device may be selected from the group consisting of furnaces,
engines, boilers, grain driers, clothes driers, water heaters,
combined furnace/water heaters, hot air balloons, space heaters,
wood burning stoves, gas fireplaces, gas turbines, and electrical
generators.
[0073] An additional embodiment of the invention, therefore,
provides a device operating using the energy derived by this
method. In certain embodiments, the device has been adapted from
the primary design of the device to operate using the energy. In
other embodiments, the device has a primary design to operate using
the energy.
[0074] In another embodiment, the invention provides a method of
operating a combustion device including mixing a substantially
explosible powder with an oxidizing gas to form an explosible
powder dispersion, directing the explosible powder dispersion in a
controlled stream to an ignition source, and igniting the
explosible powder dispersion to produce a stationary deflagrating
combustion wave, thereby substantially consuming the explosible
powder to produce energy and operate a combustion device using this
energy.
[0075] FIG. 2 depicts a method 200 of utilizing a powdered fuel. In
step 202, a gas flow is generated. In step 204, a controlled
quantity of powdered fuel is dispensed into the gas flow to create
a desired fuel/gas dispersion. In some embodiments, the controlled
quantity of powdered fuel is dispensed from a positive displacement
powder dispersion device. Positive displacement powder dispersion
devices, which are described herein, allow for a highly
controllable release of powder. In some embodiments, the powder
dispersing rate of the positive displacement powder dispersion
device may be linear or quasi-linear with respect to a voltage that
drives the positive displacement powder dispersion device.
[0076] In step 206, the powder/air dispersion is released into a
combustion area. The powder/air dispersion may be transported from
the location where the dispersion is formed by air pressure from
the gas flow. The powder/air dispersion may flow through one or
more components such as conduits, nozzles, manifolds, and valves to
reach the combustion area.
[0077] In step 208, the powder/air dispersion is ignited. The
powder/air dispersion may be ignited by a variety of techniques and
apparatuses known to those of skill in the art, including a flame
or a pilot light, such as a pilot light consuming methane or
propane, and electrical spark or arc, for example, from a spark
plug.
[0078] In some embodiments of the invention, exhaust gases are
analyzed as shown in step 210. Exhaust gases may be analyzed to
detect the presence and or quantities of a variety of substances.
In some embodiments, the oxygen level of the exhaust gases is
analyzed to determine if the fuel/gas dispersion is stoichiometric.
If sufficient oxygen is not present in the exhaust gases, the
fuel/gas dispersion is too rich and the quantity of powder fuel to
be dispensed will be reduced. If too much oxygen is present, the
dispersion is too lean and additional powder fuel will be
dispensed. Additionally or alternatively, exhaust gases may be
analyzed for the presence of carbon monoxide, which indicates that
the fuel/gas mixture is too rich.
[0079] The present invention also provides a method of operating a
combustion device including feeding an operating engine with a
first fuel mixture including a ratio of a liquid fuel to a powdered
fuel; and then decreasing the ratio of liquid fuel to powdered fuel
progressively to produce a second fuel mixture, thereby operating
the combustion device. In certain embodiments, the first fuel
mixture includes only liquid fuel. In certain embodiments, the
second fuel mixture includes only powdered fuel. The ratio may be
adjusted as a function of at least one input selected from the
group consisting of: engine temperature sensors, engine speed
sensors, throttle sensors, intake temperature sensors, exhaust
temperature sensors, intake gas sensors, and exhaust gas
sensors.
[0080] In another embodiment, the invention provides a method of
operating a combustion device including generating an airflow;
dispersing a controlled quantity of powdered fuel into the airflow
to create a explosible mixture; and introducing the explosible
mixture to a combustion area for deflagration, thereby operating a
combustion device. In certain embodiments, the airflow is in a
turbulence chamber. The method may further include measuring the
airflow; and adjusting the controlled quantity of powdered fuel to
be dispersed as a function of the airflow, e.g., where adjusting
the controlled quantity of powdered fuel to be dispersed includes
adjusting the speed of a powder dispersing device. Additionally,
the method may further include measuring a secondary airflow; and
adjusting the controlled quantity of powdered fuel to be dispersed
as a function of the secondary airflow, e.g., where adjusting the
controlled quantity of powdered fuel to be dispersed includes
adjusting the speed of a powder dispersing device.
[0081] The above embodiments facilitate starting an engine using a
liquid or gaseous fuel and transitioning to combustion, in whole or
in part, of powdered fuel. Such a method may be particularly useful
for "cold starts" of a combustion device. In some embodiments the
liquid or gaseous fuel may be selected from gasoline, hydrogen,
vegetable oil, biodiesel, bioalcohol, butanol, bioethanol,
biomethanol, biogas, 2,5-dimethylfuran (DMF), dimethyl ether (DME),
Bio-DME, Fischer-Tropsch diesel, wood diesel, ethane, methane,
propane, butane, diesel fuel, fuel oils, jet fuel, kerosene,
liquefied petroleum gas, and natural gas. Additionally or
alternatively, the liquid or gaseous fuel may include a starting
fluid such as dimethyl ether.
IV. Kit for Deflagration of Powdered Fuels
[0082] In another embodiment, the invention further provides a
combination of mechanical elements useful to adapt a device to
operate using the energy derived by the methods described herein
above, i.e., the energy produced by directing a controlled stream
to an ignition source to produce a stationary deflagrating
combustion wave. For example, the invention described herein
provides a kit for adapting a combustion device to deflagrate
powdered fuels. Accordingly, one embodiment of the invention
provides a kit for adapting a combustion device to deflagrate
powdered fuel, the kit including a turbulence chamber; a powder
dispersing device; a compressed gas source, e.g., where the
compressed gas source is adapted for connection with the turbulence
chamber; and an optional gas flow sensor, e.g., a mass flow sensor.
The inclusion of the optional gas flow sensor will be based on the
combustion device being adapted. In certain embodiments, the kit
further includes a nozzle, which, in certain embodiments, may be
adapted for connection with the turbulence chamber.
[0083] In certain embodiments, the gas flow sensor is selected from
the group consisting of a vein meter mass flow sensor, a hot wire
mass flow sensor, a cold wire mass flow sensor, and a membrane mass
flow sensor. In particular embodiments, the gas flow sensor is
adapted for connection with the fuel controller. In additional
particular embodiments, the gas flow sensor is adapted for
communicative coupling with the powder dispersing device. Moreover,
the speed of the powder dispersing device may be governed by the
gas flow sensor. Mass flow sensors are available from Sensata
Technologies of Attleboro, Mass.; Robert Bosch GmbH of Gerlingen,
Germany; DENSO Corporation of Aichi, Japan; Visteon of Van Buren
Township, Mich.; Delphi Corporation of Troy, Mich.; Hitachi, Ltd.
of Tokyo, Japan; and Kolbenschmidt Pierburg AG of Neckarsulm,
Germany.
[0084] With respect to the powder dispersing device, a number of
embodiments may be considered within the scope of the present
invention. For example, the powder dispersing device may be a
positive displacement powder dispersion device. Additionally, the
powder dispersing device may include a hopper, e.g., where the
hopper is tapered. The powder dispersing device may further include
a vibrator in contact with the hopper. In some embodiments, the
vibrator may be an ultrasonic (ultrasound) vibrator. The powder
dispersing device may also further include an auger positioned
within the hopper, and a power source connected to the auger to
rotate the auger. In addition, the powder dispersing device may
also include a horizontal auger positioned below the hopper, an air
lock, a mixer located within the hopper, a conduit, where the
turbulence chamber and the nozzle are connected by the conduit,
and/or be adapted for connection with the turbulence chamber.
[0085] In an additional embodiment, the powder dispersing device
may further include a second conduit for connection with the powder
dispersing device, and a second powder dispersing device for
connection with the conduit. Moreover, in certain embodiments, the
second powder dispersing device may include a second hopper, e.g.,
where the second hopper is tapered. In another embodiment, the
second powder dispersing device may include a second auger
positioned within the second hopper; and a second motor connected
to the auger to rotate the second auger. In a particular
embodiment, the second powder dispersing device may further include
a second vibrator in contact with the second hopper. The second
hopper may also include an air lock.
[0086] An exemplary embodiment of the invention provides a kit
further including one or more sensors selected from the group
consisting of engine temperature sensors, engine speed sensors,
throttle sensors, intake temperature sensors, exhaust temperature
sensors, intake gas sensors, and exhaust gas sensors; and a fuel
controller communicatively coupled with the one or more sensors and
adapted to adjust the quantity of the powdered fuel released from
the powder dispersing device. In certain embodiments, the fuel
controller adjusts the quantity of the powdered fuel released from
the powder dispersing device to maintain excess oxygen in exhaust
gases.
[0087] The kits of the invention may be used to adapt any device
capable of operating under the power of powdered fuel, e.g., a
powdered fuel described herein. In fact, in certain embodiments,
the kit may be adapted for use of a powdered fuel described herein.
Particular embodiments, which are not intended to be limiting of
the invention, include a furnace, an engine, a boiler, a grain
drier, a clothes drier, a water heater, a combined furnace and
water heater, a hot air balloon, a space heater, a wood burning
stove, and a gas fireplace. Such embodiments may be achieved by
replacing and/or supplementing an existing system for combusting
fuels. For example, in a grain drier such as those available from
Farm Fans, Incorporated of Assumption, Illinois, a powdered fuel
burner could replace and/or supplement conventional burners that
require propane or natural gas. Similarly, in a clothes dryer or a
space heater, a powder fuel burner could supplement or enhance
conventional electric or natural gas heating elements. A wood
burning stove could be retrofitted to utilize the powdered fuel
technology described herein by mounting a powdered fuel burner
within a combustion area of the wood stove. In a fireplace
embodiment, the powdered fuel burner could supplement or replace
the flames produced through a liquid or gaseous fuel such as
natural gas.
[0088] Accordingly, the kits may include instructions for
assembling the kit in order to adapt the existing to device to
operate on a powdered fuel. In a specific embodiment, the kit may
further include instructions for installing the kit in a furnace.
In another specific embodiment, the kit may further include
instructions for installing the kit in an engine.
[0089] The invention may be further clarified by utilization of an
exemplary embodiment and modifications thereto, the modification of
which should be understood as applicable to kits in general. FIG. 3
depicts such a kit 300.
