U.S. patent application number 15/417509 was filed with the patent office on 2017-05-18 for heat and energy recovery and regeneration assembly, system and method.
This patent application is currently assigned to Commercial Energy Saving Plus, LLC. The applicant listed for this patent is Commercial Energy Saving Plus, LLC. Invention is credited to Stewart Kaiser.
Application Number | 20170138612 15/417509 |
Document ID | / |
Family ID | 58690557 |
Filed Date | 2017-05-18 |
United States Patent
Application |
20170138612 |
Kind Code |
A1 |
Kaiser; Stewart |
May 18, 2017 |
HEAT AND ENERGY RECOVERY AND REGENERATION ASSEMBLY, SYSTEM AND
METHOD
Abstract
A heat recovery system including a chamber having a cooling
intake, an emissions intake, and a chamber exhaust, a heat recovery
exchanger, a fluid circuit in communication with the heat recovery
exchanger, a heat extraction exchanger, at least one controller
operably linked to at least one operating component of the heat
recovery system and at least one sensor configured to collect at
least one environmental measurement and system related data from
within the habitat. The system further includes a central thermal
recovery unit in signal communication with the at least one
controller and the at least one sensor. The central thermal
recovery unit is configured for determining an operating
instruction based on the at least one environmental measurement and
system related data received from the at least one sensor and/or a
third party database or interface, and transmitting the operating
instruction to the at least one controller.
Inventors: |
Kaiser; Stewart; (Boca
Raton, FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Commercial Energy Saving Plus, LLC |
Boca Raton |
FL |
US |
|
|
Assignee: |
Commercial Energy Saving Plus,
LLC
Boca Raton
FL
|
Family ID: |
58690557 |
Appl. No.: |
15/417509 |
Filed: |
January 27, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14029011 |
Sep 17, 2013 |
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15417509 |
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13753585 |
Jan 30, 2013 |
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14029011 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24H 3/06 20130101; F24D
2220/06 20130101; Y02B 30/00 20130101; F24D 12/02 20130101; F24D
5/04 20130101; F24D 19/1084 20130101; F24H 3/12 20130101; Y02B
30/14 20130101; F24D 2200/18 20130101; F24D 2200/22 20130101 |
International
Class: |
F24D 19/10 20060101
F24D019/10; F24H 3/06 20060101 F24H003/06; F24D 12/02 20060101
F24D012/02; F24H 3/12 20060101 F24H003/12 |
Claims
1. A heat recovery system in a habitat comprising: a chamber
including a cooling intake, an emissions intake and a chamber
exhaust, the emissions intake is configured for receiving exhaust
gas emitted as a result of fuel combustion in the furnace and the
chamber exhaust is configured to discharge emissions from the
chamber; a heat recovery exchanger disposed within the chamber for
contacting a mixture of cooling gas introduced through the cooling
intake and the exhaust gas introduced through the emissions intake
such that heat exchange is effected; at least one fluid circuit in
communication with the heat recovery exchanger; a heat extraction
exchanger in fluid communication with the heat recovery exchanger
through the at least one fluid circuit to effect heat exchange
between the heat extraction exchanger and an airstream running
therethrough; at least one controller operably linked to at least
one operating component of the heat recovery system; at least one
sensor configured to collect and transmit at least one
environmental measurement and system related data from within the
habitat; a central thermal recovery unit in signal communication
with the at least one controller and the at least one sensor and
configured for: determining an operating instruction based on the
at least one environmental measurement and system related data
received from the at least one sensor; and tray transmitting the
operating instruction to the at least one controller.
2. The system of claim 1, wherein the operating instruction
comprises a specific operation sequence of the operating components
connected to the at least one controller.
3. The system of claim 1, wherein the operating instruction
determined based on achieving a highest system efficiency.
4. The system of claim 1, wherein the operating instruction
determined to achieve a balance of high efficiency and low thermal
pollutant release.
5. The system of claim 1, wherein the central thermal recovery unit
is configured to determine the operating instruction using adaptive
learning process.
6. The system of claim 1, wherein the operating component
controlled by the at least one controller pc comprises a
compressor, a condenser, a meter, a fan, a humidifier, a pump, a
motor, valve, a switch, a rotor, a capacitor, and a conductor.
7. The system of claim 1, further comprising a third party
database, and wherein the operating instruction is further based on
data retrieved from the third party database.
8. The system of claim 1, wherein the central thermal recovery unit
is in signaling communication to a smart device for receiving and
displaying at least one operating parameter, climate information,
user preference, and potential system issues.
9. The system of claim 1, wherein the environment measurement and
the system related data comprises temperature and pressure at
specific point of the system, humidity, barometric pressures, dew
points, wind direction, geographical location and elevation of the
system, temperature in the habitat, thermostats settings, chemical
breakdown, fuel consumption, electrical consumption, fuel price and
electrical energy prices in real time.
10. The heat recovery system of claim 1, wherein the heat recovery
exchanger and the heat extraction exchanger comprise a multi-stage
heat exchange system including at least: a first stage having a
primary heat recovery exchanger element and a primary heat
extraction exchanger element communicably coupled to each other
through a primary fluid circuit of the at least one fluid circuit;
and a second stage having a secondary heat recovery exchanger
element and a secondary heat extraction exchanger element
communicably coupled to each other through a secondary fluid
circuit of the at least one fluid circuit.
11. A method of controlling a heating, ventilation and air
conditioning (HVAC) system of a habitat, the method comprising:
providing at least one sensor for receiving at, least one
environmental measurement and system related data within the
habitat; providing at least one controller opera y inked to at
least one operating component of the HVAC system; providing a
central thermal recovery unit in signal communication with the at
least one controller and the at least one sensor; determining an
operating instruction via the central thermal recovery unit based
on the at least one environmental measurement and system related
data; and transmitting the operating instruction to the at least
one controller, wherein the operating instruction comprises a
specific operation sequence of the operating components connected
to the at least one controller.
12. The method of claim 11, wherein the operating instruction is
determined based on achieving a highest system efficiency.
13. The method of claim 11, wherein the operating instruction is
determined to achieve a balance of high efficiency and low thermal
pollutant release.
14. The method of claim 11, further comprising retrieving or
storing data related to the parameters to a third party
database.
15. The method of claim 11, further comprising, transmitting to and
receiving from at least one operating parameter, climate
information, user preference, and potential system issues related
to the system to a smart device.
16. A method for recovering heat in a habitat, the method
comprising: providing a chamber including a cooling intake, an
emissions intake and a chamber exhaust, where the emissions intake
receives exhaust gas emitted as a result of fuel combustion in the
furnace and the chamber exhaust discharges emissions from the
chamber; providing a heat recovery exchanger disposed within the
chamber for contacting a mixture of cooling gas introduced through
the cooling intake and the exhaust gas introduced through the
emissions intake such that heat exchange is effected; providing a
heat extraction exchanger in fluid communication with the heat
recovery exchanger through at least one fluid circuit for effecting
heat exchange between the heat extraction exchanger and an
airstream running therethrough; providing at least one sensor for
receiving at least one environmental measurement and system related
data within the habitat; providing at least one controller operably
linked to at least one operating component of the chamber, the heat
recovery exchanger, and the heat extraction exchanger; providing a
central thermal recovery unit in signal communication with the at
least one controller and the at least one sensor; determining an
operating instruction via the central thermal recovery unit based
on the at least one environmental measurement and system related
data; and transmitting the operating instruction to the at least
one controller, wherein the operating instruction comprises a
specific operation sequence of the operating components connected
to the at least one controller.
17. The method of claim 16, wherein the operating instruction is
determined based on ac hie it g a highest system efficiency
18. The method of claim 16, wherein the operating instruction is
determined to achieve a balance of high efficiency and low thermal
pollutant release.
19. The method of claim 16, further comprising transmitting and
storing system operating parameters to a third party database.
20. The method of claim 16, further comprising transmitting and
receiving at least one operating parameter, climate information,
user preference, and potential system issues related to the system
to a smart device. 7
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 14/029,011 filed Sep. 17, 2013 which is a
continuation of U.S. patent application Ser. No. 13/753,585 filed
Jan. 30, 2013, the disclosures of which applications are
incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] The disclosed embodiment relates generally to the field of
air conditioning and heating systems; more particularly, it
concerns a system for efficiently combusting fossil fuels for
heating a space.
BACKGROUND
[0003] The conventional methodology used in utilizing fossil fuels
for heating habitable spaces in commercial, industrial and
residential buildings or structures is firing the fuel in a
controlled heating chamber or heat exchanger. The heat created by
the burning fuel is drawn away by air or water flowing around the
outside of the heat exchanger. This can be accomplished by blower
fans or pumps. The heat is transferred into the surrounding air or
water, heating the conditioned space. The waste or emissions from
the combustion reaction is allowed to flow outdoors usually
utilizing flue piping to a chimney or stack. The efficiency of the
furnace or boiler is calculated by the amount of heat which can be
extracted from the heat exchanger and utilized to heat the
conditioned space and the percentage of heat and by-products
permitted to escape through the flue to be vented outside. This
rating or efficiency quantification is placed on the furnace or
boiler to depict how efficient it will be.
[0004] Releasing carbon and heat saturated emissions into the
atmosphere contribute to environmental problems, such as global
warming. Not only does carbon monoxide and carbon dioxide add to
blanketing the release of heat into space, discharging heat through
flue gas emissions adds to this issue by heat pollution. Just an
average low to medium efficient residential natural gas, LPG or oil
furnace can emit about a half million BTU's of heat waste into the
atmosphere each day. Commercial and industrial units can discharge
hundreds of millions, and occasionally billions, of BTU's per unit
per day. In addition, these common and conventional methods of
discharging the flue gas into the atmosphere are wasteful and
inefficient.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The foregoing aspects and other features of the disclosed
embodiment are explained in the following description, taken in
connection with the accompanying drawings, wherein:
[0006] FIG. 1 is a schematic illustration of heat recovery assembly
in accordance with aspects of the disclosed embodiment.
[0007] FIG. 1A is a schematic illustration of a portion of a heat
recovery assembly in accordance with aspects of the disclosed
embodiment.
[0008] FIG. 1B is a schematic illustration of a portion of a heat
recovery assembly in accordance with aspects of the disclosed
embodiment.
[0009] FIG. 1C is a schematic illustration of a portion of a heat
recovery assembly in accordance with aspects of the disclosed
embodiment.
[0010] FIG. 1D is a schematic illustration of a portion of a heat
recovery assembly in accordance with aspects of the disclosed
embodiment.
[0011] FIG. 2 is a schematic illustration of heat recover assembly
in accordance with aspects of the disclosed embodiment.
[0012] FIG. 3 is a schematic illustration of the functionality of
aspects of the heat recovery assembly of FIGS. 1 and 2.
[0013] FIG. 4 is a schematic illustration of a heat exchange
process utilized in aspects of the heat recovery assembly of FIGS.
1 and 2.
[0014] FIG. 5 is a schematic illustration of a heat recovery system
in accordance with aspects of the disclosed embodiment.
[0015] FIG. 5A is a schematic illustration of a heat recovery
system in accordance with aspects of the disclosed embodiment.
[0016] FIG. 6 is a schematic illustration of a heat recovery system
utilizing a heat recovery ventilator assembly in accordance with
aspects of the disclosed embodiment.
[0017] FIG. 7 is a schematic illustration of a wiring diagram in
accordance with aspects of the heat recovery system illustrated in
FIGS. 5 and 5A.
[0018] FIG. 8A is a perspective view of a heat recovery system in
accordance with aspects of the disclosed embodiment.
[0019] FIG. 8B is a perspective view of a heat recover system in
accordance with aspects of the disclosed embodiment.
[0020] FIG. 9 a perspective view of a heat recovery system in
accordance with aspects of the disclosed embodiment.
[0021] FIG. 10 is a schematic illustration of a cut-away view in
accordance aspects of be heat recovery system illustrated in FIG.
9.
[0022] FIG. 10A is a schematic illustrate on of away view in
accordance with aspects of the heat recovery system illustrated in
FIG. 9.
[0023] FIG. 11 is a schematic illustration of a heat recovery
system in accordance with aspects the disclosed embodiment.
[0024] FIG. 12 is a schematic illustration of a heat recovery
system in accordance with aspects of the disclosed embodiment.
[0025] FIG. 13 is a schematic illustration of a heat recovery
system in accordance with aspects of the disclosed embodiment.
[0026] FIGS. 14A-14F are schematic illustrations of a portion of a
heat recovery system in accordance with aspects of the disclosed
embodiment
[0027] FIG. 15 is a schematic illustration of a heat recovery
system in accordance with aspects of the disclosed embodiment.
[0028] FIG. 16 is a schematic illustration of a heat recovery
system in accordance with aspects of the disclosed embodiment.
[0029] FIG. 17 is a schematic illustration of a portion of a heat
recovery system in accordance with aspects of the disclosed
embodiment.
[0030] FIGS. 18A-18C are a flow diagram for operation of a heat
recovery system in accordance with aspects of the disclosed
embodiment.
[0031] FIG. 19 is a block diagram of a heat recovery system
employing a central thermal recovery unit.
[0032] FIG. 20 is a block diagram illustrating the central thermal
recovery unit of FIG. 19.
[0033] FIG. 21 is system diagram illustrating a heat recovery
system employing a central thermal recovery unit.
[0034] FIGS. 22-23 are example user interfaces for receiving system
related information.
[0035] FIGS. 24-26 are example system operating reports showing
system operation parameter and analysis.
[0036] Like reference numerals refer to like parts throughout the
several views of the drawings.
DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENT
[0037] As illustrated in the accompanying drawings, the aspects of
the disclosed embodiment are directed to a heat and energy recovery
assembly and system, in addition to methods of using the same. The
heat and energy recovery assembly and system in accordance with
aspects of the disclosed embodiment may be adapted for use with any
suitable heating unit such as in a furnace of an HVAC system,
boiler system or any other system where heat energy from fuel
combustion is utilized for heating air spaces or other fluid
medium. Although the aspects of the disclosed embodiment will be
described with reference to the drawings, it should be understood
that the aspects of the disclosed embodiment can be embodied in
many forms. In addition, any suitable size, shape or type of
elements or materials could be used.
[0038] Ire one aspect of the disclosed embodiment, a heat recovery
assembly/system 100 is provided, as illustrated in FIG. 1 which
when combined with a heating furnace 2000 in a heat recovery system
200 (see for exemplary purposes only FIGS. 5 and 5A) delivers heat
to an area or habitat to be heated such that the heat recovery
assembly 100 captures and delivers heat from heated air that is
circulated in the habitat, exhaust gas from the furnace 2000 and
heat stored in the thermal mass that is the furnace assembly. As
may be realized, the furnace 2000 includes a controller 1311F that
includes any suitable non-transitory program code for effecting a
heating cycle of the furnace 2000. For example, every time a
thermostat, such as thermostat TSH, calls for heat, the controller
1311F of the furnace 2000 detects the call for heat (e.g. receives
a signal from the thermostat TSH) and starts the furnace heating
cycle by first activating the furnace exhaust induction fan motor.
Once the controller 1311F confirms proper exhaust pressure is
present, the furnace igniter is turned on and verified by the
control system. The furnace fuel valve FV opens, the furnace
burners FBRN light and heat creation begins. As an example, on a
100,000 btuh furnace, heat is created at a rate about 28 btus per
second. The motor of the furnace blower FIB cannot be turned on
until the furnace heat exchanger FHX is hot enough to deliver warm
air to a habitat to be heated. For a period (e.g., a latent heating
period) of about 1 to about 2 minutes on most furnaces, while the
heat exchanger is warming up, there is no air blowing along the
outside of the furnace heat exchanger FXH. If the furnace heat
exchanger FHX warm up or latent cycle is about 1 minute long, for
exemplary purposes only, approximately 1500 btus of fuel is
consumed and that energy is either stored in the thermal mass of
the furnace heat exchanger FHX or exhausted out of the furnace
exhaust 2100. When the motor of the furnace blower FIB is finally
turned on heat is transferred from the furnace heat exchanger FHX
to, for example the air from the return plenum 1300 (e.g. the
source heating period). When the heat call from the thermostat TSH
is satisfied, the furnace burners FBRN are turned off however,
according to the furnace programming the furnace blower continues
to run for about 2 to about 4 minutes delivering additional heat to
the house (e.g. the residual heating period). As may be realized,
the about 1 to about 2 minute warm up period and the about 2 minute
to about 4 minute cool down period represents about 3 to about 6
minutes (5-10% of an hour) of furnace operation at lower efficiency
than the rated steady state efficiency of the furnace 2000 so, for
example, is a furnace 2000 is cycled on and off 3 to 5 times an
hour (where, e.g., each cycle corresponds to a heat call from the
thermostat), then about 15% to about 50% of the time the furnace
2000 is running, the furnace is running below its rated
efficiency.
[0039] The heat recovery assembly/system 100 of the aspects of the
disclosed embodiment include a multiple stage heat exchange system
120EX that is configured to recover heat lost during, for example,
the warm up and cool down periods of the furnace. Further, in a
conventional system the furnace is in an on state (e.g. burners
FBRN lit) for 100% of the time during the heat call. The aspects of
the disclosed embodiment described herein operate to
discontinuously run the furnace 2000 in short bursts during a heat
call so that the furnace 2000 is cycled on and off to achieve a
higher efficiency by creating the start up and cool down furnace
cycles/periods as frequently as, for example, 20 times per hour
(based on, for example, a 1 hour long heat call) where, for
example, during each 180 second cycle the burners FBRN are on for
approximately 100 seconds and off for about 80 seconds so that heat
is extracted/recovered during the start up and cool down periods,
as described herein, to increase furnace efficiency and decrease
fuel consumption. As will be described herein, during the furnace
off times at least one stage of the multiple stage heat exchange
system 120EX extracts residual heat from the furnace 2000 to
balance a heat exchange to the supply air for heating the habitat
(e.g. the multiple stage heat exchange system 120EX operates as a
thermal balance to maintain a temperature of the supply air above a
predetermined set point for heating the habitat during periods of
the heat call where the furnace 2000 is turned off).
[0040] In one aspect, the assembly 100 includes a heat recovery
chamber 110 which comprises a cooling intake 112 and an exhaust gas
or emissions intake 114 for receiving exhaust gas and waste
products emitted as a result of fuel combustion. It should be
understood that while the heat recovery chamber 110 is illustrated
in the figures as being cuboid in shape in other aspects the heat
recovery chamber 110 has any suitable shape and/or configuration.
For example, in other aspects, the heat recovery chamber 110 is a
cylindrical drum, a pyramid or any other suitable shape. In one
aspect, referring to FIG. 11, a portion of the heat recovery
chamber 110B, such as a mixing portion 110C, may be integral with,
for example, the exhaust gas intake 114 or any other suitable
ducting so that exhaust from a furnace 2000 or boiler and cooling
gas from cooling intake 112 is at least partially mixed within the
ducting prior to contacting a heat exchanger, such as a first
multiple stage heat exchanger 118 (which includes one or more heat
exchange elements 116A, 116B), of the multiple stage heat exchange
system 120EX, for recovering heat described below. In one aspect
the heat recovery chamber 110 is an insulated chamber while, in
other aspects the heat recovery chamber 110 is uninsulated. The
heat recovery chamber 110 is made from any suitable material such
any suitable non-metallic material, plastics, PVC, ceramics, metals
or alloys. In one aspect the heat recovery chamber 110 is made of
stainless steel and/or titanium alloy.
[0041] The assembly 100 further includes a portion of the multiple
stage heat exchange system 120EX such as the first multiple stage
heat exchanger or absorber 116 (referred to herein as heat
exchanger 116) noted above. In one aspect the first heat exchanger
116 is disposed within the heat recovery chamber 110 while in other
aspects the first heat exchanger 116 is communicably coupled to the
heat recovery chamber 110 in any suitable manner. For example, as
described above with respect to FIG. 11, a pre-mixing/mixing
chamber 110C, in one aspect, is integrated into any suitable
ducting so that the exhaust gas and cooling gas are mixed (e.g.
pre-mixed) prior contacting the first heat exchanger 116. In this
aspect, illustrated in FIG. 11, the first heat exchanger 116 is
disposed in a heat recovery chamber 110B that may be substantially
similar to heat recovery chamber 110 however, the exhaust gas, and
cooling gas may be substantially combined prior to entering the
heat recovery chamber 110B. Also referring to FIG. 12 the heat
recovery chamber 110 constitutes a premix chamber 110A in which
cooling gas from the cooling intake 112 and exhaust from the
exhaust gas intake 114 mix or otherwise combine. The mixed gas
flows into the heat exchange chamber 110B in which the first heat
exchanger 116 is disposed. The first heat exchanger 116 includes
one or more heat exchange elements 116A, 116B structured for
contacting a mixture made up of cooling gas introduced via the
cooling intake 112 and exhaust gas (e.g. made up of carbon
emissions) introduced via the exhaust gas intake 114. In one aspect
heat exchange element 116A is larger than heat exchange element
116B while in other aspects the one or more heat exchange elements
116A, 116B have any suitable size relationship with each other. In
one aspect, one or more coil sensors CS1, CS2 are in contact with
one or more of the heat exchange elements 116A, 1116B of the first
heat exchanger 116 to relay any problems with the functionality
(such as, for example, icing or frosting) of the one or more heat
exchange elements 116A, 116B of the first heat exchanger 116 to a
central logic board (discussed later herein) or any other suitable
controller, such as controller 1311 (FIGS. 1 and 13) which is
connected to the furnace controller 1311F in any suitable manner
and is configured to operate the heat, recovery assembly system 100
as described herein. In one aspect, the one or more heat exchange
elements 116A, 116B of the first heat exchanger 116 are made from
any suitable material, such as a metallic or non-metallic material
that allows for an exchange of heat. In one aspect the one or more
heat exchange elements 116A, 116B of the first heat exchanger 116
are constructed of, for example metals and/or alloys, such as but
not limited to, copper, aluminum and the like. In one aspect, the
one or more heat exchange elements 116A, 116B of the first heat
exchanger 116 is/are heat exchange coil(s) such as an evaporative
coil(s) and/or use any suitable coolant or refrigerant such as a
single phase coolant.
[0042] It should be understood that while the first heat exchanger
116 is illustrated as having two heat exchange elements 116A, 116B
in FIG. 1, in other aspects the first heat exchanger 116 has more
(see e.g. FIG. 1A) or less (see e.g. FIG. 10) than two heat
exchange elements. For example, referring to FIG. 1A the heat
recovery chamber 110 includes a first heat exchanger 116 that
includes four heat exchange elements 116A, 116B, 116C, 116D
disposed in sets of two (e.g. each set having a large and small
heat exchange element or any suitably sized heat exchange elements
as described above) having an opposing relationship so that gases
passing through the heat recovery chamber 110 pass through one of
the sets of heat exchange elements 116A, 116B, 116C, 116D. As may
be realized, the recovery chamber 110, in one aspect, includes
sub-chambers 110C1, 110C2. As can be seen in FIG. 1A the furnace
exhaust and cooling gas are introduced into sub-chamber 110C1, flow
through sub-chamber 110C1 and into sub-chamber 110C2 where the heat
exchange elements 116A, 116B, 116C, 116D (e.g., of the stage one
and stage two fluid circuits 120, 120A as described below) are
located. Also referring to FIG. 1D, in one aspect the stage two
fluid circuit 120A includes one heat exchange element 116B located
in sub-chamber 110C1 while the heat exchange elements of the stage
one fluid circuit 120 are located in the sub-chamber 110C2. It
should also be understood that the one or more heat exchange
elements 116A, 116B, 116C, 116D have any suitable arrangement
within the heat recovery chamber 110. As may also be realized, each
heat exchange element has, is part of a fluid circuit that is
independently operable from other fluid circuits (e.g. each heat
exchange element forms part of a separate stage of the multiple
stage heat exchanger).
[0043] The cooling intake 112 has any suitable shape and/or
configuration and in one aspect structured as a single intake or in
other aspects as multiple intakes. The cooling intake(s) 112 are
configured to introduce one or more of indoor air or cooling gas
(which is discharged from the heat recovery chamber 110 and
recirculated) into the heat recovery chamber 110. In one aspect the
cooling intake 112 is a closed loop extending from the chamber
exhaust 118 to the heat recovery chamber 110 as described below. As
will also be described below, in one aspect the cooling intake
includes an active or passive orifice ORIF (which in one aspect
includes a valve 112V--see FIGS. 1A and 13) that is opened and
closed to direct any predetermined volume of cooling gas back to
the recovery chamber 110. In one aspect about 50% of the gas
exiting the recovery chamber is recirculated back to the recovery
chamber 110 while in other aspects any suitable volume of gas is
recirculated. In one aspect of the disclosed embodiment any
suitable fans or blowers are provided in any suitable manner to
generate a balanced pressure environment within the heat recovery
chamber 110 as described herein. In another aspect one or more of
the cooling intake(s) 112 are communicably connected to a pressure
regulator inducer blower (also referred to herein as a fan) 140
(see e.g. FIG. 4) that may be part of any suitable pressure
equalization system to assist in moving the gas inside the heat
recovery chamber 110 out of the heat recovery chamber where a
portion of the exhaust is directed out of the chamber exhaust 118
and a portion of the exhaust is directed to the cooling intake 112.
In one aspect the inducer blower 140 is located on the exhaust side
of the heat recovery chamber 110 as will described below while in
other aspects the inducer blower is located at any suitable
location. In one aspect the fan 140 includes a variable speed motor
that is controlled by any suitable sensors in communication with an
interior of the heat recovery chamber 110 and configured to detect
proper temperature and/or humidity and/or pressure of the gas
inside the heat recovery chamber 110.
[0044] In one aspect the one or more heat exchange elements 116A
116B of the first heat exchanger 116 are interconnected in any
suitable manner to a respective stage of a multi-stage fluid
circuit system. For example, heat exchange element is connected to
stage one fluid circuit 120 and heat exchange element is connected
to stage two fluid circuit 120A (e.g. each heat exchange element is
interconnected with a fluid circuit that is separate and distinct
(e.g. independently operable) from other fluid circuits of other
heat exchange elements where each fluid circuit has its own
compressor 150, 150A) where the fluid circuits 120, 120A are any
suitable fluid circuits. In other aspects the one or more heat
exchange elements 116A, 116B are interconnected to a common fluid
circuit such that coolant is shared between the one or more heat
exchange elements 116A, 116B. The respective fluid circuit(s) 120,
120A include any suitable conduit 122, 122A for conveying fluid
within the respective fluid circuit 120, 120A. The multiple stage
heat exchanger system 120EX of the assembly 100 includes a second
multiple stage heat exchanger or emitter 130 (e.g. a heat
extraction exchanger) including one or more heat exchange elements
130A, 130B disposed exterior to the heat recovery chamber 110 such
that each heat exchanger 130A, 130B of the second multiple stage
heat exchanger 130 (referred to herein as heat exchanger 130) is in
fluid communication with a respective fluid circuit 120, 120A via
the respective conduit 122, 122A. In one aspect, heat exchange
element 130A of the second heat exchanger 130 and heat exchange
element 116A of the first heat exchanger 116 are communicably
interconnected via the conduit 122 of the fluid circuit 120 such
that the heat exchange element 116A of the first heat exchanger 116
contacts or otherwise interfaces with (e.g. within the heat
recovery chamber 110 or in any other suitable manner as described
herein) the mixture made up of cooling gas introduced via the
cooling intake 112 and exhaust gas introduced via the exhaust gas
intake 114, while the heat exchange element 130A of the second heat
exchanger 130 contacts or otherwise interfaces in any suitable
manner with air to be heated, outside of the heat recovery chamber
110. Similarly, heat exchange element 130B of the second heat
exchanger 130 and heat exchange element 116B of the first heat
exchanger 116 are communicably interconnected via the conduit 122A
of the fluid circuit 120A such that the heat exchange element 116B
of the first heat exchanger 116 contacts or otherwise interfaces
with (e.g. within the heat recovery chamber 110 or in any other
suitable manner as described herein) the mixture made up of cooling
gas introduced via the cooling intake 112 and exhaust gas
introduced via the exhaust gas intake 114, while the heat exchange
element 130B of the second heat exchanger 130 contacts or otherwise
interfaces in any suitable manner with air to be heated, outside of
the heat recovery chamber 110. In other aspects, the heat exchange
elements of the first and second heat exchangers 116, 130 are
interconnected in any suitable manner. It should be realized, that
while a two stage heat exchange system is illustrated and described
in other aspects the heat exchange system has any suitable number
of stages, such as more or less than two stages. As may also be
realized, the heat exchange element 116A, fluid circuit 120 and
heat exchange element 130A constitute the first stage of the
multiple stage heat exchange system 120EX and the heat exchange
element 116B, fluid circuit 120A and heat exchange element 130B
constitute the second stage of the multiple stage heat exchange
system 120EX.
