COMBUSTION ENGINE

TECHNICAL FIELD

The subject matter described herein, in general, relates to method and device and system for filtering flue gases. More particularly, the invention relates to a method and device and system for filtering flue gases released from the exhaust system of various combustion systems.

BACKGROUND

Particulate matters and hydrocarbon are the most hazardous, volatile organic compounds having very toxic properties. Particulate matters are having negative effects on the environment and human health. Diesel particulate matters are most harmful and toxic and cause of probable human carcinogenic in nature. Most of the Particulate matters are invisible to human eyes so they can also be called as‘Invisible killers’.

Premature death, lung cancer, exacerbation of COPD, development of chronic lung disease, heart attacks, hospital admissions and ER visits for heart and lung disease, respiratory symptoms and medication use in people with chronic lung disease and asthma, decreased lung function, pre-term birth, low birth weight, etc. These are the already known health-related issues due to particulate matters. The severity of particulate matter is very high and adversely affecting not only on the health of human beings but also on the animals. Particulate matter (PM) describes a wide variety of airborne material. PM pollution consists of materials (including dust, smoke, and soot), that are directly emitted into the air or result from the transformation of gaseous pollutants. Most harmful particles come from human activities of burning fossil fuels. Sources may emit PM directly into the environment or emit precursors such as Nitrogen dioxide (NOx), carbon dioxide (C0 ₂ ), sulfur dioxide (S02), carbon monoxide (CO), volatile organic compounds (VOCs), Particulate matters (PM) and hydrocarbon(HC), etc.

Particulate matters get mixed with the environment after the emission of exhaust gases after fossil fuel combustion. It will enter the human body through breathing. The nose and throat remove PM (> 10 pm), Trachea and Upper Bronchi remove coarse PM (< 10 pm and > 2.5 pm), fine PM (< 2.5 pm and >0.1 pm) are deposited in Bronchioles and Alveoli, Ultrafme PM (<0.1 pm) reach all areas of lung and to some degree diffuse into body tissues. These Particulate matters are harmful and toxic in nature so it causes adverse health effects on human. We can observe the main fact here; all human and animal bodies eventually absorb these harmful particulate matters from the environment through breathing.

To reduce, emission control for the pollutants such as particulate matter and hydrocarbon from exhaust flue gases of the internal combustion engines have the technical issues facing the automotive industry and causes a major headache for all environmental protection agencies to defend the global environment for next improved and towards the safe level. For an internal combustion engine, some forms of exhaust gas after-treatment processes are necessary for removing maximum level pollutants to protect the environment. For existing exhaust system, particulate filters and regeneration processes had been implemented to control the emission of particulate matter from the exhaust flue gases. These are working very well in the direction to protect the environment, but the filters for particulates are having some technical limitations for further improvements, for implementing very fine filtering and to collect the very small sized, ultrafine sized particulate matter. The finer filter means more frequently clogging of the particulate filter causes frequent exhaust flue gases back pressure and adversely affects the fuel economy and vehicle performance. So these filters are having further technical constraints to remove the very small sized, ultrafine and fine particulate matters at a further improved, safe expected level of the environment. Regeneration processes had been established very well in the existing exhaust system to remove clogged particulates by burning processes, increasing flue gases temperatures.

It has been seen from the last few years that the particulate filter technology is also having the constraint to remove very small sizes of particulate matter. Therefore no major improvement has been observed in the existing filter technology concerning the removal of nanoscale size, very small sized, fine and ultrafine particulate matters. Also, this can be the benchmark by studying regulatory emission standards. Referring to, the Bharat Stage V (euro 5) and Bharat Stage VI (euro 6) emission regulatory standards. It is observed that no major improvements had been incorporated there, regarding PM emission reduction, because of constraints, limitations in existing technology. So it is needed on a priority basis to invent and develop a new technology to achieve the improved results for safety environment. Hence some forms of exhaust gas after-treatment processes will be necessary, to remove the remaining most hazardous, harmful and invisible toxic fine and ultrafine particulate matters and hydrocarbons, from the exhaust gases of Internal Combustion engine and other fossil fuel combustion system.