A. Exemplification and Modifications Thereof
[0090] The kit 300 includes a nozzle 302. Nozzle 302 is designed
for connection to turbulence chamber 304. The turbulence chamber
304 is designed for connection with a powder dispersing device 306.
The turbulence chamber 304 is designed for connection with a gas
source 308. The components 302, 304, 306, 308 of kit 300 may be
produced and sold as individual, disassembled components, or one or
more of the components may be combined, in manufacturing and/or
after manufacturing.
[0091] Nozzle 302 may be adapted for coupling, mounting, and/or
placement in a variety of locations. In an application of the
inventions related to internal combustion engines, nozzle 302 may
be coupled with an intake manifold, throttle body, or inside the
combustion chamber in a manner similar to conventional gasoline or
diesel fuel injectors. In applications of the inventions to
furnaces, the nozzle 302 may be located in a burner chamber.
Similarly, with respect to kits for adapting a device such as a
torch or a flame thrower, nozzle 302 may be located externally to
the device and in close proximity to the flame during operation.
Once the powdered fuel mixture leaves the nozzle 302 and any
extensions thereto, the powdered fuel mixture is ignited and
combusts in the presence of secondary oxygen as in combustion
devices for liquid fuels such as propane or methane. By utilizing
secondary oxygen for combustion, the nozzle velocity may be reduced
allowing for the production of a sustainable flame.
[0092] Accordingly, the nozzle 302 may be composed of a variety of
materials to reflect the environment in which the nozzle 302 will
be placed (e.g. high temperature, high vibration environments).
Exemplary materials include, but are not limited to, iron, steel,
stainless steel, tungsten steel, copper, brass, aluminum, gold,
silver, titanium, alloys thereof, and polymers.
[0093] In some embodiments of nozzle 302, the nozzle may contain a
single orifice for ejecting the fuel mixture. Additional orifices
for ejecting combustion gases are not required, but may be included
to achieve particular flow rates and/or fuel dispersion patterns.
Sufficient gas for combustion will generally be supplied in the
fuel mixture and the combustion environment, such as a burner
chamber or an engine cylinder. For furnace applications, it may be
desirable for economic and noise reduction motives to configure the
system where the fuel/gas dispersion passes through the nozzle at
as low a pressure and flow rate as is practicable.
[0094] Nozzle velocity may be controlled through nozzle 302
selection and/or adjustment of the gas source. Various applications
may require different nozzle velocities. Lower velocities allow the
flame to spread laterally from the direction of the fuel mixture,
which may be desired in furnace applications. Generally, as the
nozzle velocity increases, the flame length increases and the
distance between the ignition point and the nozzle 302 may need to
be increased. Adjusting the nozzle velocity to reflect the
properties of the fuel mixture may create a sustainable flame.
[0095] In some embodiments, the nozzle 302 may be, or may be
similar to conventional fuel injectors for gasoline or diesel
fuels. Nozzle 302 may also be a nozzle designed for powder
spraying, for example, nozzles produced by Nordson Corporation of
Westlake, Ohio; EXAIR of Cincinnati, Ohio; and Powder Parts, Inc.
of Elgin, Ill.
[0096] In some embodiments, a nozzle extender or extension tubing
may be coupled to the nozzle 302 to allow for positioning of the
nozzle 302 away from the desired location for powder dispersal.
Suitable tubing includes 1/2'' CTS Genova CPVC 4120, available from
Genova Products, Inc. of Davison, Mich., and other tubing available
from Nordson Corporation of Westlake, Ohio and EXAIR of Cincinnati,
Ohio.
[0097] Turbulence chamber 304 may be composed of any material
capable of withstanding turbulent pressure flows used to form a
powder-gas mixture or dispersion. Examples include, but are not
limited to pipes and tubing included of iron, steel, stainless
steel, tungsten steel, copper, brass, aluminum, gold, silver,
titanium, alloys thereof, plastics, and polymers.
[0098] In some embodiments, the turbulence chamber 304 may be
connected to the nozzle 302 by a conduit (not shown). The conduit
may include any material suitable for channeling the powder-gas
dispersion to the nozzle 302, such as pipes and tubing included of
iron, steel, stainless steel, tungsten steel, copper, brass,
aluminum, gold, silver, titanium, alloys thereof, plastics, and
polymers. The size of the conduit will vary to reflect the
particular application of the kit. Exemplary internal diameters for
the tubing are 1/4'', 3/8'', 1/2'', 5/8'', 3/4'', 7/8'', 1'',
11/4'', 11/2'', 13/4'', and 2''. Exemplary tubing includes tubing
available from Nordson Corporation of Westlake, Ohio and EXAIR of
Cincinnati, Ohio.
[0099] Powder dispersing device 306 may be any device capable of
distributing a controlled amount of powdered fuel. One embodiment
of the powder dispersing device 306 is depicted in FIG. 3a. The
powder dispersing device 306 includes a hopper 310, an auger 312,
and a motor 314 for rotating the auger. Hopper 306 may be any
vessel capable of holding the powdered fuel. Exemplary hoppers are
described in Franklin D. Jones, Ingenious Mechanisms For Designers
and Inventors 483-94 (1930). While the motor 314 is depicted within
the hopper 310, motor 314 may be located either internally or
externally and may be connected directly with auger 312 directly or
through any linkage known to those of skill in the art. The auger
312 may also be driven by the engine in an automobile. The auger
312 may be of any length, but generally will be less than 12'' in
length. Sample auger systems are described in U.S. Pat. No.
4,895,274 to Morimoto et al., U.S. Pat. No. 6,951,230 to Wegman,
and U.S. Patent Application Pub. No. 2003/0090957 of Kressin et
al., the contents of which are incorporated by reference herein.
Sample powder dispensing devices are available from ALLFILL Inc. of
Exton, Pa. and Carolina Conveying, Inc. of Canton, N.C.
[0100] To enhance movement of the powder 316 and reduce the
occurrence of agglomerates in the hopper 310, one or more vibrators
318 may be located in contact with or in proximity to the hopper
310, the powder 316, and or both. Vibrators are well known in the
art and are described in U.S. Pat. No. 7,271,516 to Matsubara et
al., U.S. Patent Application Pub. No. 2007/0145840 of Ki, and U.S.
Patent Application Pub. No. 2007/0159016 of Olivier, the contents
of which are incorporated by reference herein.
[0101] Compressed gas source 308 may be any device for producing
compressed gas, as is known in the art. Compressed gas source 308
may be powered mechanically or electrically. For example, in
heating application such as home furnaces, compressed gas may be
provided by a 150 psi high volume gas compressor such as a Central
Pneumatic 12 volt, 150 psi, high volume gas compressor available
from Harbor Freight Tools of Camarillo, Calif. (catalog
#93186-ovga). Larger gas flow rates may be desired for automotive
or industrial applications and may be provided, for example, by a
Central Pneumatic 115 psi, 2 gallon gas compressor, available from
Harbor Freight Tools of Camarillo, Calif. (catalog #94724-ovga) or
a compressor capable of delivering 3.4 cfm at 40 psi.
[0102] In other embodiments, the compressed gas source 308 may be a
compressed gas tank. Compressed gas tanks are well known in the art
and are described in various publications from organizations such
as the Compressed Gas Association of Chantilly, Va. One or more
compressed gas tanks may provide a gas or mixture of gases to the
turbulence chamber 304.
[0103] The gases provided to the turbulence chamber 304 may be any
of a variety of gases including air. In certain embodiments, the
gas may be an oxidizer such as oxygen, ozone, fluorine, chlorine,
or bromine. In particular embodiments, the gas is air or another
oxygen source, e.g., O.sub.2 gas.
[0104] In some embodiments, the kit includes a fuel controller to
regulate the volume of fuel released into the turbulence chamber
304. The fuel controller may be any hardware, software, or
mechanical component as is known to those of skill in the art, such
as computers, microprocessors, and RISC microprocessors.
[0105] The fuel controller may be connected to one or more sensors.
For automotive embodiments, the sensor may include engine
temperature sensors, engine speed sensors (tachometers), throttle
sensors, intake temperature sensors, exhaust temperature sensors,
intake gas sensors, and exhaust gas sensors. Automotive sensors are
well know in the art.
[0106] In certain furnace embodiments, sensors may include flame
temperature sensors, compressed gas temperature sensors, sensors
that measure temperatures from a thermostat, sensors that measure
temperatures from within the furnace (e.g. water temperatures in a
boiler or heat exchanger temperatures), oxygen sensors, intake gas
sensors, and exhaust gas sensors. Temperature sensors may include a
variety of devices, including thermocouples, known to those skilled
in the art.
[0107] The fuel controller may also receive additional input
indicating data about the fuel(s) used in the combustion device.
For example, data on powdered fuels may include the type of fuel
(e.g. hardwood, softwood, metal, and coal) and specification of the
fuels (e.g. particle size, ash percentage, volatile mass
percentage). Data on liquid fuels may include the type of fuel
(e.g. gasoline, diesel fuel, kerosene, heating oil) and the
specification of the fuels (e.g. octane content, additives). The
input may be transmitted, for example, by a console in a vehicle, a
computer or thermostat in communication with a furnace, or a sensor
in the fuel storage or transport system, or the input may be
preset.
[0108] The fuel controller will adjust fuel flow rates based on one
or more inputs from the one or more sensors. For example,
additional fuel may be needed as the throttle is opened to allow
more gas to flow into the intake manifold or the compressed gas
source 308 is adjusted to allow more fuel into the turbulence
chamber 304. On a more advanced level, fuel flow(s) can be
controlled to minimize emissions. Emissions may be reduced through
maintenance of a stoichiometric combustion reaction in which there
is sufficient oxygen for the powdered fuel and any other fuel to
oxidize completely (e.g., which may be evidenced by monitoring the
oxygen emissions, i.e., excess oxygen in the emissions may indicate
sufficient oxygen during the combustion process). Additionally, the
fuel controller will adjust fuel flow rates to maximize combustion
device performance.
[0109] Air flow rates for the fuel/gas dispersion may be adjusted
in some embodiments, in most situations, the air flow rate need not
be adjusted. This is because secondary air will in most instances
be sufficient to ensure a stoichiometric dispersion. This is
particularly true when using powdered fuel dispersions in
combination with liquid fuels such as gasoline, which require much
higher ratios of air to fuel.