[0045] Referring to FIGS. 1B and 1C the one or more heat exchange
elements 130A, 130B of the second heat exchanger 130 are, in one
aspect, condenser coils having any suitable size(s), shapes and/or
arrangement. In one aspect the heat exchange element 130A includes
two heat exchange elements 130A1, 130A2 coupled together in series
to form a slab condenser coil. In one aspect, the two heat exchange
elements 130A1, 130A2 of the heat exchange element 130A include
vertical pipes and horizontal fins. In other aspects the heat
exchange element is a single heat exchange element having
horizontal pipe and vertical fins or vortical pipe and horizontal
fins. The heat exchange element 130B is smaller than heat exchange
element 130A and in one aspect includes horizontal pipes and
vertical fins or vertical pipes and horizontal fins. As may be
realized, the pipe and fin arrangement of the one or more heat
exchange elements 130A, 130B is such that the pipes and fins of
heat exchange element 130A intersect the pipes and fins of heat
exchange element 130B (e.g. where heat exchange element 130A
includes horizontal pipes and vertical fins the heat exchange
element includes vertical pipes and horizontal fins) to facilitate
a maximized heat transfer through the one or more heat exchange
elements 130A, 130B.
[0046] In one aspect the heat recovery chamber 110 includes exhaust
and drainage components. An exhaust 118 for discharging the exhaust
gas (e.g. a portion of which is recirculated as cooling gas) after
heat exchange occurs is configured or otherwise structured to
interconnect, for example, the heat recovery chamber 110 to the
outside environment and/or to cooling intake 112 for recirculating
at least a portion of the exhaust gas (e.g. the cooling gas) back
into the heat recovery chamber 110 as will be described in greater
detail below. The heat recovery assembly/system 100 when combined
with, for example, a furnace 2000 having about an 80% efficiency
produces exhaust gas temperatures (As described herein) that enable
the exhaust duct (e.g. exhaust 118) to be formed of PVC rather than
metal of ceramic (e.g. effects the coupling of a PVC exhaust duct
to the combination of the heat recovery assembly/system 100 and the
furnace 2000). In one aspect, the exhaust 118 is a single two-inch
pvc vent pipe while in other aspects the exhaust 118 has any
suitable size and is constructed of any suitable material such as
composites, metals, etc. In one aspect a drain 111 is connected to
the heat recovery chamber 110 and is configured to carry condensate
water WD that may include particulates, ash and/or soot out of the
heat recovery chamber 110. In one aspect for example, a mister 113
is included in the heat recovery chamber 110, however in other
aspects the mister 113 is not provided. The mister 113 is
configured to saturate the gas within the heat recovery chamber 110
with moisture and to help capture and remove particulates, ash
and/or soot from the exhaust gases in any suitable manner, such as
by the particulates, ash and/or soot becoming saturated with water
from the flash heat steam from, for example, the super heated oil
combustion exhaust gas and falling to the bottom of the chamber to
be discharged through the drain 111. In other aspects, the mister
113 may not be provided such that the condensate water WD is formed
from moisture in the exhaust gas and/or cooling gas introduced
through cooling intake 112 and helps capture and remove
particulates, ash and/or soot from the exhaust gases. In one aspect
a filter or other mechanical separation unit is provided to remove
the particulates, ash and/or soot from the condensate water WD
discharged through the drain 111. Where the mister 113 is provided
the mister 113 is, in one aspect, connected to a pressurized water
tube to provide water to the heat recovery chamber 110 to raise the
dew point within the heat recovery chamber 110 to raise the heat
transfer potential.
[0047] The aspects of the disclosed embodiment illustrated in FIG.
1 are designed for use when the exhaust gas input through the
exhaust gas intake 114 originates from the burning of cleaner
burning propane or other natural gases, such as but not limited to,
a natural gas-burning furnace component of a heating, ventilation
and air conditioning (HVAC) unit. However, it should be understood
by those skilled in the art that the assembly 100 could be utilized
in other situations where the surrounding air is to be heating by
fossil fuel combustion.
[0048] FIG. 2 illustrates an aspect of the disclosed embodiment of
the assembly 100 that may be used when the exhaust gas input to the
heat recovery chamber 110 through the exhaust gas intake 114
originates from an oil-burning furnace. As may be realized, this
aspect of the disclosed embodiment may also be used when the
exhaust gas input to the heat recovery chamber 110 through the
exhaust gas intake 114 originates from burning of natural gas as
well. The components and configuration of this aspect of the
disclosed embodiment are generally the same as in FIG. 1; however,
additional aspects are included for capturing the heat that is
stored in the condensate water WD that may accumulate within, such
as at the bottom, of the heat recovery chamber 110. While the
capturing of heat stored in the condensate water WD is described
with respect to the heat recovery chamber 110 in FIG. 2 it should
be understood that, in other aspect, capturing heat stored in
condensate water WD in the heat exchange chamber 110B (see e.g.
FIGS. 11 and 12) is provided in a manner substantially similar to
that described herein. In other aspects heat captured in the
condensate water WD may be recovered from the heat recovery chamber
110, 110B. The aspects of the disclosed embodiment illustrated in
FIG. 2 include a third heat exchanger 117 in fluid communication
with one or more of the first heat exchanger 116 and the second
heat exchanger 130 via a second conduit 124 for absorbing the
excess heat stored in the water as it accumulates from the
condensate water WD produced within the heat recovery chamber.
Since the second conduit 124 is in communication with one or more
of the first heat exchanger 116 and the second heat exchanger 130,
the third heat exchanger 117 may be further in fluid communication
with one or more of the fluid circuits 120, 120A as a whole. The
drain 111 in FIG. 2 is shown, for exemplary purposes, to be
structured such that condensate water WD and ash/soot within the
condensate water WD does not drain from the heat recovery chamber
110 until the water rises to a certain level, WL. This allows the
third heat exchanger 117 to remain underneath the surface of the
condensate water WD as it absorbs the excess heat energy stored in
the condensate water WD so that very little, or none, of the heat
energy remains unabsorbed in the entire process (e.g. substantially
all heat energy is extracted from the condensate water WD).
[0049] During operation of the assembly and/or system of the
disclosed embodiment, hot exhaust gases and combustion products
(carbon monoxide, carbon dioxide, H20, etc.) are exhausted into the
heat recovery chamber 110. In one aspect, one or more of indoor air
and cooling gas is introduced into the heat recovery chamber 110 in
any suitable manner to mix with the hot exhaust gas. A large, cubic
footprint of gas is saturated and heated as a result of the mixing.
This mixture flows across one or more heat exchange elements 116A,
116B of the first heat exchanger 116 while the dew point rises,
holding water and heat (saturation). The heat is extracted from the
mixture via the one or more heat exchange elements 116A, 116B of
the first heat exchanger 116 (and third heat exchanger 117 when
provided) and transferred to a respective one of the one or more
heat exchange elements 130A, 130B of the second heat exchanger 130
such that heat transfer occurs at the one or more heat exchange
elements 130A, 130B of the second heat exchanger 130 to heat, for
example, indoor air or any other suitable medium. Cooler, dry gas
from the heat recovery chamber 110 is exported outdoors in any
suitable manner, such as through any suitable chimney or exhaust
flue, with a reduced heat, moisture and carbon content. In
addition, as described herein, at least a portion of the cooler,
dry gas from the heat recovery chamber 110 is recirculated (e.g. as
cooling gas) back into the heat recovery chamber 110. This process
allows heat energy to be pulled from the gas introduced into the
heat recovery chamber such that it is compounded with the heat
energy already being produced by the fossil fuel combustion
process. This provides the assembly and system described herein in
accordance with the aspects of the disclosed embodiment the
potential to achieve a higher efficiency of fuel burn.
[0050] By way of example and referring to FIG. 3, aspects of the
disclosed embodiment of the heat recovery assembly/system 100 are
illustrated with respect to an exemplary 80% annual fuel
utilization efficiency (AFUE) furnace rated at 100,000 input/80,000
output. Hot, moist exhaust, gases are extracted from the furnace at
approximately 375.degree. F. with approximately 90% plus humidity
at approximately 55CFM. In other aspects the exhaust gases have any
suitable temperature and humidity and are extracted at any suitable
rate. The hot, water-saturated, exhaust gas carries a large heat
potential (of e.g. at least 20,000 British Thermal Units per Hour
(BTUH)). In addition to heat energy, the water-saturation of the
exhaust gas (e.g. misting may increase this water-saturation where
provided) includes high levels of potential energy for extraction.
These exhaust gases are mixed with dry, cool gas (e.g. the cooling
gas) of equal cubic feet per minute (CFM) using, for example,
pressure regulation in the heat recovery chamber 110. In one aspect
the cool dry gas (e.g. cooling gas) is obtained from the discharge
118 of the heat recovery chamber 110 (as shown in, for example,
FIG. 4A) where after heat extraction at least a portion of the
discharge exhaust gas is returned to the heat recovery chamber 110
under the influence of a fan 140. Referring also to FIG. 4 the
pressure regulation of the heat recovery assembly 100 effected by a
balanced pressure system where the fan 140 is placed downstream of
the heat recovery chamber 110 so as to draw or suck the gasses out
of the heat recovery chamber 110. In one aspect, the fan 140 is
sized so as to be substantially equal to two-times the cfm of the
furnace inducer fan motor so that the discharged exhaust gas from
the heat recovery chamber is split so that substantially half the
discharged exhaust gas (e.g. cool dry gas or cooling gas) is
returned to the heat recovery chamber to cool and be mixed with the
gases from the furnace 2000 that enter the heat recovery chamber
through gas intake 114. In other aspects, the fan 140B is sized to
recover any suitable portion of the discharged exhaust gas from the
heat recovery chamber for mixing with and cooling the gases from
the furnace 2000 input to the heat recovery chamber 110 through gas
intake 114. As may be realized, mixing the gases from the furnace
with the cooling gas from the heat recovery chamber 110
substantially eliminates any influence of fluctuating outdoor
temperatures on the heat recovery assembly 100 and substantially
isolates the furnace from outdoor pressure/wind influences. As may
be realized, the fan(s) 140 controlled in any suitable manner, such
as by controller 1311 and/or by a rheostat to allow balancing of
gas flow volume and velocity through the heat recovery assembly
100.
[0051] Within the teat recovery chamber 110 under controlled
conditions, in one aspect, the cooling gas, described herein, is
saturated by the misted water within the exhaust gas, resulting in
an increase in the dew point while in other aspects the cooling gas
is not misted. The heat energy released in the exhaust gas (which
may have a temperature of approximately 375.degree. F. or any other
suitable temperature) mixes with the cooling gas, resulting in a
mean temperature of approximately 160.degree. F. (or any other
suitable temperature). The combined gases include oxygen (O.sub.2)
assisting in the heat transfer process. The combined gases are a
warm (about 160.degree. F. or other suitable temperature), high dew
point gas having, for example, a high-energy potential for high
efficiency heat and energy extraction.
[0052] This combined gas mixture passes over one or more of the
heat exchange elements 116A, 116B of the first heat exchanger 116.
The fluid, e.g. refrigerant, in the one or more heat exchange
elements 116A, 116B of the first heat exchanger 116 is under
controlled pressurized conditions and is able to extract a large
amount of heat energy from the combined gas mixture and transfer
the heat energy to the a respective one of the one or more heat
exchange elements 130A, 130B of the second heat exchanger 130 via
the respective fluid circuit 120, 120A such that the transferred
heat energy warms the indoor air as the indoor air flows over the
one or more heat exchange elements 130A, 130B of the second heat
exchanger 130. The flow of refrigerant in the fluid circuit 120,
120A between each of the components of the assembly is illustrated
by arrows in FIG. 3. The exhaust gas discharged from the heat
recovery chamber following the controlled and regulated mixing
within the heat recovery chamber 110 may be dry, cool exhaust gas.
For exemplary purposes, the average discharged exhaust gas from the
heat recovery chamber 110 has a temperature of about 42.degree. F.
to about 49.degree. F., a humidity of about 10%, and about a
0.05-0.00 PPM CO (carbon monoxide) content. In one aspect one or
more suitable thermostat or temperature sensor TS is mounted on the
furnace supply plenum or duct 1301 (and/or on the furnace return
plenum 1300) and is positioned outside of any thermal influence of
the heat that radiates from the thermal mass of the one or more
heat exchange elements 130A, 130B. The thermostat TS is connected
to the controller 1311 in any manner so as to effect operation of
the heat recovery system 100 as described herein.
