Gradual oxidation with heat control

• US 9,328,916 B2
• Filed: 03/09/2012
• Issued: 05/03/2016
• Est. Priority Date: 03/09/2012
• Status: Active Grant

• Current Assignee: ReductoNox Corp.
• Original Assignee: Ener-Core Power, Inc. (Ener-Core, Inc.)
• Inventors: Lampe, Steve, Hamrin, Douglas
• Primary Examiner(s): Sutherland, Steven
• Application Number:
  US13/417,105
• Publication Number:
  US 20130232944A1
• Time in Patent Office: 1,516 Days
• Field of Search: 60/391.82, 607/74, 607/22, 607/23, 607/33, 607/77, 60/395, 60/382.81, 607/91, 431/7, 431/268, 431/5, 431/2, 422/168, 422/173
• US Class Current: 1/1
• CPC Class Codes: F23C 2202/10 Premixing fluegas with fuel and combustion air
• CPC Class Codes: F23C 2900/99001 Cold flame combustion or flameless oxidation processes
• CPC Class Codes: F23C 9/08 for reducing temperature in combustion chamber, e.g. for protecting walls of combustion chamber
• 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 2206/203 with a power/heat generating installation
• CPC Class Codes: F23G 5/46 Recuperation of heat
• 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: F23M 2900/05004 Special materials for walls or lining
• CPC Class Codes: F23N 1/022 using electronic means
• CPC Class Codes: F23N 1/082 using electronic means
• 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: F23R 2900/00002 Gas turbine combustors adapted for fuels having low heating value [LHV]
• CPC Class Codes: Y02E 20/12 Heat utilisation in combustion or incineration of waste
• 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 method for oxidizing fuel, comprising:

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

directing the gas, received from the inlet, in a first direction through a first channel within the reaction chamber while oxidizing at least some of the gas in the first channel;

directing the gas, received from the first channel, in a second direction through a second channel within the reaction chamber while oxidizing at least some of the gas in the second channel;

directing the gas, received from the second channel, to the outlet; and

heating the gas in the first channel with heat transferred from the second channel through a membrane separating the first channel from the second channel, such that (i) a temperature of at least some of the gas in the first channel is maintained above an autoignition threshold of the fuel, and (ii) the reaction chamber maintains oxidation of the fuel within the reaction chamber without a catalyst;

wherein the gas has a first temperature at an inlet side of the first channel, a second temperature, greater than the first temperature, at an outlet side of the first channel, and a third temperature, less than the second temperature, at an inlet side of the second channel.

2. The method of claim 1, wherein the reaction chamber maintains oxidation of the oxidizable fuel beneath a flameout temperature of the fuel.

3. The method of claim 1, further comprising receiving the gas from the reaction chamber in a turbine or a piston engine and expanding the gas.

4. The method of claim 1, further comprising, prior to introduction of the gas into the reaction chamber, compressing the gas with a compressor.

5. The method 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.

6. The method of claim 1, wherein the second direction is counter to the first direction.

7. The method of claim 1, wherein the second channel is disposed on opposite sides of the first channel along a length of the first channel.

8. A method for oxidizing fuel, comprising:

receiving a gas comprising an oxidizable fuel into an oxidizer having a first reaction chamber with an inlet and an outlet, the first reaction chamber being configured to maintain an oxidation process of the fuel;

directing the gas, received from the inlet, in a first direction through first channels within the reaction chamber while oxidizing at least some of the gas in the first channels;

directing the gas, received from the first channels, in a second direction through second channels within the reaction chamber while oxidizing at least some of the gas in the second channels;

directing the gas, received from the second channels, to the outlet; and

heating the gas in the first channels with heat transferred from the second channels through membranes separating the first channels from the second channels, such that a temperature of at least some of the gas in the first channels is above an autoignition threshold of the fuel.

9. The method of claim 8, wherein the reaction chamber maintains oxidation of the fuel within the reaction chamber without a catalyst.

10. The method of claim 8, further comprising receiving the gas from the reaction chamber in a turbine or a piston engine and expanding the gas.

11. The method of claim 8, further comprising, prior to introduction of the gas into the reaction chamber, compressing the gas with a compressor.

12. The method of claim 8, 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.

13. The method of claim 8, wherein the gas has a first temperature at an inlet side of the first channels, a second temperature, greater than the first temperature, at an outlet side of the first channels, and a third temperature, less than the second temperature, at an inlet side of the second channels.