[0110] In other embodiments, a fuel controller is not required for
responsive powder distribution. A simple system has been fabricated
without the use of a computer or other microprocessor. One or more
gas flow sensors are positioned in proximity to the compressed gas
source 308, turbulence chamber 304, throttle, or intake manifold.
The gas flow sensor measures the amount of gas entering the
combustion device and generates electrical signals (e.g. DC
voltage) which represent the measured gas flow. These electrical
signals are used to control the powder dispersing device 306. For
example, the powder dispersing device 306 may include a DC motor
for rotating auger 312 and the motor speed may be governed in whole
or in part by the electrical signals generated by the gas flow
sensors.
[0111] In further embodiments, the kit may include a feedback loop
where inputs from sensors such as exhaust sensors are used to
control the powder dispersing device 306. By monitoring values such
as the oxygen content of exhaust gases, the combustion device can
be monitored to ensure that combustion is stoichiometric. The fuel
mixture can then be adjusted if it is too lean or rich.
[0112] In addition, the dispersing shear rate should be
monitored/adjusted immediately prior to flame ignition, as
continued confinement of a completely dispersed suspension of
particles in gas may lead to reagglomeration as the particles
impact the walls of an 8 inch extension from the nozzle even if the
internal diameter of the pipe is only 3/8 inch due to the chemical
properties of PVC pipe. It is generally observed that if gas flow
rates are in the range of 5 to 10 mph, larger particles and/or
agglomerates may fall out of the gas stream, while gas flow shear
rates in the range of 40 to 80 mph in embodiments with a 1/8 inch
nozzle aperture are sufficient to re-disperse powder particle
agglomerates.
[0113] In certain embodiments, the powder does not accumulate or
encounter a restriction at any point after it leaves the hopper
bottom until it is finally dispersed in a gas stream. For the
horizontal auger system the powder should fall freely into moving
auger flights rotating at a sufficient RPM so that the flights are
not completely filled. If these flights are filled as the powder is
advanced, the powder has a tendency to pack sufficiently to stop
the auger motor. After the powder falls off the end of the auger
tube it should fall without restriction directly into the
dispersing gas jet chamber which leads directly to the high shear
exit nozzle. Particular designs will avoid the accumulation of
powder at any of these points. It is therefore possible that a drop
down hopper can function without an auger if the powder drops down
directly to the turbulence chamber 304.
[0114] For heating or other applications requiring a precise
control of fuel supply rates over a range of a factor of ten,
vertical auger systems in the intermediate storage tank may drive
the powder into the 1/2 to 1 inch ID metering section (see vertical
auger system schematics.) By varying the auger RPM, the powder
supply rate can be increased from 5 grams per minute to 100 grams
per minute. With different auger diameters, this 20 fold range can
be shift, expanded, or contracted.
[0115] Embodiments of the inventions described herein may use
either a gas flame pilot light or a continuous electric arc as the
ignition source. The electric arc ignition source may be or
resemble a conventional spark plug. Any ignition source may be
incorporated with the nozzle 302.
[0116] With a particular drop down hopper configuration it was
demonstrated with 200 mesh that the feed rate is partially
controllable by varying the auger speed, but this control may be
limited by the basic drop down powder feed rate, which is
controlled, by the vibration and the shape of the hopper and the
outlet opening. Thus, in certain embodiments, the basic
intermediate hopper system used for furnaces may be sized for the
powder used and the BTU rating for the unit.
[0117] In a specific embodiment, the dispersion of small,
uncompacted agglomerates in a gas stream may be reduced to an
explosible stream of individual particles using a gas flow rate in
the range of 3 cubic feet/minute (cfm). The gas flow was obtained
with a 3 psi gas pressure and a 1/16-inch nozzle aperture. The
powder was dropped into the gas jet in a 1-inch diameter chamber
that smoothly tapers from 11/2 inch opening to nozzle exit opening
of 3/8 inch. The powder-gas dispersion exiting this nozzle system
showed no visible evidence of agglomerates with the use of 200 mesh
powder and essentially complete combustion was obtained after
ignition (less than 0.1% recovered after combustion).
[0118] FIG. 3b depicts a hopper and auger similar to those shown in
FIG. 3a. As in FIG. 3a, hopper 310 is tapered. An auger 312 is
located within the hopper 310.
B. Additional Exemplification
[0119] Another embodiment, system 400 depicted in FIG. 4, employs a
drop down hopper 402. A drop down hopper 402 is characterized by
the absence of an auger for agitation and vertical movement of the
powder contained within the hopper 402. Powder is primarily moved
vertically by the force of gravity. To enhance movement of the
powder and reduce the occurrence of agglomerates in the hopper, one
or more vibrators 403 may be located in contact or in proximity to
the hopper 402, the powder, and or both. This hopper 402a design
may incorporate a mechanism for stirring the powder in the hopper
403.
[0120] Powder supply is delivered from a bulk storage tank 404 to
the top of the drop down hopper 402a feeding the horizontal auger
tube 406 that transports a metered quantity of powder to the end
408 of the auger tube 406 where the powder is dropped down to the
turbulence chamber 409 and nozzle 410 as described above. Auger
tube 406 houses an auger powdered by a power source 411. The powder
may be dropped any distance as may be desired for various
embodiments. Alternatively, the gas flow to the turbulence chamber
409 may be delivered via a vacuum generating annular array of gas
jets in which case the intermediate storage hopper 402 could be
open to atmospheric pressure. The powder delivery rate is governed
by the vibration and stirring applied to the hopper contents and
the dimensions of the hopper 402 bottom (e.g. tapered) as well as
the rotational speed of the auger in tube 406. This design has the
advantage of using a low gas flow and pressure drop and can be
effective for powder flow rates as low as 50 grams/minute. Higher
powder flow rates can be achieved with higher gas flow rates,
nozzle diameters and higher powder delivery rates.
[0121] It is desirable for the gravity fed bottom opening of the
drop down hopper 402 to be in the range of 1 inch diameter or
larger. It is also desirable to remove the powder from this drop
down exit area before it can accumulate. Thus the powder may drop
down to the flights of a 1 inch diameter horizontal auger tube 406
or if the horizontal auger tube 406 is omitted, the powder may drop
down to a gas jet (supplied by compressed gas source 407) leading
directly to the dispersing nozzle 410 and the extension of nozzle
if necessary. Upon departing the nozzle 410, the dispersion passes
by an ignition source 411a.
[0122] FIG. 4a depicts the horizontal auger tube 406, turbulence
chamber 409, and nozzle 410 in greater detail. In one embodiment,
auger tube 406 is a 1'' diameter pipe housing an auger 412. The
auger 412 operates to advance the powdered fuel until reaches point
408 where it falls into the turbulence chamber 409. In this
embodiment, the turbulence chamber is a 3/4'' ID "T" fitting, with
one end closed except for a 1/16'' opening for a gas flow. The
turbulence chamber is coupled with a nozzle 410. As depicted, the
nozzle 410 may be coupled with an extension tube 416.
Alternatively, the nozzle 410 may be coupled to the turbulence
chamber 409 via the extension tube 416.
[0123] In some embodiments, for example, where 80 mesh fuel is
used, it may be advantageous to provide additional gas flow by
ventilating the end 418 of auger tube 406. This may be accomplished
in a variety of means, for example providing holes in end 418 or
equipping end 418 with a removable cap. The means for ventilation
may be adjustable.
[0124] Another embodiment of the invention is depicted in FIG. 5.
Again, a hopper is employed for distributing the powdered fuel.
Powdered fuel is delivered to the angled side opening 504 of the
hopper 502 through which a vertical auger 306 drives the powder
down into the metering section 308 of the auger tube from which the
metered powder flow drops to the gas jet dispersion chamber 510
whose exit leads to the nozzle 512. For continued powder supply
from the storage hopper, it may be advantageous for all of the drop
down systems to have a side entry port for powder delivery. Nozzle
512 may be a metal extension attached to the hopper 502. The powder
delivery rate again is governed by the same intermediate hopper
dimension factors as in FIG. 2 but the rate of powder delivery with
this system can be directly controlled by the auger rpm. The length
of the metering section 508 of the auger may be reduced depending
on the powder used.
[0125] The embodiment depicted in FIG. 5 may have a variety of
dimensions to reflect the many applications of the inventions
herein. One possible embodiment, system 500a is depicted in FIG.
5a. Powder supply is delivered to the angled side opening 504a of
the drop down hopper 502a with vibration (provided by vibrator
514a) and stirring by the vertical auger 506a which drives the
powder down into the metering section 508a of the auger tube from
which the metered powder flow drops to the turbulence chamber 510a
whose exit leads to the nozzle 512a. The tapered dimensions of the
hopper, the surface characteristics, the vibration, and the
stirring ensure a smooth supply of powder to the auger which
permits direct control of the rate of powder delivery by the auger
rpm. The length of the metering 508a section of the auger may be
reduced depending on the powder used.
[0126] The auger 506a in this embodiment is 7/8'' diameter with
11/4'' flight spacing and is enclosed in 1'' internal diameter
piping.
[0127] For the nozzle system using a single gas jet for dispersion,
the powder is dropped down from the end of the auger into
turbulence chamber 510a, which in this example is a 3/4 inch ID
tube that is 2 inches long. Alternative embodiments could use a "T"
fitting for the turbulence chamber 510a. One end of the turbulence
chamber 310a is plugged except for a 1/16'' hole for connection
with the gas source. The gas source provides a gas at a pressure of
approximately 3 to 10 psi at a flow rate of approximately 1 to 3
cubic feet per minute. The other end of the turbulence chamber 510a
leads to the nozzle 512a. In this instance, nozzle 512a has an
aperture of 5/16 inch ID which opens to 3/4'' inch ID to couple
with turbulence chamber 510a and has a length of 11/2 inches. This
system can be used effectively for both 200 mesh hardwood and 80
mesh pine, 325 mesh powdered grass as well as powdered sugar,
starch, or flour.