[0053] Still referring to FIG. 3 and also to FIGS. 18A-18C, an
operation of the heat recovery assembly and systems described
herein is described in greater detail. In one aspect the controller
1311 is in a monitoring state that monitors a state of the furnace
2000 and one or more thermostats TSH that control the heating in
one or more heating zones of a building or other area to be heated
(FIG. 18A, Block 9000). When the one or more thermostats TSH detect
a temperature that is less than a predetermined set temperature of
the thermostat TSH the thermostat sends any suitable signal to the
controller 1311. The controller 1311 detects the signal and the
heat call embodied in that signal (FIG. 18, Block 9001). The
controller 1311 is, in one aspect, configured to determine if the
heat call is a false alarm. Where the heat call is a false alarm
the controller 1311 returns to the monitoring state (FIG. 18, Block
9002). Where the heat call is valid the controller 1311 forwards
the heat call to the furnace controller 1311F to effect turning the
furnace 2000 and the fan 140 on (FIG. 18A, Block 9003). The
controller 1311 is also configured to determine if the heat call
remains active (FIG. 18A, Block 9005). In one aspect, the
controller 1311 waits any suitable predetermined time period before
determining if the heat call remains active (FIG. 18A, Block 9004).
If the heat call is no longer active the controller 1311 turns the
furnace 2000 off (FIG. 18A, 9006) by sending any suitable signal to
the furnace controller 1311F and returns to the monitoring state
(FIG. 18A, Block 9007). Where the heat call remains active the
controller 1311 turns on compressor 150 (FIG. 18A, Block 9008) and
compressor 150A (FIG. 18A, Block 9009). In one aspect, the
controller 1311 waits any suitable predetermined amount time period
between the starting of compressor 150 and the starting of
compressor 150A. The controller 1311 determines if the heat call
remains active (FIG. 18A, Block 9010). Where the heat call is
inactive the controller 1311 turns the furnace 2000, the fan 150,
150A and the compressors 150, 150A off (FIG. 18A, Block 9011) and
returns to the monitoring state (FIG. 18A, Block 9012). Where the
heat call remains active controller proceeds to an active state
(FIG. 18A, Block 9014). In one aspect the controller waits any
suitable predetermined time period before proceeding to the active
state (FIG. 18A, Block 9013).
[0054] In the active state the controller 1311 monitors whether the
thermostat TSH temperature is satisfied (FIG. 18B, Block 9015).
Where the thermostat TSH temperature is satisfied the controller
1311 turns the compressors 150, 150A, the fan 140 and the furnace
off (FIG. 18B, Blocks 9016, 9018) and returns to the monitoring
state 9019. In one aspect the controller 1311 waits any suitable
time period before turning the fan 140 off (FIG. 18B, Block 9017).
If the thermostat TSH temperature is not satisfied the controller
determines, from any suitable temperature sensors whether the one
or more heat exchange elements, such as heat exchange elements
116A, 116B, require defrosting (FIG. 18B, Block 9020).
[0055] If one or more heat exchangers require defrosting the
controller 1311 determines if the call for defrosting is valid such
that if the call for defrosting is not valid the controller 1311
returns to the active state (FIG. 18B, Block 9021). Where the call
for defrosting is valid the controller 1311 turns the compressor(s)
150, 150A off (FIG. 18B, Block 9022), waits a predetermined amount
of time suitable for defrosting (e.g. a defrost cycle) the one or
more heat exchange elements 116A, 116B (FIG. 188, Block 9023) and
returns to the monitoring state (FIG. 18B, Block 9024). If the
thermostat heat call is satisfied during the defrost waiting period
the defrost cycle ends and the controller 1311 returns to the
monitoring state (FIG. 18B, Block 9025). Where there is no call for
defrosting the one or more heat exchange elements 116A, 116B the
controller 1311 determines if the furnace 2000 has failed (FIG.
18B, Block 9026).
[0056] Where the controller receives a furnace fail call from, for
example, any suitable sensors connected to the furnace, the
controller 1311 determines if the furnace fall call is valid and if
the furnace fail call is not valid the controller 1311 returns to
the active state (FIG. 18B, Block 9027). If the controller 1311
determines that the furnace fail call is valid the controller 1311
turns the compressor(s) 150, 150A and the furnace 2000 off (FIG.
18B, Block 9028) and waits a predetermined period of time (FIG.
18B, Block 9029) before turning the fan 140 off (FIG. 18B, Block
9030) and returning to the monitoring state (FIG. 18B, Block 9031).
Where there is no furnace fail call the controller determines if
the heat recovery assembly 100 has failed (e.g. the controller
receives a heat recovery assembly fail call from any suitable
sensors connected to the heat recovery assembly 100) (FIG. 18B,
Block 9032).
[0057] Where the controller receives a heat recovery assembly fail
call the controller 1311 determines if the heat recovery assembly
fail call is valid and if the heat recovery assembly fail call is
not valid the controller 1311 returns to the active state (FIG.
18B, Block 9033). If the controller 1311 determines that the heat
recovery assembly fail call is valid the controller 1311 turns the
compressor(s) 150, 150A and the furnace 2000 off and turns the fan
140 on (FIG. 18B, Block 9034). The controller effects any suitable
aural and/or visual alert indicating a reset of the heat recovery
assembly 100 is needed (FIG. 18B, Block 9035) and when the heat
recovery assembly 100 is reset the controller 1311 returns to the
monitoring state (FIG. 18B, Block 9036). If there is no heat
recovery assembly fail call the controller 1311 enters, a heat
cycle mode (FIG. 18B Block 9037).
[0058] As described above, a temperature sensor TS is mounted on or
within the furnace supply plenum or duct 1301 of the furnace 2000.
When the furnace 2000 is burning gas (e.g. is turned on the heat
recovery assembly 100 is extracting heat from the furnace exhaust
gas and preheating the air in the return plenum 1300 so that hot
air is produced at elevated temperatures compared to the furnace
2000 running by itself. The sensor TS is monitored by the
controller 1311 (FIG. 18C, Block 9038) and is set to trigger or
otherwise send a signal to the controller at any suitable
predetermined high temperature threshold or set point, such as
about 130.degree. F. (in other aspects the high temperature
threshold is more or less than 130.degree. F.) When the controller
1311 receives a signal from the temperature sensor TS that the high
temperature threshold is reached the controller interrupts the
thermostat TSH heat call which closes the furnace fuel valve FV and
shuts off the burners FBRN (e.g. turns the furnace off however, the
blower FIB remains running for a predetermined period of time per
furnace programming as described herein) and turns the stage 2
compressor 150A off (FIG. 18C, Block 9039). In this aspect, the
heat recovery assembly 100 leverages the furnace programming (e.g.
incorporates the embedded furnace controller 1311F that continues
to run the blower FIB for a predetermined period of time, as
described above, after the burners FBRN are turned off) and
continues to extract and transfer heat from the residual heat from
the furnace 2000 in the chamber 110 and into the supply air stream
(e.g. the blower FIB continues to operate so that air moves
over/through the heat exchanger(s) 130A, 130B, FH X while the heat
being transferred from the heat exchanger 116A decreases). As may
be realized, the temperature sensor TS in the supply plenum 1301 is
further configured to send a signal to the controller 1311
indicating a predetermined low temperature threshold or set point,
such as about 100.degree. F. (in other aspects the low temperature
threshold is more or less than 100.degree. . F). The controller
1311 monitors the temperatures sensor TS for a low temperature
threshold signal (FIG. 18C, Block 9040) and if the low temperature
threshold signal is received by the controller 1311, the controller
1311 reinstates the thermostat TSH heat call so that the furnace
2000 and the stage 2 compressor 150A are turned on (FIG. 18C, Block
9041) and the process returns to block 9038 so that the furnace is
discontinuously run in short bursts so that the furnace is cycled
between the on and off states during the heat call. As may be
realized, the low temperature threshold is such that the low
temperature threshold is reached before the blower FIB turns off so
that air is continually circulating through the furnace heat
exchanger FHX for delivering heat to the supply air during the heat
call whether the burners FBRN are lit or off. In other aspects, the
controller 1311 includes any suitable programming for turning the
burners FBRN back on prior to the blower FIB being turned off (e.g.
if the low temperature threshold is not met or for any other
suitable reasons). If the low temperature threshold signal is not
received the controller 1311 monitors the furnace blower timeout
(e.g. the period of time the blower FIB operates after the burners
FBRN are turned off) (FIG. 18C, Block 9040A). If a predetermined
time period prior (e.g. any suitable time period such as seconds
before the expiration of the timeout, a minute before the timeout,
etc.) to the timeout period expiring has not been reached (FIG.
18C, Block 9040B) the controller 1311 continues to monitor for the
low temperature threshold signal. If the predetermined time period
prior to the timeout period expiring has been reached (FIG. 18C,
Block 9040B) the controller 1311 reinstates the thermostat TSH heat
call so that the furnace 2000 and the stage 2 compressor 150A are
turned on (FIG. 18C, Block 9041) and the process returns to block
9038 so that the furnace is discontinuously run in short bursts so
that the furnace is cycled between the on and off states during the
heat call.
[0059] If the thermostat TSH heat call is satisfied the controller
1311 returns to the monitoring state and the furnace 2000,
compressor(s) 150, 150A and fan 140 are turned off (FIG. 18C, Block
9042). As may be realized, the monitoring of the temperature sensor
TS in the supply plenum 1301 effects a repeating on/off cycling of
the furnace burners FBRN (e.g. the furnace is cycled between being
turned on and being turned off) until the thermostat TSH heat call
is satisfied which shuts the furnace 2000 and the heat recovery
assembly 100 down until the next thermostat TSH heat call. In other
words, the controller 1311 is coupled to the temperature sensor TS
having predetermined hi and low temperature set points and is
configured or otherwise programmed so that in response to the heat
call from the thermostat TSH the furnace is repeatedly cycled (e.g.
run discontinuously or turned on and off) when the controller 1311
registers the temperature sensor TS signal corresponding to the hi
temperature set point (e.g. the furnace is turned off) and the low
temperature set point (e.g. the furnace is turned on).
[0060] The following is an exemplary table illustrating tests
performed on various furnaces where the input/size is the btu
rating of the furnace tested, cfm is the amount of air moved by the
furnace tested, target is the targeted btus from the heat recovery
assembly/system 100 to be added to the furnace heat output, the
cycles per hour is the number of times the furnace tested was
discontinuously run (e.g. turned on and off) over a one hour heat
call, the average supply temperature (.degree. F.) is the average
temperature of the air passing through the return plenum 1300
during both furnace on and off states/periods, the average return
temperature (.degree. F.) is the average temperature of the air
returning to the return plenum 1300 during both furnace on and off
states/periods, the average delta temperature (.degree. F.) is the
difference between the average supply temperature and the average
return temperature, the added btus are the btus recovered by the
heat recovery assembly/system 100 described herein and the fuel
btus is the amount of btus obtained from burning fuel during
furnace on states/periods, efficiency is the fuel conversion
efficiency of the furnace with the heat recovery assembly/system
100, variation is the difference between the target btus and the
added btus, on second refers to the amount of firm the furnace was
in the on state during each cycle of the discontinuous furnace
operation, off seconds refers to the amount of time the furnace was
in the off state during each cycle of the discontinuous furnace
operation, therms is the amount of heat energy from fuel burned
(e.g. the fuel btus), latent refers to an amount of heat (btus) of
e-strained water and recovered by the heat recovery assembly/system
100 throughout the heating cycle, source is the amount of heat
(btus) recovered by the heat recovery assembly/system 100 during
furnace operation, and residual is the amount of heat (btus)
recovered by the heat recovery assembly/system 100 during furnace
cool down periods.
TABLE-US-00001 Cycles Average Average Average Input/ per supply
return delta Furnace size Cfm Target hour temp temp temp 2 60000
1150 48000 13.90 120.3 64.8 55.5 1 88000 1210 70400 19.40 116.1
66.6 49.5 4 100000 1674 80000 23.50 115.4 67.1 48.3 6 120000 1513
96000 29.00 124.9 67.7 57.2 5 140000 1500 112000 23.00 140.5 71.6
68.9
TABLE-US-00002 Added Fuel On Off Furnace btus btus Efficiency
Variation seconds seconds 2 72122 35900 200.9% 24122 115 150 1
67695 35180 192.4% (2705) 110 85 4 91365 62720 145.7% 11365 95 55 6
97794 64910 150.7% 1794 65 50 5 116786 73800 158.2% 4786 95 55
TABLE-US-00003 Furnace therms latent source residual 2 0.3590 2901
35900 33321 1 0.3518 2843 35180 29672 4 0.6272 5068 62720 23577 6
0.6491 5245 64910 27639 5 0.7380 5963 73800 37022
[0061] It is noted that all values in the above table are
approximate and provided for exemplary purposes only. As can be
seen from the above table, the discontinuous operation (e.g.
cycling between on and off states) of the furnace during a heat
call decreases an amount of fuel used during the heat call while
the heat recovered during the latent, source and residual heating
periods by the heat recovery assembly/system 100 increases the fuel
conversion efficiency of the furnace 2000.
[0062] During the latent, source and residual heating periods (e.g.
respectively the period where the furnace 2000 is warming the
furnace heat exchanger FHX, the periods the furnace is on and the
periods where the furnace 2000 is turned off during the heat call)
one or more stages of the multiple stage heat exchanger 120EX
operate as described herein to increase, balance or otherwise
continue heat transfer to the return air travelling through the
return plenum 1300 for heating the supply air delivered to the
habitat through the supply plenum 1301. For example, in accordance
with aspects of the disclosed embodiment, the stage one compressor
150 runs substantially 100% of the time (e.g. when the furnace is
on and when the furnace is off) the during a full thermostat heat
call cycle (e.g. a duration of the heat call) so as to extract heat
(e.g. residual furnace heat) from the chamber 110 and transfer heat
to the supply air. In one aspect the secondary compressor 150A only
runs while the furnace is turned on (e.g. the furnace burners FBRN
are lit) while in other aspects the secondary compressor 150A also
runs when the furnace burners FBRN are not lit (e.g. the furnace is
turned off). In other aspects, the first and second stages of the
heat exchange system are operated at any suitable times, either
together or individually, during the heat call. For example, in one
aspect, only stage one operates during furnace off times and only
stage two operates during furnace on times or vice versa. In
another aspect, stage one operates to a point where a temperature
of the supply air reaches a predetermined temperature at which time
stage one is turned off and stage two is turned on, or vice versa.