14. The method of claim 8, wherein the second direction is counter to the first direction.

15. The method of claim 8, wherein the second channels are disposed on opposite sides of a corresponding one of the first channels along a length of the corresponding one of the first channels.

16. The method of claim 8, wherein directing the gas, received from the second channels, comprises directing the gas through at least one third channel within the reaction chamber.

17. The method of claim 16, wherein directing the gas through the at least one third channel comprises directing the gas in the first direction, counter to the second direction.

18. The method of claim 16, wherein the at least one third channel is disposed on opposite sides of a corresponding one of the second channels along a length of the corresponding one of the second channels.

19. The method of claim 16, wherein the first channels extend through a first plate on an inlet side of the reaction chamber and the at least one third channel extends through a second plate on an outlet side of the reaction chamber.

20. A method for oxidizing fuel, comprising:

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

directing the gas, received from the inlet, in a first direction through a first channel within the reaction chamber while oxidizing at least some of the gas in the first channel;

directing the gas, received from the first channel, in a second direction through a second channel within the reaction chamber while oxidizing at least some of the gas in the second channel;

directing the gas, received from the second channel, to the outlet; and

heating the gas in the first channel with heat transferred from the second channel through a membrane separating the first channel from the second channel, such that (i) a temperature of at least some of the gas in the first channel is maintained above an autoignition threshold of the fuel, and (ii) the reaction chamber maintains oxidation of the fuel within the reaction chamber without a catalyst;

wherein directing the gas, received from the second channel, comprises directing the gas through a third channel within the reaction chamber;

wherein directing the gas through the third channel comprises directing the gas in the first direction, counter to the second direction.

21. The method of claim 20, further comprising receiving the gas from the reaction chamber in a turbine or a piston engine and expanding the gas.

22. The method of claim 20, further comprising, prior to introduction of the gas into the reaction chamber, compressing the gas with a compressor.

23. The method of claim 20, wherein the second channel is disposed on opposite sides of the first channel along a length of the first channel.

24. A method for oxidizing fuel, comprising:

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

directing the gas, received from the inlet, in a first direction through a first channel within the reaction chamber while oxidizing at least some of the gas in the first channel;

directing the gas, received from the first channel, in a second direction through a second channel within the reaction chamber while oxidizing at least some of the gas in the second channel;

directing the gas, received from the second channel, to the outlet; and

heating the gas in the first channel with heat transferred from the second channel through a membrane separating the first channel from the second channel, such that (i) a temperature of at least some of the gas in the first channel is maintained above an autoignition threshold of the fuel, and (ii) the reaction chamber maintains oxidation of the fuel within the reaction chamber without a catalyst;

wherein directing the gas, received from the second channel, comprises directing the gas through a third channel within the reaction chamber;

wherein the third channel is disposed on opposite sides of the second channel along a length of the second channel.

25. The method of claim 24, further comprising receiving the gas from the reaction chamber in a turbine or a piston engine and expanding the gas.

26. The method of claim 24, further comprising, prior to introduction of the gas into the reaction chamber, compressing the gas with a compressor.

27. The method of claim 24, wherein the second channel is disposed on opposite sides of the first channel along a length of the first channel.

28. A method for oxidizing fuel, comprising:

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

directing the gas, received from the inlet, in a first direction through a first channel within the reaction chamber while oxidizing at least some of the gas in the first channel;

directing the gas, received from the first channel, in a second direction through a second channel within the reaction chamber while oxidizing at least some of the gas in the second channel;

directing the gas, received from the second channel, to the outlet; and

heating the gas in the first channel with heat transferred from the second channel through a membrane separating the first channel from the second channel, such that (i) a temperature of at least some of the gas in the first channel is maintained above an autoignition threshold of the fuel, and (ii) the reaction chamber maintains oxidation of the fuel within the reaction chamber without a catalyst;

wherein directing the gas, received from the second channel, comprises directing the gas through a third channel within the reaction chamber;

wherein the first channel extends through a first plate on an inlet side of the reaction chamber and the third channel extends through a second plate on an outlet side of the reaction chamber.

29. The method of claim 28, further comprising receiving the gas from the reaction chamber in a turbine or a piston engine and expanding the gas.

30. The method of claim 28, further comprising, prior to introduction of the gas into the reaction chamber, compressing the gas with a compressor.

31. The method of claim 28, wherein the second channel is disposed on opposite sides of the first channel along a length of the first channel.