[0128] In one embodiment of this system, an Exair Line Vac provides
an annular array of gas jets to aid in the evacuation of the
dispersion chamber and may be used in place of the exit nozzle
described above. The 1/2-inch ID opening of the Exair outlet is
reduced to 3/8 inch ID with plastic tubing.
[0129] The above embodiment, like other embodiments described
herein, may be assembled from a variety of components. In the above
example, a Nordson #900650c CHO6F extension hose, available from
Nordson Corporation of Westlake, Ohio, was coupled with the nozzle.
Vibrators 514, 514a were fabricated from 12 volt DC fan motors
operating at approximately 1,800 rpm with 10 gram weights offset
approximately 3' from the shaft. 12 volt DC fan motors geared down
to produce approximately 20 rpm of the stirrer blade power the
auger.
[0130] Another embodiment of the invention is depicted in FIG. 6.
Again, a hopper 602 holds and dispenses the powdered fuel. The
powdered fuel may be delivered via an air lock 604 above the angled
side opening 606 since a second gas supply 608 may be used to
assist in moving the powder to the drop down gas dispersion nozzle
chamber 610. Alternatively, the gas flow 612 to the dispersing
nozzle 614 may be delivered via a vacuum generating annular array
of gas jets in which case the intermediate storage hopper 602 could
be open to atmospheric pressure. An auger is not required in these
systems, but may be added. Vibrators 616, 618, 620 may apply
vibration to the hopper walls and stirring of the contents to
ensure consistent powder flow to the dispersing chamber 610 below
the hopper.
[0131] Yet another embodiment of invention is depicted in FIG. 7.
As in the previous embodiments, a hopper 702 holds and dispenses
the powdered fuel. The depicted embodiment includes an optional
angled side opening 704. Unlike the previously described
embodiments, system 700 includes an internal mixer 706 for stirring
the powdered fuel. A gear motor 708 may drive the mixer.
[0132] All of the schematics noted above are depicted with either
an air lock system to supply the hopper with powder or an open side
port powder delivery point. In certain embodiments an air lock is
used when a gas supply is introduced into the hopper. In alternate
embodiments, the angled side port is used, e.g., with any of these
systems.
[0133] The above embodiment, like other embodiments described
herein may be assembled from a variety of components. In the above
example, the internal mixer 706 is stirred with a StrikeMaster
model VO6829AA83 24 volt DC motor, available from StrikeMaster Ice
Augers of Big Lake, Minn., geared to produce approximately 15 rpm.
The auger motor is a Denso 12 volt 10 u R730557-7030 motor,
available from Denso Corporation of Aichi, Japan, set to operate at
approximately 160 rpm at 12 volts.
[0134] The auger shaft tubing is 3/4'' PVC pipe available from
Charlotte Pipe and Foundry Company of Charlotte, N.C. Other pipe
components listed throughout refer to PVC pipe with specific
internal diameters where specified. However, the examples described
herein are examples provided to illustrate the concepts of the
inventions. For this reason, any material known to those of skill
in the art, for example, stainless steel, can be substitute for PVC
or any other component described herein.
[0135] FIGS. 8a-8f depict several rotary disks 800, 806, 812 for
positive displacement powder dispersion. Each disk 800, 806, 812
includes a plurality of recesses 802, 808, 814 for receiving a
volume of a powdered fuel. As depicted in FIGS. 8a-8f, a variety of
patterns may be utilized to achieve particular objectives such as
powder dispersion rate and powder dispersion patterns. In some
embodiments, the rotary disks include a central opening 804, 810,
816 for mounting and rotation.
[0136] FIG. 8g depicts a positive displacement powder dispersion
system including a rotary disk 816 and a hopper 818. The rotary
disk 816 rotates to dispense a controlled amount of powdered fuel.
As the rotary disk 816 rotates, recesses in the rotary disk 816
align with one or more holes in a plate (not shown) at the bottom
of the hopper 818, allowing powdered fuel to flow into the
recesses. As the rotary disk 816 continues to rotate, centrifugal
force causes the powder to disperse from the rotary disk 816. In
some embodiments, the hopper 818 includes an auger including a
shaft 822 and one or more blades 824. In some embodiments, the
shaft 822 rotates the rotary disk 816. In further embodiments, the
hopper may include a vibrator 826 for promoting powder flow. In
some embodiments, vibrator 826 may produce ultrasonic (ultrasound)
waves. The rotary disk 816 (and, in some embodiments, the auger) is
rotated by an electric motor, a servo, or other power source.
[0137] FIG. 8h depicts the interaction between the plate at the
bottom of hopper 818 and rotary disk 816. As described, the plate
includes a hole 828. In the hatched region 830, the hole 828 and
recess 832 of the rotary disk 816 align and powder flows into the
recess 832. As the rotary disk 816 spins, the powder is dispersed
by centrifugal force. The dispersal pattern may be adjusted by
adjusting the rotational speed of the rotary disk 816. For example,
dashed line 834 represents a radius of dispersal at lower
rotational speeds while line 836 represents a radius of dispersal
at higher rotational speeds.
[0138] In some embodiments, a powder dispersing system may include
a rotary wire brush mounted within the hopper or below the hopper
to fluidize any agglomerates that may form in the powder. Suitable
brushes are available from a variety of produces including DEWALT
Industrial Tool Co. of Baltimore, Md.
[0139] Other positive displacement powder dispersion devices may be
used in embodiments of the inventions herein. In a reciprocating
positive displacement powder dispersion devices, a stationary slide
is mated directly below a reciprocating slide. When aligned, the
one or multiple mini portions of powdered fuel are simultaneously
released from the upper metering slide, and fall through the lower
mask slide, either into an air stream for immediate dispersion, or
onto a conveyor belt or shelf or table for subsequent dispersion
using techniques described elsewhere herein. A major benefit of
this embodiment is the conversion of mini, well controlled portions
of explosible powder into a continuous stream flow for accurate
volumetric feed control.
[0140] In another embodiment, linear auger systems are used to fill
the powder dispersing devices. One or more linear augers feed a
plurality of powder dispensing devices which may be located in
proximity to each other. For example, in an inline four cylinder
engine, a single linear auger may feed four powder dispensing
devices. In another example, in a V-8 engine, a first linear auger
may feed four powder dispensing devices on one side of the engine
while a second linear auger system feeds the other four powder
dispensing devices on the other side of the engine. This linear
auger system is particularly compatible with the discrete cylinder
feed system depicted in FIG. 13b and described herein.
[0141] A variety of control techniques are available to insure
mini-hopper supply. In the simplest embodiment, for a four cylinder
PDPD configuration, a near continuous stream of powder would pass
over each hopper, driven by the long auger, with powder dropping
out in response to the available room, to maintain full
mini-hoppers, which fill with priority from the nearest to the
farthest from the supply system. Level sensing on the farthest
hopper, in communication with the powder supply system, ultimately
controls the feed frequency and rate.
[0142] Another embodiment employs a stacked multi-disk hopper
metering for continuous and smooth PDPD powder feeding. This system
employs three disks stacked below a hopper to perform a discrete
sequence of metering, handling and linear dispersion functions in
sort of a "bucket brigade" fashion. Each is a mask and an outlet
for the next. The top disk has one or more through slots along the
radius/diameter line to establish the feeding zones and set the
maximum volume. In the simplest embodiment, this disk is
stationary, although this is not a firm requirement, as the disks
may be geared together in rotational ratios to better accomplish
the same function.
[0143] In operation, powder falls through the aperture slots of the
first disk, and rests on the solid blank surface of the second
disk, in intimate contact just below, while the second, identically
slotted lower disk continues to rotate. When the slots of the
second lower disk align with the stationary top disk, the volume of
powder immediately falls into the slotted cavities of disk #2. Its
bottom is formed by the blank surface of the third or lowest
rotating disk. Disk #3 rotates at a greater speed in ratio with
disk #2. Disk #3's slots are configured at an angle, rather than
radially, for linearly transferring the powdered fuel through and
out of the angled slot on disk #3.
[0144] The net result is a continuous volumetric flow of powder
that is then dispersed into the zone below disk #3 and entrained
into an air/powder dispersion using methods described elsewhere in
this application. The result is a uniform, smooth and non-pulsing
flow. Ultrasonic energy may aid in the highly accurate performance
of this embodiment.
[0145] This three disk assembly can be fabricated by anyone skilled
in the art using ratio type gear drives, and function over a wide
range of speed when driven by a DC or other drive under electronic
control.
[0146] In another embodiment, the powder dispersing device includes
a volumetric rectangular "ladder" or pocket conveyor metering feed
system. This embodiment uses a volumetric approach, a type of
pocket conveyor, to remove known quantities of powder material from
a round, oval or rectangular surge or supply hopper above. This
hopper is supplied by a remote system using level sensing for
powder supply control and vibration, for example ultrasonic
vibration, to insure uniform flow into the metering device over
time and the wide dynamic range of operation.
[0147] A "ladder conveyor" involves use of a linear chain type
conveyor with divided, segmented "rungs" to create a series of
known volumes for powder metering. These "rungs" may be thin metal
blades or other dividing "walls" for easy connection with the
flexible transport chain mechanism and smooth contact with the
hopper surfaces. This dividing blade chain may be integrated with
the flexible bottom of the conveyor to form one continuous
assembly, or ride atop a more traditional conveyor belt running at
the same speed, which forms the bottom of the "pocket" volume.
[0148] A major advantage of this approach is its ability to provide
a continuous supply of premeasured volumetric portions of
explosible powder, while running in a variable speed mode and
driven by a DC or pulsed stepper motor over a wide dynamic range of
flow conditions and rates.
V. Powdered Fuel Adapted Furnace
[0149] In contrast to the addition of a kit to an existing device
to adapt it to utilize a powdered fuel source, changes to a device
for utilization of a powdered fuel may be incorporated into any
device's primary design. Such primary designs and methods of
modification, e.g., designs that allow for the use of the powdered
fuel of the present invention, are intended to be within the scope
of the present invention.
[0150] As such, one particular embodiment provides a furnace
adapted to operate using the energy source described herein through
the deflagration of powdered fuel. The furnace includes a nozzle, a
turbulence chamber coupled with the nozzle, a powder dispersing
device coupled with the turbulence chamber, and a compressed gas
source coupled with the turbulence chamber. In particular
embodiments, the nozzle and the turbulence chamber may be directly
coupled or coupled by a first conduit. Additionally, the powder
dispersing device and the turbulence chamber may be directly
coupled or coupled by a second conduit. Moreover, the compressed
gas source and the turbulence chamber may be directly coupled or
coupled by a second conduit.