In one aspect, the controller 1311 is configured to stagger a
starting of the stage one compressor 150 and the stage one
compressor 150A to, for example, avoid a combined electrical surge
of the compressors 150, 150A.
[0063] As may be realized, the heat recovery assembly/system 100
described herein is adapted to attach to or otherwise interface
with any suitable furnace having any age or configuration. In one
aspect the assembly 100 may be attached to a furnace with about 78%
AFUE or higher efficiency, resulting in an increased efficiency of
the system. Carbon discharge, exhaust gas temperature, and humidity
may also be reduced if the assembly 100 is employed with a
furnace.
[0064] Still referring to FIGS. 1 and 3, in one aspect a pressure
sensors S5 placed the heat recovery chamber exhaust 118 and is
connected to the controller 1311 in any suitable manner (such as
through a wired or wireless connection). The pressure sensors S2 is
configured to monitor an exhaust vent pressure of the furnace 2000
and/or heat recovery assembly 100 and send any suitable signal to
the controller to turn the furnace off if the exhaust vent pressure
exceeds a predetermined pressure and to turn the furnace back on if
be exhaust, vent pressure falls below the predetermined pressure.
The controller 1311 is configured to, based on the signals from the
sensor S2, to turn off the furnace 2000 by interrupting the heat
call from the thermostat TSH. In one aspect, a temperature sensor
S3 is disposed in the heat recovery chamber exhaust 118 and is
connected to the controller 1311 for monitoring the exhaust gas
exiting the heat recovery chamber. Where the sensor S3 detects the
exhaust gas has a temperature above any suitable predetermined
threshold temperature the controller 1311 is configured to, based
on the sensor S3 signals, turn off the furnace 2000 by interrupting
the heat call from the the at TSH. In one aspect, a temperature
sensor S1 is disposed in the furnace exhaust 2100/intake 114 and is
connected to the controller 1311 for monitoring a temperature of
the exhaust gas entering the heat recovery chamber from the furnace
2000 (or in other words monitoring of the exhaust gas exiting the
furnace 2000). Where the sensor S1 detects the exhaust gas from the
furnace 2000 passing through the intake 114 is below a
predetermined temperature threshold the controller 1311 is
configured to, based on the sensor S1 signals, turn off the
compressor(s) 150, 150A to protect the compressor(s) 150, 150A and
substantially prevent freezing of the heat exchange elements 116A,
116B. In one aspect each fluid circuit 120, 120A includes a
temperature sensor S5, S6 for monitoring a temperature of the
cooling fluid within the respective fluid circuit 120, 120A. The
temperature sensors S5, S6 are connected to the controller 1311 and
suitable signals to the controller when, for example, a low
temperature threshold is met so that the controller 1311 effects a
defrosting of the heat exchange elements 116A, 116B in any suitable
manner.
[0065] Referring next to FIG. 5 and FIG. 10, a heat recovery system
200 is illustrated in accordance with aspects of the disclosed
embodiment. The system 200 may include a furnace 2000 comprising an
exhaust 2100 and a furnace intake 2300. The system 200 further
includes heat recovery chamber 110 having a cooling intake 112 and
an exhaust gas intake 114. In other aspects the system 200 may
include a premix chamber 110A, 110C and a heat exchange chamber
110B as described above with respect to FIGS. 11 and 12. The
exhaust gas intake 114 may be configured to be communicably coupled
to (e.g. in communication with) the exhaust 2100 of the furnace to
receive exhaust gas resulting from fuel combustion in the furnace
2000. A first heat exchanger 116A may be disposed within the heat
recovery chamber 110 and is in fluid communication with a fluid
circuit 120 that includes a conduit 122 configured to convey a
fluid therein, such as a refrigerant. In other aspects the first
heat exchanger 116, which includes heat exchange element 116A, may
be communicably disposed outside the heat recovery chamber. The
first heat exchanger 116 may be configured such that during
operation of the furnace 2000 it is in thermal communication with a
mixture comprising cooling gas introduced via the cooling intake
112 and exhaust gas introduced via the exhaust gas intake 114 that
is connected to the furnace exhaust 2100.
[0066] The system 200 may include a second heat exchanger 130,
which includes heat exchange element 130A, in fluid communication
with the fluid circuit 120 and disposed in thermal communication
with an airstream being drawn into the furnace for heating (see
INDOOR AIR passing through the second heat exchanger 130 in FIG.
5). Refrigerant is heated in the first heat exchanger 116 and moved
to the second heat exchanger 130 via the pressure gradient created
by the heat exchange and, optionally, with assistance from any
suitable compressor such as the micro-compressor or the like (as
described above), where heat exchange occurs between the airstream
flowing from the indoor air source and the second heat exchanger
130. The preheated air from the second heat exchanger 130 is
directed into the heat exchanger 2200 of the furnace such that the
air is further heated and then directed into the home or other
habitable structure for heating the home or other habitable
structure.
[0067] The system 200 may include a drain 111 exiting the heat
recovery chamber 110. The drain 111 may be substantially similar to
that described above and structured as, for example, in FIG. 1 or
FIG. 2, depending on the type of furnace being utilized in the
system 200 (as explained previously herein). As may be realized, a
system 200 including the drain 111 as illustrated in FIG. 2 would
include a third heat exchanger 117 as previously described
herein.
[0068] The system 200 may also include any suitable compressor 150
that may be substantially similar to that previously described
herein. In one aspect the compressor may be a micro-compressor to
aid in energy conservation. In another aspect a furnace inducer
blower, IB, may be in connection with the furnace exhaust 2100 to
actively draw exhaust from the furnace 2000 into the exhaust gas
intake 114 of the heat recovery chamber 110.
[0069] The assembly 100 and system 200 of the disclosed embodiment
may further include a heat recovery ventilator. Heat recovery
ventilators have been a known art in the HVAC industry for many
years: however, the typical ventilator is much less efficient and
structurally different than the aspects of the disclosed embodiment
in combination with the assembly and system herein. A conventional
Heat Recovery Ventilator (HRV) draws in fresh outdoor air to
replace exhausted indoor air. The HRV helps create air exchanges
within home or building structures which in turn helps to reduce
pollutants, smoke, contaminants, airborne allergies, viruses, etc.
from collecting within the home or building ventilation systems.
During the air exchange process of a ventilator, fans and heat
exchangers will pass heated or cooled indoor air over unconditioned
outdoor air. The two air masses never combine but are separated by
heat exchangers. This process can transfer as much as 85% of the
heat energy from the conditioned air mass to the unconditioned air
mass. About 15% of the energy is lost in this process, causing the
home or building owner the expense of heating or air conditioning
that loss to the newly introduced unconditioned air in order to
maintain the same comfort level within the structure.
[0070] Referring to FIGS. 5A and 10A a heat recovery system 200' is
illustrated in accordance with aspects of the disclosed embodiment.
The heat recovery system 200' is substantially similar to heat
recovery system 200 described above with respect to FIGS. 5 and 10
however, in this aspect the heat recovery system also includes the
stage two cooling circuit 120A as described above. As such, the
first heat exchanger 116 of the heat recovery system 200' includes
heat exchange elements 116A and 116B disposed in the heat recovery
chamber 110 and the second heat exchanger 130 includes heat
exchange elements 130A and 130B through which the indoor air passes
for pre-heating the indoor air. As can be seen in FIG. 5A the cool,
dry exhaust gas (e.g. cooling gas) introduced in the heat recovery
chamber through cooling intake 112 is, in one aspect mixed with
recovery indoor air introduced into the cooling intake 112 in any
suitable manner such as by any suitable fan while in other aspects,
the recovery air is omitted. It is also noted that the fan or
blower 140 is positioned to suck or draw the gases through the heat
recovery chamber 110 while in other aspects, the fan is located in
any suitable location for moving the gases through the heat
recovery chamber 110.
[0071] FIG. 6 illustrates a heat recovery ventilator (HRV) assembly
160 configured in relation to a heat recovery assembly 100 for
providing fresh outdoor air to the interior environment in
accordance with aspects of the disclosed embodiment. The HRV
contains a ventilator outdoor air intake 162 that is structured to
be in communication with the second heat exchanger 130 for heating
outdoor air as it is drawn into the air intake of a heating
apparatus or furnace. The HRV provides clean, outdoor air for
circulation within the home or building. It directs the air into
the airstream being drawn across the second heat exchanger 130 such
that it can be heated by the energy efficient process of the heat
recovery assembly 100 or system 200, as previously described
herein. In one aspect the HRV assembly 160 may include a motorized
damper 164 in communication with the outdoor air intake 162 such
that the flow of outdoor air is regulated. A thermostat 166 may be
in communication with the motorized damper 164 for controlling the
opening and closing of the damper 164 based on the outdoor air
temperature. In one aspect the damper 164 may allow air
temperatures ranging from about 10.degree. F. to about 70.degree.
F. to pass therethrough. In other aspects the damper 164 may allow
air having any suitable temperature to pass therethrough. The
thermostat 166 may include a temperature sensor 168 to communicate
the outside air temperature. In one aspect the inducer blower, such
as fan or blower 140B is located on an outlet side (e.g. on a side
of the heat exchanger where the combined cooling gas and exhaust
gas exit from the heat exchanger) of the heat recovery chamber 110
so that gas is "pulled" through the first heat exchanger 116 while
in other aspects the fan is located at any suitable location for
moving gas through the heat recovery chamber.
[0072] FIG. 7 illustrates an electrical wiring diagram of a heat
and energy recovery system in accordance with aspects of the
disclosed embodiment. The diagram illustrates the connections
between a logic board or other suitable controller 1311 of the
system and the furnace control board and thermostat of an HVAC
system. In one aspect, the logic board or controller 1311 may
include a LCD scroll display 171 for a visual depiction of the
operational parameters of the system. Heat recovery,
troubleshooting, and normal operating conditions may be indicated
by LED lights (see "POWER", "TROUBLE", "COMP1" and "COMP2") or in
any other suitable visual and/or aural manner. Various connections
between sensors and switches (e.g., low and high pressure switches)
are also depicted. The inducer blower or fan and micro-compressor
connections and requisite relays are also depicted but may not be
provided such as when the system does not include an inducer blower
or compressor. Connections between one or more components of the
system may be wired with the controller 1311 to provide centralized
control and functionality of the system.
[0073] FIGS. 8A, 8B and 9 illustrate operational aspects of the
heat and energy recovery system 200 with a furnace 2000 in
accordance with the disclosed embodiment. As shown, the system 200
may be adapted to fit on the furnace unit either on a wall of the
(FIG. 8A) or in line with the air intake (e.g. return plenum) of
the furnace (FIG. 9). In other aspects the system 200 may have any
suitable positional relationship relative to the furnace 2000. A
cut-away illustration is shown in FIG. 10 where, in one aspect of
the disclosed embodiment, the system 200 is structured to be in
line with the furnace intake 2300 (which is substantially similar
to return plenum 1300) for receiving air as it is drawn into the
furnace 2000. As can be seen in FIG. 8A, different configurations
with respect to the placement of the return plenum 1300, the
recovery chamber 110 and the first and second heat exchangers 116,
130 relative to the furnace 2000.
[0074] In one aspect the heat recovery system 100, 200, 200' may
substantially be a modular unit that can be connected to, for
example, furnace 2000 having a common housing 200HA (such as that
shown in FIG. 9) in which at least the first and second heat
exchangers 116, 130 are located. In one, aspect the heat recovery
system 100, 200, 200' has a two part modular configuration such
that the first heat exchanger 116 is included in one modular 200A
unit having a first housing 200HB and the second heat exchanger is
included in another modular unit 200B having a second housing 200HC
that can be placed at different locations relative to each other
and/or the furnace 2000 or boiler such as illustrated in FIG. 8A.
In other aspects the heat recovery system 100, 200, 200' includes
more than two modules where each module includes one or more of the
heat exchange elements of the first and second heat exchangers 116,
130, for example, additional heat exchangers and/or other
components of the heat recovery system 100, 200 may be disposed in
respective modular units each having a respective housing for
placement at any suitable location relative to other modular units.
Also referring to FIG. 8B the modular unit 200A may include the
first heat exchanger 116, the recovery chamber 110 and any other
suitable components of the heat recovery system 100, 200, 200' such
as one or more of the features illustrated in FIGS. 7, 7A and 7B.
The modular unit 200B may include the second heat exchanger 130
disposed within housing 200HC. As can be seen in FIG. 8B the
modular units 200A, 200B may be placed at any suitable locations
relative to each other and/or the furnace 2000 (or boiler) which in
one aspect may depend on available space in the installation
location of the heat recovery system 100. 200.
[0075] Referring to FIG. 15, in one aspect of the disclosed
embodiment, at least a portion of the heat recovery system may be
integrated within a housing 2000H of the furnace 2000. For example,
in one aspect the housing 2000H may house combustion chamber 2000CH
and at least the first heat exchanger 116 so that the furnace 2000
has an integral refrigerant heat exchange. In one aspect the first
heat exchanger may be disposed within a heat exchange chamber 110B
(e.g. substantially similar to that described with respect to FIG.
12) where a gas inlet is provided at least partly in the housing
2000H for transferring combined exhaust gas and cooling gas to the
first heat exchanger from the exhaust gas inlet 114 and cooling
intake 112. In other aspects the first heat exchanger 116 may be
disposed within the heat recovery chamber 110 (which is disposed
within the housing 2000CH) while in other aspects the heat recovery
chamber 110, 110B may be separate from a heat exchange chamber 110B
(where the first heat exchanger is located within the heat exchange
chamber 110B) as described above with respect to FIGS. 11 and 12.