Existing particulate filters and regeneration processes are having technical limitation to filter, trap and remove ultrafme and fine particulate matters. Breathing in the pollution free environment is one of the basic need and rights of every human life similar to, pure food and pure water. Accordingly, healthy breathing is very important for every human being. Intake food and water can be controlled easily, however, it is very difficult to control the breathing of air, so it is very essential to create a safe and healthy environment around each of us. With this basic intention first, we have to remove unsafe and harmful emission pollutants to a maximum and towards safe level.

An emission regulation helps to protect the environment as well, simultaneously it is necessary to see the severity of these pollutants (PM), along with the realization and adverse effect of particulate matters on, the environment and every human life. Several inventions had been established in this direction for exhaust gas after treatment systems, to filter the particulate matter from exhaust gases of internal combustion engines such as Diesel Particulate Filter, Gasoline Particulate Filter, Regeneration process, etc.

Though the technology of Particulate filters and Regeneration had been increased from last few years as of now they are doing well, but because of all are bounded by some technical limitations, constraints to remove very small sized, ultrafme particulate matters from the exhaust gases. Hence existing technology is needed to improve for removing the maximum emission of ultrafme and fine particulate matter.

Existing particulate filter has technical limitation in the areas of filtration and constraints to minimize and optimize the filter size to remove very small particulate matter; otherwise, frequently exhaust flue gases will apply frequent back pressure on the engine, after frequent clogging the pores of filters, causes reduced engine performance and fuel efficiency Or increases the frequency of regeneration process causes more fuel consumption, lowering the fuel efficiency.

To get relief from frequent clogging the pores of filters, the existing regeneration process had been incorporated to burn the trapped, clogged particulate matter at high temperature still, then also the ash; soot will get gathered inside the particulate filter. Either ash, soot will block the filter to some extent or it will exit from the exhaust system and get mixed with the environment. The clogging of filter causes increased filter maintenance and reduced vehicle performance too. Existing particulate filters are very useful a lot but it has above technical constraint to remove the ultrafme and very small sized particulate matters at the maximum level from the exhaust flue gases. So it is necessary to develop a new method and technology which will filter at the maximum level the very small sized, ultrafme and fine particulate matter to protect the environment.

Therefore, there is a need to have method and device and system to remove these hazardous pollutants from exhaust gases, by the efficient way at the fine level. Particulate extraction, filtering device, method and system implementation in combination with existing exhaust system is sufficient enough to ensure the removal of harmful pollutants; all sizes of particulate matters to a maximum and improved safety level.

SUMMARY

The main object of the invention to provide a method and a device and a system for filtering flue gases to extract, separate and remove the harmful, hazardous and toxic coarse, fine and ultraf e particulate matters (PM) from the exhaust flue gases. Preferably from an internal combustion engine and from other fossil fuel combustion systems.

Another object of the invention to protect the environmental values and human health by reduction of the maximum possible harmful pollutants, particulate matter from the exhaust flue gases.

Another object of the invention to minimize other pollutants from exhaust flue gases such as carbon dioxide (C0 ₂ ), carbon monoxide (CO), nitrogen dioxide (NOx), hydrocarbons (HC), sulfur dioxide (S02), etc. from exhaust flue gases of internal combustion engine and other fossil fuel combustion systems.

Another object of the invention to increase the fuel efficiency of the vehicle and combustion system. The invention doesn't require regeneration process by eliminating the regeneration process from exhaust system the fuel efficiency shall be increased for IC engine system and fossil fuel combustion system. The present subject matter relates to a method for filtering flue gases, the method comprising the steps of receiving flue gases in a homogenous mixing chamber through an inlet pipe having a pre-determ ined path, receiving a liquid in the homogenous mixing chamber from a liquid source, mixing said flue gases with the liquid to obtain a homogenous mixture of the flue gases and the liquid, passing the homogenous mixture through a separation chamber to separate the flue gases from the homogenous mixture and expelling the treated flue gases and contaminated excess liquid accumulated in the separation chamber through a first outlet and a second outlet respectively.