[0151] The powder dispersing device may include a hopper, e.g.,
where the hopper includes an air lock, which may further include a
vibrator in contact with the hopper. The hopper may be tapered. In
addition, the powder dispersing device may further include an auger
positioned within the hopper; and a power source connected to the
auger to rotate the auger. Alternatively, the powder dispersing
device further includes a horizontal auger positioned below the
hopper. In particular embodiments, the powder dispersing device
further includes a mixer located within the hopper.
[0152] In additional embodiments, the furnace of the present
invention may further include an ignition source, a heat exchanger,
and/or a boiler. In certain embodiments, the ignition source
produces an electrical spark. In certain embodiments, the ignition
source is a pilot light.
[0153] The invention may be further clarified by utilization of an
exemplary embodiment and modifications thereto, the modification of
which should be understood as applicable to kits in general.
VI. Powdered Fuel Adapted Engines
[0154] Another particular embodiment provides an engine, e.g.,
adapted to operate using the energy source described herein through
the deflagration of powdered fuel. The engine includes at least one
cylinder defined by a cylinder block having a bore, a cylinder head
coupled to the top of the cylinder block, and a piston received in
the bore of the cylinder block. The engine also includes an intake
valve in communication with the cylinder head, an intake manifold
adjacent to the intake valve, a powder dispersing device, and at
least one gas flow sensor.
[0155] In some embodiments, the powder dispersing device is coupled
with the intake manifold. In these embodiments, the intake manifold
provides sufficient air flow and/or turbulence for the dispersion
of powdered fuel in air and effectively replaces the turbulence
chamber. Powder dispersion may be enhanced by adding one or more
throttle plates within the intake manifold, for example, in
proximity to the interface between the powder dispersing device and
the intake manifold.
[0156] Another embodiment provides an engine, e.g., a four-stroke
engine or a two-stroke engine. The engine includes a cylinder
defined by a cylinder block having a bore; a cylinder head, coupled
to the top of the cylinder block; and a piston received in the bore
of the cylinder block, an intake valve in communication with the
cylinder head, an intake manifold adjacent to the intake valve, a
nozzle for dispersing an explosible mixture of gas and powdered
fuel, e.g., where the nozzle is a Venturi aspirator or a powder
spray pump, a turbulence chamber coupled with the nozzle, a powder
dispersing device coupled with the turbulence chamber, a gas source
coupled with the turbulence chamber, and at least one gas flow
sensor, e.g., a mass flow sensor. The nozzle may, for example, be
coupled with the intake manifold and/or with the cylinder. In
particular embodiments, the gas flow sensor is selected from the
group consisting of a vein meter mass flow sensor, a hot wire mass
flow sensor, a cold wire mass flow sensor, and a membrane mass flow
sensor. In certain embodiments, this gas flow sensor may be located
within the intake manifold, coupled with the intake manifold,
and/or communicatively coupled with the powder dispersing device.
In certain embodiments, the speed of the powder dispersing device
is governed by the gas flow sensor.
[0157] In certain embodiments, the engine is of a type selected
from the group consisting of five-stroke engine, six-stroke engine,
Bourke engine, rotary engine, and Wankel engine.
[0158] Multiple embodiments of the components are considered
herein. For example, engines of the present invention may have
one-to-one ratio of nozzles to cylinders. The engine may also
further include a liquid fuel nozzle, e.g., a Venturi aspirator,
coupled with the intake manifold for dispersing a liquid fuel,
e.g., where there is a one-to-one ratio of liquid fuel nozzles to
cylinders. In another embodiment, the engine of the invention may
further include a throttle plate located within the intake manifold
and adjacent to the intake valve.
[0159] In additional embodiments, the engine may further include a
liquid valve coupled with the cylinder head, the liquid valve
adapted to release water into the cylinder before, at, and/or after
ignition of the explosible mixture. The fluid may be a water, a
lubricant, and/or a substance that promotes combustion. Suitable
substances for promoting combustion include starting fluids such as
those including dimethyl ether. The engine may also further include
a lubricant valve coupled with the cylinder head.
[0160] In a particular embodiment, the engine includes one or more
sensors selected from the group consisting of engine temperature
sensors, engine speed sensors, throttle sensors, intake temperature
sensors, exhaust temperature sensors, intake gas sensors, exhaust
gas sensors, mass airflow sensors; air/fuel ratio sensors; fuel
flow sensors; oxygen sensors; accelerometer sensors; powder supply
sensors; acoustic sensors; powder sensors; vacuum sensors; pressure
sensors; position sensors; injector-on time sensors; powder feed
speed sensors; static charge sensors; humidity sensors; moisture
sensors; particle size sensors; and knock sensors.
[0161] The engine may also include a fuel controller
communicatively coupled with the one or more sensors and adapted to
adjust the quantity of the explosible mixture released from the
nozzle. The fuel controller may be used to adjust the quantity of
the explosible mixture to maintain at least a minimum percentage of
oxygen in exhaust gases, or to maintain exhaust gas temperatures
below 500.degree. C. In certain embodiments, the fuel controller is
a closed-loop system.
[0162] In some embodiments, the engine may include a user interface
communicatively coupled with the fuel controller. The user
interface may be configured to allow a user to select a desired
fuel and/or fuel blend. In some embodiments, the user interface may
allow the user to override the fuel controller and manually select
the properties of a fuel and/or fuel blend. Such a configuration
may be advantageous for cold weather starting and/or if the engine
is "flooded" with powder.
[0163] The user interface may be any interface as is known to those
of skill in the art. The interface may be a simple analog
controller such as analog devices available from Split Second of
Santa Ana, Calif. Other embodiments of user interfaces may include
digital controls and/or displays including, but not limited to,
light emitting diodes (LEDs), liquid crystal displays (LCDs), and
touch screen interfaces.
[0164] The engines of the present invention may be specifically
adapted to use of a powdered fuel described herein. For example,
the engine may be adapted for using hardwood particles, softwood
particles, or grass particles, as described herein.
[0165] The invention may be further clarified by utilization of an
exemplary embodiment and modifications thereto, the modification of
which should be understood as applicable to kits in general.
A. Exemplification and Modifications Thereof
[0166] Another embodiment of the inventions described herein is an
internal combustion engine optimized to operate partially or
entirely on powdered fuel. The concepts described herein are
applicable to any type of internal combustion engine, such as a
two-stroke engine, four-stroke (Otto or Diesel cycle) engine,
five-cycle engine, six-cycle engine, Bourke engine, rotary engine,
and Wankel engine. For efficiency, the descriptions herein describe
a four-stroke engine adapted to deflagrate powdered fuel unless
otherwise described.
[0167] As depicted in FIG. 12 a four-stroke engine 1200 may contain
one or more cylinders defined by a cylinder block 1202 having a
bore 1204, a cylinder head 1206 coupled to the top of the cylinder
block 1202, and a piston 1208 received in the bore 1204 of the
cylinder block 1202. Typically, multiple cylinder blocks 1202 are
combined in a single cast and machined engine block or an engine
block formed from one or more modules. The cylinder block/engine
block may be made from a variety of materials, such as cast iron
and aluminum.
[0168] An intake valve 1210 and an exhaust valve 1212 are coupled
with the cylinder head 1206 to allow gas, fuel, and exhaust to
enter and exit the cylinder. Valves 1210, 1212 and valve train
assemblies for operating the intake and exhaust valves 1210, 1212
are well known and any existing or later discovered valve train
technology such as valves actuated by overhead camshafts,
cam-in-block systems (pushrod systems), and camless valve trains
using electronic systems such as solenoids may be adapted in these
embodiments.
[0169] The intake valve 1210 is adjacent to an intake manifold 1214
where a fuel gas mixture is present. The fuel mixture may include
various fuels at different quantities and/or ratios at different
points during engine 1200 operation. For example, at startup, the
engine may burn a mixture of air and liquids such as gasoline,
diesel fuel, kerosene, and/jet fuel. At other times, the engine
1200 may burn air and a mixture of liquids and powdered fuel. At
other times, the engine 1200 may burn a mixture of air and powdered
fuel. To facilitate these multi-fuel capabilities the intake
manifold 1214 is in communication with one or more nozzles 1216 for
dispersing a powder-air mixture. The intake manifold 1214 may also
be in communication with one or more fuel injectors or carburetors
(not shown) for dispersing a liquid-air mixture. The nozzle(s) 1216
may be located on the intake manifold 1214 wall and there may be
multiple nozzles 1216, for example one nozzle 1216 in proximity to
the intake valve 1210 for each cylinder. Alternatively, there may
be less than one nozzle 1216 per cylinder. This nozzle 1216 may
still be located on the intake manifold 1214. Alternatively, to the
extent that the engine 1200 uses a throttle valve or a carburetor
(not shown) that is not considered part of the intake manifold
1214, the nozzle(s) 1216 may be located in proximity or in
connection to the throttle valve (throttle body) or the carburetor.
The nozzle(s) 1216 may be any type of nozzle described here or
throughout this application. Particular applications may use a
Venturi aspirator or a powder spray pump.
[0170] In some embodiments, intake manifold 1214 may be omitted and
nozzle(s) 1216 may be directly coupled with the cylinder head.
[0171] In other embodiments, individual throttle plates are located
within the intake manifold 1214 and adjacent to the intake valve(s)
1210. The throttle plates may act to regulate gas flow into the
cylinder through the intake valve 1210 and/or create a turbulent
gas flow for better powder distribution. Moreover, in certain
embodiments, the throttle plates may allow the intake manifold to
operate at standard atmospheric conditions, namely standard
atmospheric pressure as opposed to below standard atmospheric
pressure. By ensuring that the intake manifold remains at standard
atmospheric pressure, the powder dispersion system in this
embodiment can better regulate flow because powdered fuel will not
be pulled through the auger by a pressure gradient between the
intake manifold and the powder distribution system.
