Gradual oxidation and autoignition temperature controls

• US 9,206,980 B2
• Filed: 03/09/2012
• Issued: 12/08/2015
• Est. Priority Date: 03/09/2012
• Status: Active Grant

• Current Assignee: ReductoNox Corp.
• Original Assignee: Ener-Core Power, Inc. (Ener-Core, Inc.)
• Inventors: Maslov, Boris A.
• Primary Examiner(s): Rinehart, Kenneth
• Assistant Examiner(s): PRABHU, GAJANAN MADHAV
• Application Number:
  US13/417,122
• Publication Number:
  US 20130232874A1
• Time in Patent Office: 1,369 Days
• Field of Search: 431/18, 60/395.2
• US Class Current: 1/1
• CPC Class Codes: F23C 2202/50 Control of recirculation rate
• CPC Class Codes: F23C 2900/99001 Cold flame combustion or flameless oxidation processes
• CPC Class Codes: F23C 9/00 Combustion apparatus characterised by arrangements for returning combustion products or flue gases to the combustion chamber fluidised bed combustion apparatus with means for recirculation of particles entrained from the bed F23C10/02; fluidised bed combustion apparatus with devices for removal and partial reintroduction of material from the bed F23C10/26
• CPC Class Codes: F23C 9/06 for completing combustion
• CPC Class Codes: F23C 99/00 Subject-matter not provided for in other groups of this subclass
• CPC Class Codes: F23C 99/006 Flameless combustion stabilised within a bed of porous heat-resistant material F23C13/00 takes precedence; gas burners with radiant combustion on a porous surface F23D14/16
• CPC Class Codes: F23G 5/46 Recuperation of heat
• CPC Class Codes: F23G 5/50 Control or safety arrangements
• CPC Class Codes: F23G 7/065 using gaseous or liquid fuel
• CPC Class Codes: F23K 2900/05004 Mixing two or more fluid fuels
• CPC Class Codes: F23L 2900/07002 Injecting inert gas, other than steam or evaporated water, into the combustion chambers
• CPC Class Codes: F23N 1/002 using electronic means F23N1/04 - F23N1/10 take precedence
• CPC Class Codes: F23N 1/082 using electronic means
• CPC Class Codes: F23N 2221/12 Recycling exhaust gases
• CPC Class Codes: F23N 2225/16 burner temperature
• CPC Class Codes: F23N 5/003 using detectors sensitive to combustion gas properties F23N5/02, F23N5/18 - F23N5/26 take precedence
• CPC Class Codes: F23N 5/022 using electronic means F23N5/04 - F23N5/14 take precedence
• CPC Class Codes: Y02E 20/34 Indirect CO2mitigation, i.e. by acting on non CO2directly related matters of the process, e.g. pre-heating or heat recovery
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft

Abstract

Described herein are embodiments of systems and methods for oxidizing gases. In some embodiments, a reaction chamber is configured to receive a fuel gas and maintain the gas at a temperature within the reaction chamber that is above an autoignition temperature of the gas. The reaction chamber may also be configured to maintain a reaction temperature within the reaction chamber below a flameout temperature. In some embodiments, heat and product gases from the oxidation process can be used, for example, to drive a turbine, reciprocating engine, and injected back into the reaction chamber.

Claims

1. A system for oxidizing fuel, comprising:

an oxidizer having a reaction chamber with an inlet and an outlet, the reaction chamber configured to receive a gas comprising an oxidizable fuel through the inlet and to maintain an oxidation process;

a detection module that detects when a reaction chamber temperature of the gas approaches or drops below an autoignition threshold of the gas within the reaction chamber, such that the reaction chamber will not oxidize the fuel and determines (i) an autoignition delay time and (ii) a lower flammability limit or an upper flammability limit of the gas, a flammability area being defined as a volumetric fuel concentration between the lower flammability limit and the upper flammability limit; and

a correction module that outputs instructions, based on the detection module, to change an autoignition delay time within the reaction chamber sufficient for the gas to autoignite and oxidize while within the reaction chamber and such that a flammability residence time of the gas within the flammability area is less than the autoignition delay time.

2. The system of claim 1, wherein the correction module is configured to change a chamber residence time of the gas within the reaction chamber by altering flow of the gas through the reaction chamber.

3. The system of claim 2, wherein the correction module is configured to increase the chamber residence time of the gas within the reaction chamber by decreasing flow of the gas through the reaction chamber.

4. The system of claim 2, wherein the correction module is configured to increase the chamber residence time of the gas within the reaction chamber by recirculating flow of the gas from the outlet to the inlet of the reaction chamber.

5. The system of claim 1, wherein the correction module is configured to change the autoignition delay time within the reaction chamber by changing a gas temperature within the reaction chamber.

6. The system of claim 5, wherein the correction module is configured to decrease the autoignition delay time within the reaction chamber by increasing a gas temperature within the reaction chamber with a heater.