In an embodiment of the present invention, the present invention relates to a device for filtering flue gases, the device comprising an inlet pipe having a pre-determined path to guide the flue gases inside a homogenous mixing chamber, a means to direct a liquid inside the homogenous mixing chamber from a liquid source, the liquid is mixed with the flue gases to form a homogeneous mixture, a separation chamber configured to receive the homogenous mixture to separate the flue gases from the homogenous mixture and to expel the treated flue gases and contaminated excess liquid accumulated in the separation chamber through a first outlet and a second outlet respectively.

In an embodiment of the present invention, the present invention relates to a system for filtering flue gases, the system comprising an exhaust system, a particulate filter disposed in the exhaust system, the particulate filter, a filtering device is adapted to receive flue gases from the exhaust system, a liquid filtration cum storage system fluidly connected to the particulate filter, the liquid filtration cum storage system is adapted to supply a liquid to the particulate filter and to collect contaminated liquid from the particulate filter to enable filtration of the flue gasses by the particulate filter, a catalytic converter system adapted to receive treated flue gases from the first outlet of the device, said catalyst converter system is configured to reduce emissions HC, NOx, and CO at a next fine level.

In another embodiment, the method comprises the step of spraying the liquid received in the homogenous mixing chamber on the flue gases to form the homogenous mixture.

In another embodiment, the method comprises the step of passing the homogenous mixture through a perforated structure disposed of in the separation chamber for atomizing the flue gases and forming a finer homogenous mixture of the flue gases and the liquid accumulated in the separation chamber. In another embodiment, the method the step of separating the flue gases from the liquid surface surrounding the liquid-submerged perforated structure and achieving filtration of the flue gases.

In another embodiment, the method comprises the step of further separating of the flue gases from liquid droplets by passing the flue gasses through a gas permeable and liquid impermeable membrane before expelling the treated flue gases and excess contaminated liquid from the separation chamber.

In another embodiment, the method comprises the step of expelling the contaminated excess liquid accumulated in the separation chamber to a liquid source through the second outlet. In another embodiment, the method comprises the step of expelling the treated flue gases from the separation chamber through the first outlet and directing the treated flue gases to a catalytic converter system.

In yet another embodiment, the liquid received in the homogenous mixing chamber is sprayed on the flue gases to form the homogenous mixture.

In yet another embodiment, the homogenous mixture is passed through a perforated structure disposed of in the separation chamber, said the perforated structure is adapted to atomize the flue gases and to form a finer homogenous mixture of the flue gases and previously sprayed liquid and liquid accumulated in the separation chamber. In yet another embodiment, the perforated structure is adapted to separate the flue gases from the liquid surface surrounding the liquid-submerged perforated structure and to achieve filtration of the flue gases.

In yet another embodiment, the treated flue gases are further separated from the liquid droplets by passing through a gas permeable and liquid impermeable membrane before expelling said flue gases and excess contaminated liquid are expelled from the separation chamber.

In yet another embodiment, the contaminated excess fluid accumulated in the separation chamber is expelled to the liquid source through the second outlet. In yet another embodiment, the liquid source is a liquid filtration cum storage system.

In yet another embodiment, in the liquid filtration cum storage system the liquid filtration device and liquid storage devices may be in combined or separate form. In yet another embodiment, the treated flue gases exit the separation chamber through the first outlet and the treated flue gases are directed to a catalytic converter system.

In yet another embodiment, the flue gases are released from combustion systems or internal combustion engines running on fossil fuels.

In yet another embodiment, the liquid has a tendency to attract the lightweight solid particulates, particulate matters present in, suspended inside the flue gases, then particulate matters get to adhere with liquid, by this principle method, device and system achieve the filtration of flue gases.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS

The foregoing and further objects, features, and advantages of the present subject matter will become apparent from the following description of exemplary embodiments with reference to the accompanying drawings, wherein like numerals are used to represent like elements.