[0172] In certain embodiments, to facilitate responsive
performance, particularly on acceleration, a powder distribution
system 1218 may be placed in close proximity to the engine 1200,
and more particularly, a powder distribution system may be placed
in proximity to each intake valve 1210, for example by mounting the
powder distribution system 1218 on the outside of the intake
manifold 1214. Powder distribution systems are discussed in greater
detail herein. As discussed above, the powder distribution
system(s) 1218 may be fed powdered fuel through a conduit 1220 from
a larger powder distribution system (not shown). In some
embodiments, the larger powder distribution system may be located
in the rear of the vehicle while the engine 1200 and the smaller
powder distribution system(s) 1218 are located in the front of the
vehicle, thereby preserving valuable space near the engine.
[0173] The powder distribution system 1218 dispenses a controlled
volume of powdered fuel to a turbulence chamber 1222 where the
powder is mixed with gas from a compressed gas source (not shown),
in some embodiments, via conduit 1224. Compressed gas sources are
described herein. In particular embodiments, the compressed gas may
be provided through a turbocharger powered by exhaust gases from
the engine. Turbochargers are well known in the art and not
described further. The flow rate for the compressed gas may be set
to any rate sufficient to create a powder-gas mixture, but
generally will be below 8 cfm.
[0174] The flow rate from the powder distribution system 1218 may
be modified. Gas flow rates need not necessarily be modified as the
dispersion and transport gas supply may only be a small fraction
the engine intake gas.
[0175] The operation of a four-stroke engine is well known and is
therefore only briefly summarized here. The four-stroke engine is
characterized by (1) an intake/induction stroke, (2) a compression
stroke, (3) a power stroke, and (4) an exhaust stroke. The cycle
begins at top dead center, when the piston is furthest away from
the crankshaft and therefore closest to the cylinder head. In the
intake/induction stroke, the piston descends drawing a mixture of
gas and fuel into the cylinder through the intake valve. The intake
valve closes and the compression stroke compresses the fuel
mixture.
[0176] The power stroke begins when the gas-fuel mixture is
ignited, either by a spark plug 1226 or other ignition source in an
Otto cycle engine, or by heat and pressure in a Diesel cycle
engine. The resulting expansion of burning gases pushes the piston
downward for the power stroke. In the exhaust stroke, the exhaust
valve opens and the piston returns to top dead center, thereby
pushing exhaust gases out of the cylinder.
[0177] Several enhancements to the engines described herein may be
used to improve performance and longevity of the engines. For
example, where the engines are designed for dual fuel consumption,
additives may be added to the liquid fuel for removing tar from
valve seals. Suitable additives are described in U.S. Pat. No.
5,112,364 to Rath, et al., and International Publication No. WO
85/01956 of Campbell. Additionally or alternatively, commercially
available fuel additives from STP of Boca Raton, Fla.; and
GUMOUT.RTM. products available from SOPUS Products of Houston,
Tex.
[0178] Regular use of gas intake cleaners may also promote
performance and longevity of engines adapted to use powdered fuels.
Intake system cleaners are commercially available and include
available from 3M of St. Paul, Minn. and MotorVac of Santa Ana,
Calif.
[0179] In other embodiments, one or more valves may be coupled to
the cylinder block or cylinder head to release substances into the
cylinder. A water valve may release water into the cylinder, for
example, during the power stroke. In some embodiments, the water
valve may include a nozzle and the water may be sprayed or misted.
In other embodiments, for example, in two-stroke engines, a
lubricant valve may release lubricant into the cylinder as a
substitute and/or supplement to the lubricant typically contained
in the fuel/oil mixture consumed by two-stroke engines. In some
embodiments, the lubricant may be sprayed or misted.
[0180] In some embodiments, a fuel controller may regulate the
volume of fuel (liquid and/or powdered) released into the intake
manifold. The fuel controller may be any hardware, software, or
mechanical component as is known to those of skill in the art, such
as computers, microprocessors, and RISC microprocessors.
[0181] The fuel controller may be connected to one or more sensors
such as engine temperature sensors, engine speed sensors
(tachometers), throttle sensors, intake temperature sensors,
exhaust temperature sensors, intake gas sensors, and exhaust gas
sensors. Sensors are well known in the art and are available from a
variety of vendors including Delphi Corporation of Troy, Mich.
[0182] The fuel controller may also receive additional input
indicating data about the fuel(s) used in the vehicle. For example,
data on powdered fuels may include the type of fuel (e.g. hardwood,
softwood, grass, metal, and coal, plastic) and specification of the
fuels (e.g. particle size, ash percentage, volatile mass
percentage). Data on liquid fuels may include the type of fuel
(e.g. gasoline, diesel fuel, kerosene) and the specification of the
fuels (e.g. octane content, additives). The input may be
transmitted, for example, by a console in the vehicle or a sensor
in the fuel storage or transport system, or it may be preset.
[0183] The fuel controller may adjust fuel flow rates based on one
or more inputs from the one or more sensors. For example,
additional fuel may be needed as the throttle is opened to allow
more gas to flow into the intake manifold. On a more advanced
level, fuel flow(s) can be controlled to minimize emissions.
Emissions may be reduced through maintenance of a stoichiometric
combustion reaction in which there is sufficient oxygen for the
powdered fuel and any other fuel to oxidize/combust completely.
[0184] Additionally, the fuel controller may adjust fuel flow rates
to maximize engine performance. For example, powdered fuel may be
particularly effective under conditions requiring less that 50% of
the maximum engine horsepower produced when operating on 100%
liquid fuel. Furthermore, maintenance of exhaust temperature below
500.degree. C. may minimize ash production, thereby reducing valve
fouling.
[0185] FIG. 13a depicts aspects of an exemplary embodiment of a
powdered fuel engine 1300a. A gas, e.g. air enters the engine
through intake 1302a. The gas may pass through a filter, such as an
automobile air filter as is known in the art before, during, or
after entering intake 1302a. The amount of gas passing through
intake 1302a is measured by an air sensor such as a mass air flow
sensor 1304a. Mass air flow sensors are further described herein. A
portion of the gas is diverted from the intake 1302a to a
compressor 1306a, for example a centrifugal blower. A throttle
plate 1308a regulates the flow of the gas to the compressor 1306a.
Another throttle plate 1310a (throttle body) regulates the flow of
the remaining gas to the intake manifold 1312a.
[0186] The compressor 1306a provides a gas flow to a positive
displacement powder dispersion (PDPD) device 1314a through a
conduit 1316a. PDPD 1314a is coupled with the intake manifold
1312a. In some embodiments, the interior PDPD 1314a operates at
about intake manifold vacuum pressure. In some embodiments, PDPD
1314a is located completely or partially within intake manifold
1312a. Powdered fuel is dispensed from powder dispenser into the
intake manifold 1312a where a fuel/gas dispersion is created. This
dispersion is drawn into cylinder 1318a through valve 1320a as
described herein.
[0187] The engine 1300a as described herein overcomes a major
challenge to the use of powdered fuels in variable output
combustion devices such as automobile engines. Because a gas flow
is used to create and maintain a powdered fuel dispersion, previous
attempts at powdered fuel engines have failed to provide
satisfactory performance when the throttle 1310a is closed, such as
in a cold start. The embodiments provided herein overcome this
challenge through the use of "make-up gas" which passes through
throttle 1308a to compressor 1306a, through conduit 1316a to PDPD
1314a. The make up allows the creation and maintenance of a
powdered fuel dispersion even when throttle 1310a is closed or
partially closed.
[0188] In some embodiments, "make-up gas" is provided from an
auxiliary gas source prior to ignition. In some embodiments,
compressor 1306a may be actuated prior to ignition of the engine
and throttle plate 1308a partially or completely open to allow for
a powdered fuel dispersion to be created prior to cranking of the
engine. In other embodiments, a gas such as pure oxygen may be
provided from a compressed oxygen tank prior to cranking.
[0189] FIG. 13b depicts aspects of another exemplary embodiment of
a powdered fuel engine 1300b. Again, a gas, e.g. air enters the
engine through intake 1302b. The amount of gas passing through
intake 1302b is measured by an air sensor such as a mass air flow
sensor 1304b. A portion of the gas is diverted from the intake
1302a to a compressor 1306a, for example a centrifugal blower. A
throttle plate 1308a regulates the flow of the gas to the
compressor 1306a. Another throttle plate 1310a (throttle body)
regulates the flow of the remaining gas to the intake manifold
1312a.
[0190] Instead of providing a gas flow to a single PDPD as in FIG.
13a, the compressor 1306b in FIG. 13b provide a gas flow to a
conduit 1316b for each cylinder. The conduit 1316b directs the gas
flow to a PDPD 1314b (e.g. a hopper system as described herein) for
each cylinder. In alternative embodiments, there need not be a PDPD
1316b for each cylinder 1318b. Rather, there may be one PDPD 1314b
for a number of cylinders. Exemplary ratios of PDPDs to cylinders
include 1:1, 1:2, 1:3, 1:4, 1:5, 1:6; 1:7, 1:8, 1:9, 1:10, 1:11,
and 1:12.
[0191] PDPD 1314a is coupled with the intake manifold 1312b in
proximity to each cylinder. In some embodiments, the interior PDPD
1314b operates at about intake manifold vacuum pressure. In some
embodiments, PDPD 1314b is located completely or partially within
intake manifold 1312b. Powdered fuel is dispensed from powder
dispenser into the intake manifold 1312b where a fuel/gas
dispersion is created. This dispersion is drawn into cylinder 1318b
through a valve 1320b as described herein.
[0192] FIG. 13c depicts aspects of another exemplary embodiment of
a powdered fuel engine 1300c. Again, a gas, e.g. air enters the
engine through intake 1302c. The amount of gas passing through
intake 1302c is measured by an air sensor such as a mass air flow
sensor 1304c. Unlike system 1300b as shown in FIG. 13b, system
1300c does not utilize a separate throttle plate for the gases
which bypass the intake manifold 1312c. Moreover, system 1300c
includes a distributor 1322c instead of a compressor or centrifugal
blower. This embodiment recognizes the fact that atmospheric
pressure may be sufficient to produce and maintain a powdered fuel
dispersion. Moreover, this embodiment is suited for engines
including a turbocharger which boosts intake gas pressure. The
distributor 1322c may simply split the gas flow into a plurality of
conduits 1316c. In other embodiments, the distributor may include
one or more control devices such as solenoids to oscillate the gas
flow to individual PDPDs 1314c.
