Systems and methods for heating water using biofuel

• US 9,568,214 B2
• Filed: 08/25/2015
• Issued: 02/14/2017
• Est. Priority Date: 08/06/2010
• Status: Expired due to Fees

• Current Assignee: Greenwood Clean Energy, Inc.
• Original Assignee: Greenwood Clean Energy, Inc.
• Inventors: Sharpe, David S., Kuehner, Michael R., Denton, Douglas S., Louviere, Bryan J.
• Primary Examiner(s): Huson, Gregory
• Assistant Examiner(s): Mashruwala, Nikhil
• Application Number:
  US14/835,563
• Publication Number:
  US 20150362216A1
• Time in Patent Office: 539 Days
• Field of Search: 126/58, 126/112, 126/73, 110/204, 110/210, 110/214, 110/297, 431/10, 431/12
• US Class Current: 1/1
• CPC Class Codes: F23G 2207/30 Oxidant supply
• CPC Class Codes: F23G 2209/26 Biowaste
• CPC Class Codes: F23G 5/50 Control or safety arrangements
• CPC Class Codes: F24B 1/1881 the heat exchange medium being either water or air
• CPC Class Codes: F24B 13/004 Doors specially adapted for stoves or ranges doors for open fires F24B1/192
• CPC Class Codes: F24H 1/0027 using fluid fuel
• CPC Class Codes: F24H 1/08 Packaged or self-contained boilers, i.e. water heaters with control devices and pump in a single unit
• CPC Class Codes: F24H 15/174 Supplying heated water with desired temperature or desired range of temperature
• CPC Class Codes: F24H 15/20 characterised by control inputs
• CPC Class Codes: F24H 15/212 Temperature of the water
• CPC Class Codes: F24H 15/235 Temperature of exhaust gases
• CPC Class Codes: F24H 15/242 Pressure
• CPC Class Codes: F24H 15/33 Control of dampers
• CPC Class Codes: F24H 15/35 Control of the speed of fans
• CPC Class Codes: F24H 15/355 Control of heat-generating means in heaters
• CPC Class Codes: F24H 15/395 Information to users, e.g. alarms
• CPC Class Codes: F24H 9/2035 using fluid fuel

Abstract

The present invention may be embodied as a biofuel heating system comprising a controller for operating a fan based on a load operating parameter such that air flows along a flow path extending through a combustion chamber, through a burn-out port, through a burn-out chamber, through a heat exchange port, through a heat exchange chamber, and out of an exhaust port. A heat exchange system transfers heat energy from air flowing through the heat exchange chamber to a working fluid. The controller operates in a char mode based at least in part on the load operating parameter, and the biofuel remains within the combustion zone during the char mode.

Claims

1. A biofuel heating system for converting biofuel to heat energy to be delivered to a working fluid for transferring heat to a load formed by at least one of a domestic hot water system and a domestic space heating system, comprising:

a combustion chamber;

a burn-out chamber;

a burn-out port arranged to allow fluid to flow out of the combustion chamber and into the burn-out chamber;

a heat exchange chamber;

a heat exchange port arranged to allow fluid to flow out of the burn-out chamber and into the heat exchange chamber;

an exhaust port arranged to allow fluid to flow out of the heat exchange chamber;

a heat exchange system arranged at least partly within the heat exchange chamber, where the working fluid is circulated between the heat exchange system and the load;

a fan arranged to cause fluid to flow out of the heat exchange chamber through the exhaust port;

at least one load sensor configured to sense a load operating parameter corresponding to a working fluid temperature of the working fluid after the working fluid returns from the load to the heat exchange system; and

a controller for operating the fan based on the load operating parameter such that air flows along a flow path extending through the combustion chamber, through the burn-out port, through the burn-out chamber, through the heat exchange port, through the heat exchange chamber, and out of the exhaust port;

an under-fire damper; and

an over-fire damper;

whereby

the heat exchange system transfers heat energy from air flowing through the heat exchange chamber to the working fluid;

the controller operates in a char mode based at least in part on the load operating parameter, where

the biofuel remains within the combustion zone during the char mode, and

when the controller operates in the char mode, the controller varies an under-fire damper state of the under-fire damper and varies an over-fire damper state of the over-fire damper.

2. A biofuel heating system as recited in claim 1, further comprising a plurality of system sensors configured to sense at least one system operating parameter, where the controller further operates at least one of the fan, the under-fire damper, and the over-fire damper based on the at least one system operating parameter.

3. A biofuel heating system as recited in claim 2, comprising:

a first temperature sensor for detecting a combustion chamber temperature within the combustion chamber; and

a second temperature sensor for detecting a burn-out chamber temperature within the burn-out chamber;

wherein

the controller operates at least one of the fan, the under-fire damper, and the over-fire damper in a pre-char mode and in the char mode based on the combustion chamber temperature and the burn-out chamber temperature.

4. A biofuel heating system as recited in claim 2, comprising:

a first temperature sensor for detecting a combustion chamber temperature within the combustion chamber;

a second temperature sensor for detecting a burn-out chamber temperature within the burn-out chamber; and

a third temperature sensor for detecting an exhaust chamber temperature within the exhaust chamber;

wherein

the controller operates at least one of the fan, the under-fire damper, and the over-fire damper based on the combustion chamber temperature, the burn-out chamber temperature, and the exhaust chamber temperature.

5. A biofuel heating system as recited in claim 2, in which the at least one load sensor comprises a temperature sensor for detecting the working fluid temperature of the working fluid circulating between the heat exchange system and the load, where the controller operates at least one of the fan, the under-fire damper, and the over-fire damper based on the combustion chamber temperature, the burn-out chamber temperature, the exhaust chamber temperature, and the working fluid temperature.

6. A biofuel heating system as recited in claim 2, in which the controller further operates at least one of the fan, the under-fire damper, and the over-fire damper based on a set point temperature.

7. A biofuel heating system as recited in claim 1, in which the heat exchange system comprises a heat exchanger, a circulation system, and a conditioning system, where the conditioning system is operatively connected between the heat exchanger and the load.

8. A biofuel heating system as recited in claim 2, further comprising at least one external relay adapted to be electrically connected to the load, where the controller further operates the at least one load relay to alter a state of the load based on the at least one system operating parameter.

9. A biofuel heating system as recited in claim 1, in which

the controller further operates in a pre-char mode, where, when the controller operates in the pre-char mode, the controller varies an under-fire damper state of the under-fire damper.

10. A biofuel heating system as recited in claim 1, in which the controller further operates in a cold start mode to reduce the time required to achieve a set point temperature when the temperature within the combustion chamber is below a predetermined start threshold value.

11. A biofuel heating system as recited in claim 1, in which the controller further operates in a hot start mode to reduce the time required to achieve a set point temperature while maintaining a clean burn.

12. A biofuel heating system as recited in claim 1, in which the controller further operates in a fuel out mode to extend the burn life of biofuel remaining in the combustion zone.

13. A biofuel heating system as recited in claim 1, in which the controller further operates in a load mode to configure the biofuel heating system to receive a fresh load of biofuel.

14. A biofuel heating system as recited in claim 1, in which the controller further operates in a door open mode to prevent smoke within the combustion chamber from being drawn out of the furnace assembly when a door assembly of the biofuel heating system is opened.