7. The system of claim 5, wherein the correction module is configured to decrease the autoignition delay time within the reaction chamber by circulating product gas from the outlet to the inlet.

8. The system of claim 1, wherein the reaction chamber is configured to maintain oxidation of the oxidizable fuel beneath the flameout temperature without a catalyst.

9. The system of claim 1, further comprising a turbine or a piston engine that receives gas from the reaction chamber and expands the gas.

10. The system of claim 1, further comprising a compressor that receives and compresses gas, comprising a fuel mixture, prior to introduction of the fuel mixture into the reaction chamber.

11. The system of claim 1, wherein the oxidizable fuel comprises at least one of hydrogen, methane, ethane, ethylene, natural gas, propane, propylene, propadiene, n-butane, iso-butane, butylene-1, butadiene, iso-pentane, n-pentane, acetylene, hexane, and carbon monoxide.

12. The system of claim 1, wherein the flammability area is between an upper flammability limit and a lower flammability limit of the gas.

13. The system of claim 1, wherein the flammability residence time of the fuel within the flammability area is between about 30% and about 75% of the autoignition delay time.

14. A system for oxidizing fuel, comprising:

an oxidizer having a reaction chamber with an inlet and an outlet, the reaction chamber configured to receive a gas comprising an oxidizable fuel through the inlet and to maintain an oxidation process;

a detection module that detects when a reaction chamber temperature of the gas approaches or drops below an autoignition threshold of the gas within the reaction chamber, such that the reaction chamber will not oxidize the fuel and determines (i) an autoignition delay time and (ii) a lower flammability limit or an upper flammability limit of the gas, a flammability area being defined as a volumetric fuel concentration between the lower flammability limit and the upper flammability limit; and

a correction module that is configured to determine, with a processor and based on the detection module, a change to a chamber residence time of the gas within the reaction chamber sufficient for the gas to autoignite and oxidize while within the reaction chamber and such that a flammability residence time of the gas within the flammability area is less than an autoignition delay time;

wherein the oxidizer is configured to, based on the change to the chamber residence time, oxidize the gas while the gas is within the reaction chamber.

15. The system of claim 14, wherein the correction module is configured to change the chamber residence time of the gas within the reaction chamber by altering flow of the gas through the reaction chamber.

16. The system of claim 15, wherein the correction module is configured to increase the chamber residence time of the gas within the reaction chamber by decreasing flow of the gas through the reaction chamber.

17. The system of claim 15, wherein the correction module is configured to increase the chamber residence time of the gas within the reaction chamber by recirculating flow of the gas from the outlet to the inlet of the reaction chamber.

18. The system of claim 14, wherein the correction module is configured to change the autoignition delay time within the reaction chamber by changing a gas temperature within the reaction chamber.

19. The system of claim 14, wherein the correction module is configured to decrease the autoignition delay time within the reaction chamber by increasing a gas temperature within the reaction chamber with a heater.

20. The system of claim 14, wherein the correction module is configured to decrease the autoignition delay time within the reaction chamber by circulating product gas from the outlet to the inlet.

21. The system of claim 14, wherein the reaction chamber is configured to maintain oxidation of the oxidizable fuel beneath the flameout temperature without a catalyst.

22. The system of claim 14, wherein the flammability area is between an upper flammability limit and a lower flammability limit of the gas.

23. The system of claim 14, wherein the flammability residence time of the fuel within the flammability area is between about 30% and about 75% of the autoignition delay time.

24. A system for oxidizing fuel, comprising:

an oxidizer having a reaction chamber with an inlet and an outlet, the reaction chamber configured to receive a gas comprising an oxidizable fuel through the inlet and to maintain an oxidation process; and

a module that outputs instructions, based on detection of a reaction chamber temperature, to increase a reaction temperature within the reaction chamber, such that the fuel oxidizes while in the reaction chamber and such that a flammability residence time of the gas within the flammability area is less than the autoignition delay time.

25. The system of claim 24, wherein the module is configured to change a chamber residence time of the gas within the reaction chamber by altering flow of the gas through the reaction chamber.

26. The system of claim 25, wherein the module is configured to increase the chamber residence time of the gas within the reaction chamber by decreasing flow of the gas through the reaction chamber.

27. The system of claim 25, wherein the module is configured to increase the chamber residence time of the gas within the reaction chamber by recirculating flow of the gas from the outlet to the inlet of the reaction chamber.

28. The system of claim 24, wherein the module is configured to decrease the autoignition delay time within the reaction chamber by increasing a gas temperature within the reaction chamber with a heater.

29. The system of claim 24, wherein the module is configured to decrease the autoignition delay time within the reaction chamber by circulating product gas from the outlet to the inlet.

30. The system of claim 24, wherein the flammability area is between an upper flammability limit and a lower flammability limit of the gas.

31. The system of claim 24, wherein the flammability residence time of the fuel within the flammability area is between about 30% and about 75% of the autoignition delay time.