[0193] FIG. 14a depicts an additional embodiment of the powdered
fuel engines described herein. Engine 1400a is similar to some
embodiments described herein in that includes a compressed gas
source 1402a, a turbulence chamber 1404a, and a powder dispersing
device (e.g. a positive displacement powder dispersion device)
1406a coupled with a cylinder. Powder dispersing device 1406a
includes additional embodiments to enhance performance. An
ultrasound vibrator 1410a is coupled with powder dispersing device
1406a to promote powder flow and dispersion. Additionally, a level
sensor 1412a is coupled with the powder dispersing device 1406a to
monitor the amount of powder in the powder dispersing device
1406a.
[0194] FIG. 14b depicts another embodiment of the powdered fuel
engines described herein. Engine 1400b includes a powder dispersing
device 1406b which is located at least partially within the intake
manifold 1414b. An air lock 1420b maintains a constant gas pressure
within the powder dispersing device 1406b while allowing powder to
flow from and to a powder storage tank. Powder dispersing device
1406b differs in several respects from other powder dispersing
devices described herein. Powder dispersing device 1406b includes a
gated aperture 1416 for regulating the flow of powdered fuel. (In
other embodiments, the gated aperture may be replaced with a
stepping air lock.) Powder flow within the powder dispersing device
1406b is promoted by ultrasonic vibrator 1410b. Compressed gas
source 1402b provides a phased air blast to disperse powdered fuel
released through gated aperture 1416b. In some embodiments, an
ultrasonic vibrator 1418b is positioned below the gated aperture
1416b within the intake manifold 1414b to promote powder dispersion
and gas turbulence. Ultrasonic (ultrasound) devices are known in
the art and may be fabricated from piezoelectric materials such as
lead zirconate titanate (PZT).
[0195] FIG. 15 depicts systems 1500 for generating short blasts of
gas for dispersing a powdered fuel. A gas enters through intake
1502. In some embodiments, the air flows through a compressor 1504
or a distributor to divide the air flow into an air flow for each
powder dispersing device. In some embodiments, a solenoid valve
1506 is opened for brief periods of time to generate a blast of air
to disperse a powdered fuel. In other embodiments, a rotary valve
1508 is actuated by a stepper motor 1510 to generate the blast of
air.
[0196] FIG. 16 is a schematic for a microprocessor 1600 for
controlling one or more powder dispersing systems. Microprocessor
1600 is an electrical component as is known in the art capable of
performing mathematical operations as is well known in the art.
Microprocessor 1600 may be any type of microprocessor now known or
later developed including 8-bit, 16-bit, 32-bit, 64-bit, multicore
microprocessors, and RISC microprocessors. Microprocessor 1600
receives a variety of inputs including inputs from sensors and
controls, inputs from operator controls such as user interfaces,
inputs from engine control computers, inputs from the fuel supply
system and additional devices for external data analysis, fault
diagnosis, and look up table (LUT) loading. The microprocessor may
provide outputs to variety of devices including actuators for
controlling the powder dispersing devices, output displays, engine
control computers, fuel data supply monitors, and additional
devices for external data analysis, fault diagnosis, and look up
table (LUT) loading.
[0197] The microprocessor may communicate with other modules and
components through communication technologies known to those of
skill in the art including hardwire serial or parallel
communication, USB, USB-2, Firewire, wireless or other port
protocols, smart cards, memory cards, keys, RF transponders, and
the internet.
[0198] FIG. 17a depicts a schematic for controlling a powder
dispersing device. Fuel flow requirements 1702a are determined by
the throttle position and the amount of gas flowing by the mass
airflow sensor in consultation with inputs from an engine control
computer 1704a. In some embodiments, the engine control computer
1704a is configured to optimize engine performance where the engine
utilizes a plurality of fuels. Once the fuel flow requirements
1702a are determined, a set point is communicated to the powder
dispersing controls, which may receive additional inputs 1708a and
generate outputs 1710a for related devices such as compressors,
gated apertures, solenoids and the like.
[0199] FIG. 17b depicts a schematic for controlling a powder
dispersing device using a closed loop system. As in FIG. 17a, fuel
flow requirements 1702b are determined by the throttle position and
the amount of gas flowing by the mass airflow sensor in
consultation with inputs from an engine control computer 1704b. In
some embodiments, the engine control computer 1704b is configured
to optimize engine performance where the engine utilizes a
plurality of fuels. Once the fuel flow requirements 1702b are
determined, a set point is communicated to a feedback compensation
control unit 1712b. The feedback compensation control unit may
modify the set point in response to feedback from sensors. In some
embodiments, the sensors may include exhaust gas oxygen sensors,
exhaust gas flow rate sensors, and exhaust gas temperature sensors.
In some embodiments, the feedback may be modified or trimmed by the
engine control computer 1704b to achieve particular performance
objectives.
VII. Additional Embodiments of Powdered Fuel Adapted Devices
[0200] The powdered fuels, systems, kits, and methods disclosed
herein may be applied to a variety of applications including, but
not limited to, hot water heaters, clothes dryers, hot air
balloons, grain dryers, space heaters, and ovens by replacing or
supplementing existing combustion devices with powder burning
devices.
[0201] The powdered fuels described herein may be used with a
variety of combustion devices including those described in this
application. Other suitable combustion devices include burners
produced by one or more of the following manufacturers:
VarmeTeknisk Service AB of Nykoping, Sweden, Petrokraft AB of
Goteborg, Sweden, TPS Termiska Processer AB of Nykoping, Sweden,
Coen Company, Inc. of Woodland, Calif., LBE Feuerungstechnick GmbH
of Wuppertal, Germany, Thermix Combusion Systems, Inc. of Queebec,
Canada, and Alternative Green Energy Systems, Inc. of Quebec,
Canada.
VIII. Powdered Fuels
[0202] The powdered fuels of the invention have utility in numerous
applications for which an alternate, efficient, cost-effective,
clean, and renewable energy source is desired. The powdered fuels
of the present invention have significant advantages over not only
existing alternate energy sources, but also over petroleum, the
world's most utilized fuel source. Advantages include, for example,
cost efficiency, fuel efficiency, and safety.
[0203] In this regard, one embodiment of the invention provides a
powdered fuel. The powdered fuel includes a powder having a certain
particle size distribution: less than about 5% of the particles by
weight have a size greater or equal to 200 mesh; and at least about
25% of the particles by weight have a size less than 325 mesh.
Moreover, the particle size distribution is selected based on the
use of the powder as an explosible fuel. In certain embodiments,
the particle size distribution is the product of the combination of
multiple powders of separate size. Additionally, the powder may
include a mixture of two or more powder materials.
[0204] It is well known that a powder may be explosible if a
powder-gas mixture is capable of flame propagation after ignition
when mixed with an oxidizer such as air. See, e.g., Marin Hertzberg
& Kenneth L. Cashdollar, Introduction to Dust Explosions, in
ASTM Committee E-27 on Hazard Potential of Chemicals, et al.,
Industrial Dust Explosions 5-13 (1987). However, the present
invention provides for the selection of particle size distributions
in order to control/harness such explosibility as a fuel
source.
[0205] Explosibility of the powdered fuel of the invention is
controlled, in part, by particle size, with smaller particles
generally more explosible than large particles. As such, the powder
of the invention is not limited in any way by the material from
which the powder is derived. Exemplary embodiments of powdered fuel
may include biomass. In some embodiments, the powdered fuel may be
stem wood, limb wood, stem bark, or limb bark. Powdered hardwood is
available from P.J. Murphy Forest Products Corp. of Montville, N.J.
Powdered softwood is available from Custom Grinding of Oklahoma
City, Okla.
[0206] Some embodiments of powdered fuel contain cellulose and/or
lignin. For example, the powdered fuel may include greater than
approximately 10% cellulose, e.g. 20% to 50%. Powdered fuels with
high lignin content, in certain embodiments, will ignite faster
than powdered fuels with low lignin content, but may require more
oxygen for combustion. In particular embodiments, the powdered fuel
contains a low amount of ash by weight, for example less than
approximately 10% to about 0.30%. The percentage of volatile mass
may be reduced through drying of the powdered fuel, for varying
periods of time. Additionally or alternatively, powder drying may
be accomplished through the use of ultrasound (ultrasonic)
frequencies.
[0207] Other embodiments of powdered fuel include finely ground
coal, such as ultra clean coal. Additionally, grindable and/or
crushable hydrocarbon-bearing solids such as oil sands, oil shale,
and coal tar may be used as powdered fuels.
[0208] Any other explosible powder may be used as powdered fuel and
with any of the embodiments of inventions described herein. Other
exemplary materials include metals, e.g., magnesium, aluminum,
iron, titanium, tantalum, and zinc, zirconium, and compounds and
alloys thereof, such as magnalium, ferrotitanium, titanium(II)
hydride, and zirconium(II) hydride. Other materials include boron,
phosphorous, silicon, and sulfur, and compounds thereof such as
calcium silicide and stibnite. In addition, many plastics, such at
PEET, may be made to be explosible powders when ground.
[0209] Moreover, the various types of powdered fuels may have
greater consumption efficiency when the fuel conforms to certain
particle size distributions. It is within the scope of this
invention to select for these particle distributions based on the
materials which include a particular powdered fuel. In this
respect, an exemplary embodiment of powdered fuels provides a
suitable particle size distribution of a mixture having less than
5% (e.g., 4% to 0%) particles with a size greater or equal to 50
mesh, less than 15% particles with a size greater than or equal to
80 mesh, and at least 20% particles have a size less than 200 mesh.
It should be understood that these listed percentages are by
weight.
[0210] In another exemplary embodiment of powdered fuels, a
suitable particle size distribution is a mixture having less than
5% particles with a size greater or equal to 80 mesh, and at least
30% particles with a size less than 200 mesh. It should be
understood that these listed percentages are by weight.
[0211] In another exemplary embodiment of powdered fuels, a
suitable particle size distribution is a mixture having less than
5% particles with a size greater or equal to 200 mesh, at least 65%
particles with a size less than 325 mesh, and at least 25%
particles with a size less than 400 mesh. The fuel may also have
low ash content, for example less than 1.0% or 0.5% ash. It should
be understood that these listed percentages are by weight.