It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter, and are, therefore, not to be considered for limiting of its scope, for the subject matter may admit to other equally effective embodiments.

Figure 1 illustrates a diagram to show a front view of a device for filtering flue gases in accordance with an embodiment of the present subject matter.

Figure 1(a) illustrates a diagram to show a side view of a device illustrated in figure 1 for filtering flue gases in accordance with an embodiment of the present subject matter.

Figure 2 illustrates a diagram to show the process for filtering flue gases in accordance with an embodiment of the present subject matter.

Figure 3 illustrates a diagram to show another preferred design of a device for filtering flue gases in accordance with an embodiment of the present subject matter.

Figure 4 illustrates a diagram to show another preferred design of a device for filtering flue gases in accordance with an embodiment of the present subject matter.

Figure 5 illustrates a diagram to show another preferred design of a device for filtering flue gases in accordance with an embodiment of the present subject matter.

Figure 6 illustrates a diagram to show another preferred design of a device for filtering flue gases in accordance with an embodiment of the present subject matter. Figure 7 illustrates a diagram to show another preferred design of a device for filtering flue gases in accordance with an embodiment of the present subject matter.

Figure 8 illustrates a diagram to show another preferred design of a device for filtering flue gases in accordance with an embodiment of the present subject matter.

Figure 9 illustrates a diagram to show another preferred design of a device for filtering flue gases in accordance with an embodiment of the present subject matter. Figure 10 illustrates a diagram to show another preferred design of a device for filtering flue gases in accordance with an embodiment of the present subject matter.

Figure 11 illustrates a diagram to show another preferred design of a device for filtering flue gases in accordance with an embodiment of the present subject matter.

DETAILED DESCRIPTION The embodiments of the present subject matter are described in detail with reference to the accompanying drawings. However, the present subject matter is not limited to these embodiments which are only provided to explain more clearly the present subject matter to the ordinarily skilled in the art of the present disclosure. In the accompanying drawings, like reference numerals are used to indicate like components.

This invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or“having,”“containing,”“involving,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.

The present invention provides a device and a method and a system which is capable to control the emission and remove the harmful particulate matters (i.e. all sizes coarse, fine, and ultraf e) from the exhaust flue gases of the internal combustion engine and fossil fuel combustion system at the improved level. The method, the device, and the system can be implemented in-line with any suitable existing exhaust system. Particulate matter filtering device has been effectively incorporated at anywhere in the exhaust system but, preferably in the exhaust system after the 1C engine and any fossil fuel combustion system. The particulate filtering device will be used in replacement of the existed exhaust gas after treatment process devices like DPF / GPF Or after the DPF / GPF to remove the remaining pollutant particulate matters for any Internal Combustion engine and for any other fossil fuel combustion system. This device, method, and system are supportive eco-friendly to reduce and control the harmful and invisible toxic pollutants such as particulate matters before mixing it, into the environment. Hence it helps to protect environmental values.

The subject matter described herein relates to a method and device and system for filtering flue gases released from the exhaust system of various combustion systems. Figure 1 shows the device 100 for filtering flue gases. The flue gases 110 are generated by an internal combustion engine or any combustion system running on fossil fuels.

The flue gases get entered through the inlet pipe 101 which is preferably attached to the exhaust of the internal combustion engine or combustion system running on fossil fuels. The flue gases then enter to a homogenous mixing chamber 102 wherein the flue gases 110 get mixes with the liquid. The liquid is received in the homogenous mixing chamber 102 preferably through an external system configured to store the liquid. The liquid preferably but not limited should have these properties. The liquid should have a higher boiling point, should be nonflammable, should be chemically inert and stable, should be thermally inert and stable, should be nontoxic in nature, and liquid may be water soluble/natural or synthetic oil / natural or synthetic fluid / natural or synthetic liquid, should have stable cohesive properties, should have stable adhesive properties.