As may be realized, the heat recovery chamber 110, 110B and the
heat exchange chamber 110B may be disposed within the housing
1200CH such that the exhaust inlet 114 and cooling intake 112
(located at least partly within the housing) provide exhaust gas
and cooling gas to the combining chamber. In one aspect, the
housing may also house the second heat exchanger 130 that is
communicably connected to the first heat exchanger through one or
more of conduits 120, 120A.
[0076] Referring to FIG. 13 a modular heat recovery system shown in
accordance with the aspects of the disclosed embodiment. In this
aspect the return plenum 1300 returns air from the heating space to
the furnace to be heated. In one aspect outdoor or ventilation air
may be introduced to the return air through duct 1303 which may
include a blower or fan (in other aspects a fan may not be
provided) for moving the outdoor air into the return plenum 1300.
The modular unit 200B may be located, for example, between the
furnace 2000 and the return plenum 1300, within an internal passage
of the return plenum 1300 and/or in-line with the return plenum
1300. As described above, heat from the second heat exchanger 130
may be transferred to the return air for heating or otherwise
pre-heating the return air prior to heating the air with the
furnace 2000. As may be realized, the heated air may be transferred
through the supply plenum 1301 back to the heating space. In one
aspect, any suitable filter 1302 may be disposed in or in-line with
the return plenum 1300 so that filtered air is provided for
contacting the second heat exchanger 130. The modular unit 200A may
be located at any suitable location relative to one or more of the
modular unit 200B and the furnace 2000. The modular unit 200A, in
this aspect, includes the heat recovery chamber 110 and first heat
exchanger 116 (which may be in communication with the second heat
exchanger through conduit circuit 120) and blower 140. In other
aspects the modular unit 200A may include any suitable components
of the heat recovery system as described herein. Exhaust gas from
the furnace and cooling gas may be provided to the heat recovery
chamber 110 through cooling intake 112 and exhaust intake 114 in a
manner substantially similar to that described above. In this
aspect the blower 140 is provided to pull or draw gas through the
heat recovery chamber 110.
[0077] Any suitable sensor(s) 1310 may be may be provided for
sensing a pressure (or other suitable physical characteristic of
the gas within the heat recovery chamber) for determining a
pressure within the heat recovery chamber 110. The sensor(s) 1310
may be connected to any suitable controller 1311 (which may include
one or more features described above with respect to FIG. 7). In
one aspect the controller may be integral to the modular unit 200A
while in other aspect the controller may be provided at any
suitable location. The sensor(s) 1310 may include a pressure sensor
connected to the controller 1311 to form a pressure switch for
controlling a pressure within the heat recovery chamber 110. The
cooling intake 112 may include any suitable bypass valve 112V for
redirecting, limiting or substantially preventing discharge gas
from entering the cooling intake 112 for maintaining a
predetermined pressure within the heat recovery chamber 110. In one
aspect the valve 112V may be connected to the controller 1311 such
that when a predetermined pressure within the heat recovery chamber
is detected by the sensor(s) 1310 the controller operates the valve
112V to direct at least some of the discharge gas past the cooling
intake 112 for maintaining the predetermined pressure or any other
suitable pressure. In other aspect the speed of the blower 140 may
be adjusted by the controller 1311 for maintaining the
predetermined pressure. In other aspects the controller may turn
off the blower 140 to maintain the predetermined pressure within
the heat recovery chamber. As may be realized a check valve 1410V
may be provided in one or more of the heat recovery chamber exhaust
1410, exhaust inlet 114 and cooling intake 112 to substantially
prevent a back flow of gas into the heat recovery chamber where a
pressure within the heat recovery chamber is lower than atmospheric
pressure outside the heat recovery chamber.
[0078] In another aspect, still referring to FIG. 13, the sensor(s)
1310 may include a temperature sensor (similar to sensors CS1 CS2
described above) for sensing a temperature of the refrigerant
within the first heat exchanger 116. In this aspect any suitable
blower or fan 1320 may be provided for circulating air through the
return plenum 1300 and the supply plenum 1301. The blower 1320 may
be connected to the controller 1311 in any suitable manner. As may
be realized, as the furnace 2000 is operating the exhaust from the
furnace heats the refrigerant within the first and second heat
exchangers 116, 130 and the conduit circuit 120. When the furnace
2000 turns off there may be residual heat stored in the combustion
chamber 2000CH of the furnace as well as in the refrigerant. The
residual heat from the combustion chamber 2000CH may be drawn from
the combustion chamber in any suitable manner, such as by gas
flowing through the combustion chamber and into the heat recovery
chamber 110 through the exhaust intake. Any suitable blower or fan
may be provided for drawing gas from the combustion chamber into
the heat recovery chamber when the furnace 2000 is not operating
(e.g. turned off). In other aspect the air flow may be provided
through convection. In this aspect heated gas from the combustion
chamber 2000CH alone or in combination with cooling gas from the
cooling intake 112 may continue to be provided to the heat recovery
chamber after the furnace 2000 is turned off. This heated gas may
continue to heat the refrigerant within the first heat exchanger
116 for transfer to the second heat exchanger where that heat is
extracted from the second heat exchanger by the air flowing in the
return and supply plenums 1300, 1301 so that heated air is provided
to the heating space after the furnace is turned off. The sensor(s)
1310 may send a signal to the controller 1311 when the temperature
of, for example, the refrigerant reaches a predetermined
temperature. When the predetermined temperature is reached the
controller 1311 may turn off the one or more of the blowers 1320,
140 to stop the flow of air into the heating space or adjust a
speed of the blowers to decrease the flow of air. In this aspect,
any residual heat from the furnace may be extracted which may
increase the energy recovered by the system 100, 200. In other
aspects, the extraction of residual heat from the furnace may be
performed in the manner described above using pressure readings
from within the heat recovery chamber. For example, the blowers may
be turned off or the speed of the blower may be varied (e.g.
decreased) when the pressure within the heat recovery chamber
reaches any suitable predetermined pressure. In, still other
aspects pressure and temperature readings may be used to control
the blowers for the recovery of residual heat from tile
furnace.
[0079] In other aspects the sensor(s) 1310 may be configured to
detect a pressure of the refrigerant within the first heat
exchanger 116 and/or a temperature of the first heat exchanger 116
for determining the presence of frost on the first heat exchanger.
For example, a compressor 150 may be provided to at least partly
effect the flow of refrigerant through the conduit circuit 120 as
described above. The sensor(s) 1310 may be configured to send
signals to, for example, controller 1311 indicating a decrease in
pressure and/or temperature within the first heat exchanger at
which frost may form. The controller may be configured to, based on
the sensor signals, turn off the compressor 150 so that the
temperature and pressure of the first heat exchanger 116 rise to
allow dissipation of the frost. The controller 1311 may be
configured to use the sensor data (in e.g. in a closed loop
feedback system) for setting, compressor 150 on/off times where the
compressor on/off times may be adjusted by the controller in
predetermined time increments.
[0080] Referring now to FIG. 14A, in the aspects of the disclosed
embodiment described herein the heat recovery chamber 110, 110A,
110C may have any suitable configuration for mixing the exhaust gas
from exhaust intake 114 and the cooling gas from cooling intake
112. In one aspect the heat recovery chamber may have one or more
features for mixing the exhaust gas and cooling gas. For example,
ends of the cooling intake 112 and exhaust intake 114 within the
heat recovery chamber may be angled towards a wall or mixing
surface 110S (e.g. the walls may be contoured or textured) of the
heat recovery chamber 110 so that the exhaust gas and cooling gas
are reflected by the wall or mixing surface it any suitable manner
for mixing or otherwise combining the exhaust gas with the cooling
gas. In another aspect the heat recovery chamber 110, 11B may
include one or more vanes 1400 configured to direct the exhaust gas
and cooling gas in any suitable direction(s) for mixing or
otherwise combining the exhaust gas and cooling gas. In yet another
aspect the heat recovery chamber 110, 110B may include any suitable
diffuser 1402 or other suitable mixing element for mixing or
otherwise combining the exhaust gas and cooling gas. In still other
aspects, the heat recovery chamber 110, 110B may include one or
more of the mixing surface 110S, vanes 1400, diffuser(s) 1402
and/or any other suitable mixing structure for mixing or otherwise
combining the exhaust gas and cooling gas provided by the exhaust
gas intake 114 and the cooling intake 112.
[0081] Referring to FIG. 14B and FIG. 14C the heat recovery chamber
110, 110B may be configured so that the exhaust inlet 114 and
cooling intake 112 are disposed on opposing sides or sides of the
heat recovery chamber 110, 110B that are angled relative to one
another. For example, as can be seen in FIG. 14B the exhaust gas
intake 114 and the cooling intake 112 are disposed on opposing
sides of the heat recovery chamber 110, 110B so that the intakes
substantially face one another. In this aspect the exhaust gas and
cooling gas may be opposingly directed towards one another for
mixing. As may be realized, the exhaust intake 114 and cooling
intake 112 may be vertically or horizontally offset with one
another or in-line with one another so that the exhaust gas and
cooling gas provided to the heat recovery chamber impinge each
other at any predetermined angle. As may also be realized, in one
aspect, where the first heat exchanger 116 is located within the
heat recovery chamber 110, the first heat exchanger may be disposed
between an outlet or exhaust 1410 of the heat recovery chamber and
the inlets 114, 112 so that the mixture of exhaust gas and cooling
gas passes through the first heat exchanger 116 before entering the
outlet or exhaust 1410. In another aspect, where the first heat
exchanger 116 is located in a separate heat exchange chamber 110B
(e.g. such as described above with respect to FIGS. 11 and 12) the
mixture of exhaust gas and cooling gas may exit the heat recovery
chamber through outlet or exhaust 1410 for transfer to the heat
exchange chamber 110B.
[0082] As can be seen in FIG. 14C and 14D, the exhaust gas intake
114 and cooling intake 112 may be disposed on angled sides of the
heat recovery chamber in any suitable manner such as in a manner
described with respect to FIG. 14. As may be realized, where the
first heat exchanger 116 is located within the heat recovery
chamber 110, the first heat exchanger may be disposed between the
outlet or exhaust 1410 of the heat recovery chamber and the inlets
114, 112 so that the mixture of exhaust gas and cooling gas passes
through the first heat exchanger 116 before entering the outlet or
exhaust 1410. In another aspect, where the first heat exchanger 116
is located in a separate heat exchange chamber 110B (e.g. such as
described above with respect to FIGS. 11 and 12) the mixture of
exhaust gas and cooling gas may exit the heat recovery chamber
through outlet or exhaust 1410 for transfer to the heat exchange
chamber 110B.
[0083] Referring to FIG. 14E, in accordance with an aspect of the
disclosed embodiment the first heat exchanger may have any suitable
configuration. In one aspect the first heat exchanger 116 may have
a planar configuration while in other aspects the first heat
exchanger 116' (which includes one or more of heat exchange
elements 116A', 116B' which are substantially similar to heat
exchange elements 116A, 116B described above) may have cylindrical
configuration. For example, first the heat exchange element 116A'
may substantially divide the heat recovery chamber into a first
portion 110P1 and second portion 110P2 and where provided the heat
exchanger 116B further divides the heat recovery chamber into at
least a third portion disposed between the second portion and the
exhaust 1410). The exhaust gas and cooling gas is introduced into
the first portion 110P1 and the mixture of the exhaust gas and
cooling gas exits through the second portion 110P2 where the mixed
gas passes from the first portion 110P1 through the first heat
exchanger 116A to the second portion 110P2, and in one aspect,
through the heat exchanger 116B. In this example the first heat
exchanger 116A may include coils arranged in a cylindrical
arrangement so as to have an interior that forms the second portion
110P2 (and/or the heat exchanger 116B has coils arranged in a
cylindrical arrangement to form at least the third portion). The
exhaust gas and cooling gas is introduced into the first portion,
passes through the coils of the first heat exchanger 116A to the
interior and then, in one aspect, through the coils of the heat
exchanger 116B and exits the outlet or exhaust 1410. In another
aspect, as shown in FIG. 14F, the exhaust gas and cooling gas
enters the interior of the first heat exchanger (e.g. into portion
110P2) passes through the coils of the first heat exchanger 116A to
the first portion 110P1 where the gas, in one aspect passes through
heat exchanger 116B, and exits through the outlet or exhaust 1410.
In other aspects the heat exchanger 116B is is omitted.
[0084] Referring to FIG. 16 the heat recovery system described
herein can be employed with a boiler system 1600 to provide heated
air to a heating space 1650 within a habitable structure. For
example, exhaust gas from boiler 1600 may be provided to heat
recovery chamber 110 through exhaust gas inlet 114. Cool dry gas
(such as for example, indoor air and/or cooling gas from the heat
recovery chamber as described above) is provided to the heat
recovery chamber 110 through cooling intake 112. The combined
exhaust gas and cooling gas contacts the first heat exchanger 116
(which includes one or more of heat exchange elements 116A, 116B)
and at least a portion of the exhaust gas exits outside the
habitable structure through exhaust 1410. Heat is transferred from
the first heat exchanger 116 to the second heat exchanger 130
(which includes one or more of heat exchange elements 130A, 130B)
through conduit 120 (and/or conduit 120A) as described above. The
second heat exchanger 130 is disposed within or in line with an air
delivery system having a fan or blower 1621, a supply duct 1620 and
one or more air registers 1610, 1611 through which heated supply
air is introduced to the heating space 1650. In this aspect the
second heat exchanger 130 is disposed between the supply duct 1620
and the air registers 1610, 1611 so that air forced through the
supply duct by blower 1621 passes through the second heat exchanger
130 so that heat extracted from the second heat exchanger heats the
air for delivery into the heating space through the air registers
1610, 1611.