[0212] Various embodiments of powdered fuels may include additives
to enhance the performance of the fuel. Blended fuels may be
created for particular applications such as cold weather driving,
high humidity environments, and high energy output requirements.
Additionally, additives may be added to the powdered fuel to
improve its flowability and reduce any bridging and/or clumping.
Suitable additives are described, for example, in U.S. Pat. No.
5,203,906 to Schapira, et al., and U.S. Pat. No. 5,456,775 to
Schapira, et al.
[0213] It should also be understood that the powdered fuels
described herein may produce a variety of energy outputs when
combusted, and that such energy outputs of the powdered fuels may
be selected for based on the application or use of the fuel. For
example, powdered fuels may produce energy outputs in excess of
approximately 1000 BTU/lb powdered fuel, e.g., 7000 BTUs per pound
of powdered fuel.
[0214] Furthermore, the powdered fuels of the invention may, at
different times, and for different uses, behave as a solid, a
liquid, and a gas. The powder at rest behaves as a solid. Bridging
can occur and weight can be supported. When agitated, vibrated,
and/or stirred, the powder behaves as a liquid. When suspended in a
gas or fluid medium, the powder behaves as a gas. More
specifically, when powdered fuel is appropriately mixed with gas,
the mixture behaves similarly (structurally, chemically, and
economically) to fuel gases such as propane and methane.
A. Powdered Fuel Dispersions
[0215] The utility of the powder fuels of the present invention in
combustion devices particularly derives not only from the
composition of the powdered fuel, but also from the dispersion
ratios of the powdered fuel in a carrier gas, i.e., powdered fuel
dispersions. As such, one embodiment of the invention provides a
powdered fuel dispersion including a gas, e.g., air, and a powdered
fuel, e.g., cellulose, where the powdered fuel is dispersed in the
gas at a ratio one part powder to seven parts gas by mass.
[0216] The powdered fuel dispersion may be richer in some
embodiments, particularly for heating applications. Moreover, the
powdered fuel dispersion may be formed at various points throughout
a system. For example, in some embodiments, the dispersion may be
formed at the nozzle. In other embodiments, for example, engine
embodiments, the dispersion released from the nozzle may be diluted
by additional air from the intake manifold to achieve a desired
ratio for the dispersion.
[0217] Suitable powdered fuel dispersions for powdered wood include
ratios of 1 gram of powdered wood to cubic foot of air to 110 grams
of powdered wood to cubic foot of air. Ratios (in terms of grams of
powdered wood to cubic feet of air) are preferably in the range of
4 to 50 g/ft.sup.3.
[0218] Another embodiment of the invention provides a powdered fuel
dispersion, where the powdered fuel is a powdered fuel as describe
hereinabove.
[0219] For example in one embodiment, the powdered fuel dispersion
includes a powdered fuel where less than about 5% of the particles
by weight have a size greater or equal to 200 mesh, e.g., less than
about 1% of the particles by weight have size greater or equal to
200 mesh, e.g., all of the particles have sizes less than or equal
to 200 mesh; and at least about 25% of the particles by weight have
a size less than 325 mesh, e.g., at least 30% of the particles by
weight have a size less than 325 mesh.
[0220] In another embodiment, the powdered fuel dispersion includes
a powdered fuel where less than 5% of the particles by weight have
a size greater or equal to 50 mesh, less than 15% of the particles
by weight have a size greater or equal to 80 mesh, and at least 20%
of the particles by weight have a size less than 200 mesh.
[0221] In yet another embodiment, the powdered fuel dispersion
includes a powdered fuel, where less than 5% of the particles by
weight have a size greater or equal to 80 mesh and at least 30% of
the particles by weight have a size less than 200 mesh.
[0222] In yet an additional embodiment, the powdered fuel
dispersion includes a powdered fuel where the powdered fuel has a
particle size distribution such that less than 5% of the particles
by weight have a size greater or equal to 200 mesh, at least 65% of
the particles by weight have a size less than 325 mesh, and at
least 25% of the particles by weight have a size less than 400
mesh.
[0223] In certain embodiments, the dispersions described herein
produce a two-phase combustion process that is visually
indistinguishable from, and effectively, a single-phase combustion
process (see "Combustion of Two-Phase Reactive Media," L. P. Yarin,
pp 299-315, Springer).
[0224] Without wishing to be bound by theory, it is suggested that
the explosibility of the pre-mixed powder dispersions of the
present invention empirically derives from similar theoretical
considerations as a pre-mixed liquid fuel/gas mixture, as modified
by droplet combustion physics, provided that a particle's
combustion time is comparable to the transit time of a deflagrating
combustion wave in gas for a combustible gaseous fuel.
[0225] Despite the similarities to gases and liquids, powdered
fuels possess different properties to be overcome in order to
achieve clean, dependable, and efficient combustion. When liquids
are burned, combustion occurs at a virtual surface located a
certain distance away from the droplet and vapors from the liquid
diffuse to this surface. In contrast, combustion of powdered fuels
occurs at the surface of the powder particles. Accordingly, the
particle size and fuel to gas ratios take on a greater importance
in harnessing powdered fuels than in liquid fuel systems.
[0226] As such, based on the discoveries discussed herein, one
embodiment of the invention relates to the design of devices, kits
for adapting devices, and powdered fuels utilizing droplet
combustion physics. For example, it is within the scope of the
present invention to design and utilize specific components, such
as nozzles described herein, e.g., for use in burners for powder
burning systems, with greater predictability in response and
performance characteristics.
B. Preparation of Powdered Fuels
[0227] The powdered fuels of the present invention may be prepared
in any manner that provides particulates that fall within the
established criteria described herein. Accordingly, in one
embodiment powdered fuel of the invention may be fabricated by use
of a mill, for example an impact mill, to crush matter into a
powder. Meshes or sieves may be used to filter the material to the
specifications for powdered fuel. Suitable mills include, for
example, the HS 20 mill produced by Bauermeister USA, Inc. of
Memphis, Tenn. In some embodiments, the mill operates in a carbon
dioxide atmosphere to minimize any risk of explosion incident with
the production of powder.
[0228] Hammermills consist of sharp edged hammers rotating at high
speed on a shaft which drives them past cutting bars set in the
perimeter between screens which can pass particles of a given size
with the gas stream which is introduced with the feed stream.
[0229] In another embodiment, attrition grinding produces fibers
without causing excessive wear to hammers, knife edges, and
screens. Screens tend to clog up with stuck fibers but
classification by particle size/density may not separate out
fibers. Long thin fibers have on average one half the surface to
volume ratio of individual particles of the same diameter as the
fiber. This difference may not be significant for heating
applications, but may be for automotive applications. As such, in
certain embodiments, the powders of the invention include fibers,
or a mixture of particles and fibers. In certain other embodiments,
the powders of the invention do not include fibers.
[0230] In contrast to the impact milling, the attrition milling
process calls for the feed material to be ground between rotating
surfaces in which the particles are subjected to attrition rather
than cutting with the product separated based on centrifugal air
classification rather than screening. First American Scientific
Corp., of Delta, British Columbia, represents an extension of this
approach which recognizes that the impact or attrition generates
heat which can be used evaporate the water in the undried raw
chips.
C. Particular Advantages of the Powdered Fuels of the Invention
[0231] Powdered fuels, as disclosed herein, enjoy benefits over
existing biomass technologies. By providing a controlled and
selected fine grade powder, more efficient combustion occurs
resulting in less particulate emissions. Moreover, the inventions
disclosed herein do not suffer from the particulate emissions and
odors associated with other biomass fuels and devices. This is due,
in part to the fact that the size of previous biomass resulted in
combustion as a diffusion flame, which in turn resulted in the
associated soot formation. In contrast, embodiments of the
inventions described herein use powdered fuels mixed with a gas to
produce a deflagrating wave front. As a result, embodiments of the
inventions consume both hardwood and softwood powders without the
characteristic odor of burning wood.
[0232] Furthermore, unlike biomass systems that rely on larger
biomass, such as wood chips, the powdered fuels in the invention
allow for biomass combustion with the on/off and adjustment
capabilities normally associated with liquid fuels. Because the
powders burn almost instantaneously, the flame may be extinguished
without delay. Likewise, because the powders burn almost
instantaneously, the energy output from a combustion device may be
quickly increased by the addition of additional powder and gas, or
decreased by the removal of the powder gas dispersion. These
characteristics allow for the use of biomass in systems in which
controllable performance is critical, such as automobiles.
[0233] Moreover, existing alternative energy systems are only
capable of burning particular types of fuels. As a result, wide
ranges of materials are currently discarded as refuse instead of
harnessed for energy production. The methods and apparatus
disclosed herein will achieve environmental benefits by extracting
energy from materials that heretofore have been untapped. For
example, a number of approaches to biomass fuels overlook what is
colloquially referred to a "bioscrap"--materials whose value is so
low at present that it is not worth the cost of harvesting.
Examples include grasses, corn stalks, plant solids, and sugar
cane. In the example of sugar cane, the inventions disclosed herein
would allow for the capture of the 80% of the BTU content in sugar
cane that is discarded in sugar production.
[0234] Through the use of the inventions described herein, energy
may be produced from powdered fuels more cost effectively than is
currently possible with liquid fuels such as oil. For example,
using the inventions herein, if wood is priced at $50/dry ton,
which is the current price, and oil is priced at approximately
$100/barrel, which oil is forecasted to reach shortly, the
combustion of powdered wood fuel will produce five times as much
energy per dollar as the combustion of oil.
[0235] The methods and apparatuses disclosed herein also will
contribute to energy self-sufficiency. By harnessing the wealth of
powdered fuel sources, such as biomass, an individual, or country,
can shift from an economy dependent on oil to an economy that
utilizes resources that are both renewable and capable of
production by the individual, or within the country.
[0236] The entire contents of all patents, published patent
applications, and other references cited herein are hereby
expressly incorporated herein in their entireties by reference.
[0237] Accordingly, it is to be understood that the embodiments of
the invention herein described are merely illustrative of the
application of the principles of the invention. Reference herein to
details of the illustrated embodiments is not intended to limit the
scope of the claims, which themselves recite those features
regarded as essential to the invention.
* * * * *
References