[0085] As may be realized, in one aspect, the heat transferred to
the second heat exchanger 130 from the first heat exchanger 116
(whether the system is employed with a furnace or boiler) is used
to heat any suitable heat sink or heat transfer medium. Referring
to FIG. 17 in one aspect water within a hot water tank 1700 is
heated with the heat recovery system described herein. For example,
an air duct 1710 may be disposed adjacent a water chamber 1700C of
the hot water tank 1700. In this aspect the air duct 1710 is coiled
around the water chamber 1700C while in other aspects air duct(s)
1710 may be disposed within the water chamber 1700C or have any
other suitable spatial arrangement/configuration relative to the
water chamber 1700C for heating water within the water chamber 1700
in the manner described herein. In one aspect the second heat
exchanger 130 may be disposed so air passing through the air duct
1710 is forced or pulled through the second heat exchanger 130, in
any suitable manner (such as by blower 140) before entering the air
duct 1710. The second heat exchanger 130 may heat the air so that
as the heated air passes through the air duct 1710 heat is
transferred from the air to the water within the water chamber
1700C in any suitable manner. The air may be drawn from the space
in which the hot water tank 1700 is located or from any other
suitable source and exhausted back into the space in which the hot
water tank is located or to any other suitable location (such as
outside the habitable space). As may be realized the flow rate of
the air and/or the length of the air duct 1710 may be such that
substantially all of the heat stored in the air is transferred to
the water within the water chamber 1700C.
[0086] In one aspect the disclosed embodiment is directed to a
method of recovering heat and energy from fuel combustion. The
method includes feeding excess heat and exhaust gas emitted as a
result of fuel combustion into a heat recovery chamber 110 which
contains a first heat exchanger 116 (fluid filled) coupled with a
fluid containing conduit circuit(s) 120, 120A. Typically, the fluid
comprises a refrigerant. The method further includes feeding
cooling gas into the heat recovery chamber so that the cooling gas
is mixed with the exhaust gas to produce a mixed gas with potential
energy. The method may also include effectuating heat energy
exchange through the mixed gas and excess heat interacting with the
first heat exchanger 116. As a result, the temperature and pressure
within the first heat exchanger 116 and fluid containing conduit
circuit(s) 120, 120A rises. The method may also include releasing
the heat energy by, for example, forced (or any other flow of) air
blowing over a second heat exchanger 117 that is in fluid
communication with one fluid containing conduit circuit(s) 120,
120A exterior to the heat recovery chamber.
[0087] In accordance with one or more aspects of the disclosed
embodiment a heat recovery system in a habitat to be heated by a
furnace having a controller coupled to a thermostat, the heat
recovery system includes a chamber including a cooling intake, an
emissions intake and a chamber exhaust, the emissions intake is
configured for receiving exhaust gas emitted as a result of fuel
combustion in the furnace and the chamber exhaust is configured to
discharge emissions from the chamber; a heat recovery exchanger
disposed within the chamber for contacting a mixture of cooling gas
introduced through the cooling intake and the exhaust gas
introduced through the emissions intake such that heat exchange is
effected; at least one fluid circuit in communication with the heat
recovery exchanger; a heat extraction exchanger in fluid
communication with the heat recovery exchanger through the at least
one fluid circuit to effect heat exchange between the heat
extraction exchanger and an airstream running therethrough; and a
temperature sensor located in a supply plenum of the furnace and
having a predetermined hi temperature set point and a predetermined
low temperature set point; where the controller is configured so
that in response to a heat call from the thermostat, the furnace is
repeatedly cycled between on and off states when the controller
registers temperature sensor signals corresponding to the
predetermined hi temperature set point and the predetermined low
temperature set point.
[0088] It accordance with one or more aspects of the disclosed
embodiment the heat recovery system further includes a pressure
regulating assembly in communication with the chamber and the
chamber exhaust for regulating a pressure in the heat recovery
system.
[0089] In accordance with one or more aspects of the disclosed
embodiment the pressure regulating assembly includes a fan
communicably coupled to the chamber exhaust and configured to draw
the emissions from the chamber.
[0090] In accordance with one or more aspects of the disclosed
embodiment the cooling intake is communicably coupled to the
chamber exhaust and is configured to extract at least a portion of
the emissions for recirculation as the cooling gas.
[0091] In accordance with one or more aspects of the disclosed
embodiment the heat recovery exchanger and the heat extraction
exchanger comprise a multi-stage heat exchange system including at
least: a first stage having a primary heat recovery exchanger
element and a primary heat extraction exchanger element
communicably coupled to each other through a primary fluid circuit
of the at least one fluid circuit; and a second stage having a
secondary heat recovery exchanger element and a secondary heat
extraction exchanger element communicably coupled to each other
through a secondary fluid circuit of the at least one fluid
circuit.
[0092] In accordance with one or more aspects of the disclosed
embodiment each stage of the multi-stage heat exchange system is
independently operable from another stage of the multi-stage heat
exchange system.
[0093] In accordance with one or more aspects of the disclosed
embodiment the first stage of the multi-stage heat exchange system
effects heat exchange during both furnace on and off states.
[0094] In accordance with one or more aspects of the disclosed
embodiment the second stage of the multi-stage heat exchange system
is operative and effects heat exchange during furnace on states and
inoperative during furnace off states.
[0095] In accordance with one or more aspects of the disclosed
embodiment a burner of the furnace is switched on and off
corresponding to a furnace on and off cycle and a return air blower
of the furnace continues to run during the heat call.
[0096] In accordance with one or more aspects of the disclosed
embodiment, the heat recovery system is configured to be combined
with a heating furnace to effects the coupling of a PVC exhaust
duct to the combination of the heat recovery assembly/system 100
and the furnace 2000.
[0097] In accordance with one or more aspects of the disclosed
embodiment a heat recovery system includes a furnace having a
furnace exhaust, a return plenum and a controller coupled to a
thermostat; a chamber including a cooling intake, an emissions
intake and a chamber exhaust, the emissions intake being
communicably coupled to the furnace exhaust so that exhaust gas
emitted as a result of fuel combustion in the furnace is
transferred to the chamber, the chamber exhaust is configured to
discharge emissions from the chamber, and the cooling intake is
configured to effect transfer of at least a portion of the
emissions from the chamber exhaust to the chamber as cooling gas; a
heat recovery exchanger disposed within the chamber for contacting
a mixture of the cooling gas and the exhaust gas such that heat
exchange is effected; at least one fluid circuit in communication
with the heat recovery exchanger; a heat extraction exchanger in
fluid communication with the heat recovery exchanger through the at
least one fluid circuit and in thermal communication with an
airstream running through the return plenum for transferring heat
from the heat extraction exchanger to the airstream; and a
temperature sensor located in a supply plenum of the furnace and
having a predetermined hi temperature set point and a predetermined
low temperature set point; where the controller is configured so
that in response to a heat call from the thermostat, the furnace is
repeatedly cycled between on and off states throughout the heat
call when the controller registers temperature sensor signals
corresponding to the predetermined hi temperature set point and the
predetermined low temperature set point.
[0098] In accordance with one or more aspects of the disclosed
embodiment the heat recovery system further includes a pressure
regulating assembly in communication with the chamber and the
chamber exhaust for regulating a pressure in the heat recovery
system.
[0099] In accordance with one or more aspects of the disclosed
embodiment the pressure regulating assembly includes a fan
communicably coupled to the chamber exhaust and configured to draw
the emissions from the chamber.
[0100] In accordance with one or more aspects, of the disclosed
embedment the heat recovery exchanger and the heat extraction
exchanger comprise a multi-stage heat exchange system including at
least: a first stage having a primary heat recovery exchanger
element and a primary heat extraction exchanger element
communicably coupled to each other through a primary fluid circuit
of the at least one fluid circuit; and a second stage having a
secondary heat recovery exchanger element and a secondary heat
extraction exchanger element communicably coucoupled to each other
through a secondary fluid circuit of the at least one fluid
circuit.
[0101] In accordance with one or more aspects of the disclosed
embodiment each stage of the multi-stage heat exchange system is
independently operable from another stage of the multi-stage heat
exchange system.
[0102] In accordance with one or more aspects of the disclosed
embodiment the first stage of the multi-stage heat exchange system
effects heat exchange during both furnace on and off states.
[0103] In accordance with one or more aspects of the disclosed
embodiment the second stage of the multi-stage heat exchange system
is operative and effects heat exchange during furnace on states and
inoperative during furnace off states.
[0104] In accordance with one or more aspects of the disclosed
embodiment a burner of the furnace is switched on and off
corresponding to a furnace on and off cycle and a return air blower
of the furnace continues to run during the heat call.
[0105] In accordance with one or more aspects of the disclosed
embodiment the chamber exhaust comprises a PVC duct.
[0106] In accordance with one or more aspects of the disclosed
embodiment a heating furnace includes a furnace exhaust; a return
plenum; a controller coupled to a thermostat; and a heat recovery
system including a chamber including a cooling intake, an emissions
intake and a chamber exhaust, the emissions intake being
communicably coupled to the furnace exhaust so that exhaust gas
emitted as a result of fuel combustion in the furnace is
transferred to the chamber, the chamber exhaust is configured to
discharge emissions from the chamber, and the cooling intake is
configured to effect transfer of at least a portion of the
emissions from the chamber exhaust to the chamber as cooling gas; a
heat recovery exchanger disposed within the chamber for contacting
a mixture of the cooling gas and the exhaust gas such that heat
exchange is effected; at least one fluid circuit in communication
with the heat recovery exchanger; a heat extraction exchanger in
fluid communication with the heat recovery exchanger through the at
least one fluid circuit and in thermal communication with an
airstream running through the return plenum for transferring heat
from the heat extraction exchanger to the airstream; and a
temperature sensor located in a supply plenum of the furnace and
having a predetermined hi temperature set point and a predetermined
low temperature set point; where the controller is configured so
that in response to a heat call from the thermostat, the furnace is
repeatedly cycled, for a duration of the heat call, between on and
off states when the controller registers temperature sensor signals
corresponding to the predetermined hi temperature set point and the
predetermined low temperature set point.
[0107] In accordance with one or more aspects of the disclosed
embodiment the heating furnace further includes a pressure
regulating assembly in communication with the chamber and the
chamber exhaust for regulating a pressure in the heat recovery
system.
[0108] In accordance with one or more aspects of the disclosed
embodiment the pressure regulating assembly includes a fan
communicably coupled to the chamber exhaust and configured to draw
the emissions from the chamber.
[0109] In accordance with one or more aspects of the disclosed
embodiment the heat recovery exchanger and the heat extraction
exchanger comprise a multi-stage heat exchange system including at
least a first stage having a primary heat recovery exchanger
element and a primary heat extraction exchanger element
communicably coupled to each other through a primary fluid circuit
of the at least one fluid circuit; and a second stage having a
secondary heat recovery exchanger element and a secondary heat
extraction exchanger element communicably coupled to each other
through a secondary fluid circuit of the at least one fluid
circuit.
[0110] In accordance with one or more aspects of the disclosed
embodiment each stage of the multi-stage heat exchange system is
independently operable from another stage of the multi-stage heat
exchange system.
[0111] In accordance with one or more aspects of the disclosed
embodiment the first stage of the multi-stage heat exchange system
effects heat exchange during both furnace on and off states.
[0112] In accordance with one or more aspects of the disclosed
embodiment the second stage of the multi-stage heat exchange system
is operative and effects heat exchange during furnace on states and
inoperative during furnace off states.
[0113] In accordance with one or more aspects of the disclosed
embodiment a burner of the furnace is switched on and off
corresponding to a furnace on and off cycle and a return air blower
of the furnace continues to run during the heat call.
[0114] In accordance with one or more aspects of the disclosed
embodiment a heat recovery system, in a habitat to be heated by a
furnace having a controller coupled to a thermostat, includes a
chamber including a cooling intake, an emissions intake and a
chamber exhaust, the emissions intake is configured for receiving
exhaust gas emitted as a result of fuel combustion in the furnace
and the chamber exhaust is configured to discharge emissions from
the chamber; a multiple stage heat recovery exchanger disposed
within the chamber for contacting a mixture of cooling gas
introduced through the cooling intake and the exhaust gas
introduced through the emissions intake such that heat exchange is
effected, the multiple stage heat recovery exchanger including at
least a first stage and a second stage; at least one fluid circuit
in communication with the heat recovery exchanger; a multiple stage
heat extraction exchanger in fluid communication with the heat
recovery exchanger through the at least one fluid circuit to effect
heat exchange between the heat extraction exchanger and an
airstream running therethrough, the multiple stage heat extraction
exchanger having at least a first stage and a second stage; and a
temperature sensor located in a supply plenum of the furnace and
having a predetermined hi temperature set point and a predetermined
low temperature set point; where the controller is configured so
that in response to a heat call from the thermostat, one or more of
the first and second stages of the multiple stage heat recovery
exchanger and the multiple stage heat extraction exchanger are
operative during the furnace on state, the first stages of the
multiple stage heat recovery exchanger and the multiple stage heat
extraction exchanger are operative during the furnace on state, and
the second stages of the multiple stage heat recovery exchanger and
the multiple stage heat extraction exchanger are inoperative during
the furnace off state.
[0115] In accordance with one or more aspects of the disclosed
embodiment the heat recovery system further includes a pressure
regulating assembly in communication with the chamber and the
chamber exhaust for regulating a pressure in the heat recovery
system.
[0116] In accordance with one or more aspects of the disclosed
embodiment the pressure regulating assembly includes a fan
communicably coupled to the chamber exhaust and configured to draw
the emissions from the chamber.
[0117] In accordance with one or more aspects of the disclosed
embodiment the cooling intake is communicably coupled to the
chamber exhaust and is configured to extract at least a portion of
the emissions for recirculation as the cooling gas.
[0118] In accordance with one or more aspects of the disclosed
embodiment the controller is configured so that in response to a
heat call from the thermostat the furnace is repeatedly cycled
between on and off states when the controller registers temperature
sensor signals corresponding to the predetermined hi temperature
set point and the predetermined low temperature set point.
[0119] In accordance with one or more aspects of the disclosed
embodiment the chamber exhaust comprises a PVC duct.
[0120] In accordance with one or more aspects of the disclosed
embodiment a heat recovery system, in a habitat to be heated by a
furnace having a controller coupled to a thermostat, includes a
chamber including an emissions intake, a chamber exhaust and a
closed loop cooling intake communicably coupling the chamber
exhaust and the chamber, the emissions intake is configured for
receiving exhaust gas emitted as a result of fuel combustion in the
furnace, the chamber exhaust is configured to discharge emissions
from the chamber and the cooling intake is configured to
recirculate at least a portion of the emissions from the chamber
exhaust to the chamber; a heat recovery exchanger disposed within
the chamber for contacting a mixture of cooling gas introduced
through the cooling intake and the exhaust gas introduced through
the emissions intake such that heat exchange is effected; at least
one fluid circuit in communication with the heat recovery
exchanger; a heat extraction exchanger in fluid communication with
the heat recovery exchanger through the at least one fluid circuit
to effect heat exchange between the heat extraction exchanger and
an airstream running therethrough; and a temperature sensor located
in a supply plenum of the furnace and having a predetermined hi
temperature set point and a predetermined low temperature set
point; where the controller is configured so that in response to a
heat call from the thermostat, the furnace is repeatedly cycled
between on and off states when the controller registers temperature
sensor signals corresponding to the predetermined hi temperature
set point and the predetermined low temperature set point.
[0121] In accordance with one or more aspects of the disclosed
embodiment the heat recovery system further includes a fan
communicably coupled to the chamber exhaust and configured to draw
the emissions from the chamber.
[0122] In accordance with one or more aspects of the disclosed
embodiment the heat recovery exchanger and the heat extraction
exchanger comprise a multi-stage heat exchange system including at
least: a first stage having a primary heat recovery exchanger
element and a primary heat extraction exchanger element
communicably coupled to each other through a primary fluid circuit
of the at least one fluid circuit; and a second stage having a
secondary heat recovery exchanger element and a secondary heat
extraction exchanger element communicably coupled to each other
through a secondary fluid circuit of the at least one fluid
circuit.
[0123] In accordance with one or more aspects of the disclosed
embodiment each stage of the multi-stage heat exchange system is
independently operable from another stage of the multi-stage heat
exchange system.
[0124] In accordance with one or more aspects of the disclosed
embodiment the first stage of the multi-stage heat exchange system
effects heat exchange during both furnace on and off states.
[0125] In accordance with one or more aspects of the disclosed
embodiment the second stage of the multi-stage heat exchange system
is operative and effects heat exchange during furnace on states and
inoperative during furnace off states.
[0126] In accordance with one more aspects of the disclosed
embodiment the chamber exhaust comprises a PVC duct.
[0127] In accordance with one or more aspects of the disclosed
embodiment a method for recovering heat in a habitat heated by a
furnace includes providing a chamber including a cooling intake, an
emissions intake and a chamber exhaust, where the emissions intake
receives exhaust gas emitted as a result of fuel combustion in the
furnace and the chamber exhaust discharges emissions from the
chamber; providing a heat recovery exchanger disposed within the
chamber for contacting a mixture of cooling gas introduced through
the cooling intake and the exhaust gas introduced through the
emissions intake such that heat exchange is effected; providing a
heat extraction exchanger in fluid communication with the heat
recovery exchanger through at least one fluid circuit for effecting
heat exchange between the heat extraction exchanger and an
airstream running therethrough; providing a temperature sensor in a
supply plenum of the furnace and having a predetermined hi
temperature set point and a predetermined low temperature set
point; and repeatedly cycling the furnace, with a controller that,
in response to a heat call from a thermostat, repeatedly cycles the
furnace between on and off states for a duration of the heat call
when the controller registers temperature sensor signals
corresponding to the predetermined hi temperature set point and the
predetermined low temperature set point.
[0128] In accordance with one or more aspects of the disclosed
embodiment the method further includes regulating a pressure within
the chamber with fan communicably coupled to the chamber exhaust
where the emissions are drawn from the chamber.
[0129] In accordance with one or more aspects the disclosed
embodiment the method further includes supplying cooling gas in a
closed loop from the chamber exhaust to the cooling intake.
[0130] In accordance with one or more aspects of the disclosed
embodiment the heat recovery exchanger and the heat extraction
exchanger are provided as a multi-stage heat exchange system
including at least; a first stage having a primary heat recovery
exchanger element and a primary heat extraction exchanger element
communicably coupled to each other through a primary fluid circuit
of the at least one fluid circuit; and a second stage having a
secondary heat recovery exchanger element and a secondary heat
extraction exchanger element communicably coupled to each other
through a secondary fluid circuit of the at least one fluid
circuit.
[0131] In accordance with one or more aspects off the disclosed
embodiment the method further includes effecting heat exchange
during both furnace on and off states with the first stage of the
multi-stage heat exchange system.
[0132] In accordance with one or more aspects of the disclosed
embodiment method further includes effecting heat exchange during
furnace on states with the second stage of the multi-stage heat
exchange system.
[0133] In accordance with one or more aspects of the disclosed
embodiment a burner of the furnace is switched on and off
corresponding to a furnace on and off cycle and a return air blower
of the furnace continues to run during the heat call.
[0134] Referring to FIG. 19, ire accordance with one or more
aspects of the disclosed embodiment, the system includes at least
one controller 202 operably linked to respective operating
components (e.g., and/or operating zones) of the heat recovery
system. For example, the operating components coupled to the at
least one controller includes a compressor, a condenser, a heat
exchanger, a meter, a fan, a motor, a rotor, a circuit, a pump, a
valve, a conductor, a capacitor, a switch and other functional
components.
[0135] The system also includes at least one sensor 204 configured
to collect at least one environmental measurement and
system-related data. The environment measurement and the system
related data includes internal and external temperature and
pressure humidity, barometric pressures, dew points, wind
direction, sun peak and angle, annual precipitation, geographical
location and, elevation of the system, thermostats settings,
chemical analysis at specific point of the system carbon dioxide
level, motion level, fuel consumption, electrical consumption, fuel
price, and electrical energy prices in real time.
[0136] The system further includes a central thermal recovery unit
206 in signal communication with the at least one controller 202
and the at least one sensor 204. The central thermal recovery unit
206 is configured for determining an operating instruction based on
the at least one environmental measurement and system-related data
received from the at least one sensor. The central thermal recovery
unit 206 is further configured to transmit the operating
instruction to the at least one controller 204. The operating
instruction includes a specific operation sequence of a series of
operating components/zones controlled by the at least one
controller.
[0137] The central thermal recovery unit 206 can also be configured
to determine operating instruction based on environment
measurements and system related data retrieved from a third party
database 208. For example, the third party database 208 can include
information such as weather conditions, user preferred comfort
level, fuel cost, air quality, and the like. The information can
facilitate the central thermal recovery unit 206 to determine the
operating instruction that improves efficiency and extends the life
of the equipment and components of the system.
[0138] The at least one controller 202 and/or the at least one
sensor 204 can also be used to detect potential issues concerning
certain mechanical part and/or zones of the system and transmit
these issues to the central thermal recovery unit 206. For example,
the at least one controller 202 and/or the at least one sensor 204
can detect a depleted refrigerant and/or leaks at a specific
location within the system. The central thermal recovery unit 206
can in turn determine parts in need of repair or replacement and
repair or replacement sequences.
[0139] The central thermal recovery unit 206 can be configured to
determine the operating instructions (e.g., temporal operating
sequence) using an adaptive learning method. For example, the
central thermal recovery unit 206 can record and analyze operation
patterns, compare the efficiencies of each operation pattern, and
on this basis predict the most efficient sequence under certain
environmental/system conditions. The adaptive learning method will
make the heat recovery system more efficient from the continuous
determination and implementation of a more efficient operation
pattern. The central thermal recovery unit 206 will enable a
conventional HVAC system to achieve dramatically higher efficiency
levels. As an example, the operation pattern can include motor
running time, internal and external temperatures and pressures,
fuel combustion rate, fan speed and durations, inducer flow level,
blower pressures and speed, ignition timing, and the like. The
operation patterns that result in high efficiency can then be
transmitted and shared with other thermal recovery units via a
network.
[0140] The central thermal recovery unit 206 can be configured to
achieve the highest system efficiency under given conditions. For
example, if the price of fuel depends on the time of day, the
central thermal recovery unit can account for fuel price to
calculate system efficiency. As another example, for a system that
can operate on certain cycles of either refrigeration or fossil
fuels, if electric prices are more advantageous than natural gas at
a certain time of the day, the system can favor operational cycles
that use electricity over natural gas at that time of the day.
[0141] The central thermal recovery unit 206 can also be configured
to achieve a balance between high system efficiency and low thermal
pollutant release. For example, for a heat recovery system located
in certain valleys in certain states, for instance, Simi Valley,
Calif., the release of a certain pollutant will contribute to smog
accumulation. In such cases, the system can be configured to
monitor the release of CO/CO2 and other system waste products and
to balance energy consumption, system efficiency and materials
release accordingly.
[0142] As an example, given an outdoor temperature of 40.degree.
F., when a call for heat from a thermostat is received, the central
thermal recovery unit 206 will first instruct a controller 202 to
open one or more dampers to draft in external air for beat
extraction from a heat pump. This step will allow the system to
deliver a desired amount of heat without the need for a fossil fuel
burn. If the first step does not achieve the thermostat setting
within a defined period of time, the central thermal recovery unit
206 will instruct one or more dampers to be closed and a combustion
chamber to be activated to begin generating thermal energy by
burning a fuel. When the thermostat setting is achieved,
information such as temperature in the return duct flow, exterior
temperature, humidity, dew points, fuel consumption, run time, and
the like will be measured, logged and transmitted to the central
thermal recovery unit 206 and/or a data collection center. These
data are then analyzed to determine, for example, the time period
needed to activate a combustion chamber to achieve a desired
temperature setting. The central thermal recovery unit 206 can
compare present operating conditions with previous operating cycles
under similar operating conditions and determine an operating
sequence to activate and/or deactivate certain operating components
of the system.
[0143] As another example, when a call for heat from a thermostat
received, the central thermal recovery unit 206 will determine the
outdoor temperature and humidity, internal and external system
condition, combustion chamber condition to determine the starting
time and duration burn cycles and inducer drafting cycles to
achieve maximum efficiency of the system.
[0144] As another example, for a refrigeration system, the central
thermal recovery unit 206 can programmed to collect operating data
and environment data of the system on a periodic basis and respond
with operation instructions. The operating instructions can include
a sequence and duration for operating a compressor, an evaporator,
a condenser and a pressure device. Slight changes in the operating
times and pressures of specific components will increase the
efficiency of heat transfer and decrease the stress on system
components. Subtle changes in the operation of each component under
specific internal and external conditions can lead to significant
improvements in the ability of the system to extract and transfer
thermal energy.
[0145] The central thermal recovery unit 206 can also be in signal
transmission with one or more personal devices 210, a display
terminal 212, a user interface 214 (e.g., a website), and the like,
for receiving and/or displaying system operation parameters,
climate conditions, and/or user preferences. The thermal recovery
unit 206 operate at different locations and environmental
conditions can continuously transmit data to and receive data from
the user interface 214 (e.g., a website). The data input from
various central thermal recovery units 206 are displayed on the
user interface (e.g., a website) and updated periodically. As a
result, the central thermal recovery units 206 installed throughout
the world can become more and more efficient by learning operating
parameters from other thermal recovery units.
[0146] The central thermal recovery unit 206 is configured to
communicate the personal devices 210, the display terminal 212
and/or a user interface 214 via a network 216 using a variety of
transmission paths, including wireless links such as radio
frequency, satellite, Bluetooth and/or physical links such as fiber
optic cable, coaxial cable, Ethernet cable, and the like.
[0147] Referring to FIG. 20, the central thermal recovery system
206 includes a processor 218 for receiving and processing system
related data such as operation parameters, sensor measurements,
climate conditions, fuel information (e.g., fuel price, fuel
consumption, etc.). The processor 218 can be also configured to
output information such as operating instructions, system
efficiency report, system pollutant release report, system
operation history and analysis, and the like. This information can
be stored in the database 220.
[0148] FIG. 21 illustrates a block diagram of an example heat
recovery system employing a central thermal recovery unit 206, a
plurality of controllers 202, and a plurality of sensors 204 to
improve the operating efficiency of the system. The sensors 204 are
configured to receive information such as outdoor temperature,
suction temperature, plenum temperature, air quality parameters,
motor operation parameters and the like. The plurality of
controllers 202 are configured to receive operating instructions
including operating one or more system components in a specific
temporal sequence. In the depicted embodiment, the system
components coupled to controllers 202 includes a blower, a heat
coil, a compressor, a capacitor, and an inductor. The central
thermal recovery unit 206 can also be equipped with a sound warning
and/or a light warning when potential issues are detected.
[0149] FIGS. 22-2 illustrate sample user interfaces for input
system related information.
[0150] FIGS. 24-26 illustrate sample system operating parameters
and statistics.
[0151] It should be understood that the foregoing description is
only illustrative of the aspects of the disclosed embodiment.
Various alternatives and modifications can be devised by those
skilled in the art without departing from the aspects of the
disclosed embodiment. Accordingly, the aspects of the disclosed
embodiment are intended to embrace all such alternatives,
modifications and variances that fall within the scope of the
appended claims. Further, the mere fact that different features are
recited in mutually different dependent or independent claims does
not indicate that a combination of these features cannot be
advantageously used, such a combination remaining within the scope
of the aspects of the invention.
* * * * *