The liquid is sprayed 106 inside the homogenous mixing chamber 102 wherein the liquid and the generated flue gases mix to form a homogenous mixture of flue gases and the liquid.

The homogenous mixture of flue gases and liquid is then passed through the second chamber i.e. separation chamber wherein the separation chamber filters the flue gases from the mixture. The separation chamber may comprise a perforation structure 103.

The perforation structure 103 atomizes the flue gases 110 and accumulated liquid 125 for further formation of a fine homogenous mixture of the flue gases and the liquid. Suitably, the membrane/material 104 preferably but not limited should have these properties. The membrane/material should have properties such as higher corrosion resistance, higher melting point, chemically inert and stable, should be thermally inert and stable, nonflammable, nontoxic in nature, natural or synthetic base and a super fine / fine ceramic structure with a porous material of gas permeable and liquid impermeable properties Gases permeable and liquids impermeable membrane/ material properties may vary the properties from application to application and according to sizes and shapes of devices. The homogeneous and efficient mixing of exhaust gases with the suitable liquid in a perforated structure 103 inside the device, before the exit of exhaust gases to the environment. (Liquid attraction and liquid adhesion are efficiently used here to extract, separate and remove the suspended particulate matters from the exhaust flue gases by the technical way). The permeable membrane 104 also does not allow the passing of the droplets of the liquid through it to make it moisture free. After treating the flue gases the treated flue gases through respective outlets. The contaminated liquid expelled from the first outlet 115 and treated flue gases from the second outlet 107.

After filtration, extraction of particulate matters from the exhaust gases, the liquid will be in a contaminated form so that recirculation of the same liquid can be possible in the system after contaminated liquid 109 filtration process to increase the performance of the system.

Preferably, the temperature of the contaminated liquid 109 may be minimized by implementing any standard cooling system, if required as per system requirement. Then recirculation of liquid towards particulate matter extraction, filtering device will take place. This will help to enhance the performance of the total system. The device can be used with any existing exhaust system to remove the remaining particulate matters and hydrocarbon from exhaust flue gases for the internal combustion engine and other fossil fuel combustion system.

An optional requirement or an arrangement may be incorporated to the device wherein liquid stream-brush to and fro mechanism such as liquid stream brush 117 to clean the surface of any suitable system, mechanism as per device requirements. The brush may vary and depends on dimensional features, device size, and shape in various applications. The liquid flows in through flexible pipe and with support rollers on both sides on which wire rope moves to and fro for liquid stream brush. Liquid stream-brush to and fro mechanism may consist of any suitable arrangement to suit the application and requirement

Figure 2 shows a flow chart of the system to filter flue gases IC engine/fossil fuel combustion system 112. The flues gases generated by internal combustion engines are received by the device which filters the flue gases which has a very less PM suspended exhaust flue gases as output. Preferably, the catalytic converter system 111 is attached to an exhaust system wherein very fine exhaust gas (a very less PM contaminated exhaust gases) are the inputs to SCR (Selective Catalytic Reduction), the catalytic converter system 111. Hence it increases the reaction rate in the catalytic converter system 111, because of reduced obstacles of particulate matters, which causes increases the efficiency and performance of catalytic converter system 1 1 1 to reduce more HC, NOx, CO emissions to next super fine level. A catalytic converter system 1 1 1 adapted to receive treated flue gases from the first outlet of the particulate filtering device, said catalyst converter system is configured to reduce emissions HC, NOx and CO at a next fine level.

Also, a liquid filtration cum storage system 113 fluidly connected to the particulate filter, the liquid filtration cum storage system is adapted to supply liquid to the particulate filter to enable filtration of the flue gasses by the particulate filter 100. In a way, the liquid filtration cum storage system is adapted to supply liquid to the particulate filter and to recollect contaminated liquid from the particulate filter. The liquid filtration cum storage system has its some other special units /subsystem which is attached externally with it. Also, the total exhaust system is at the bottom side of the vehicle but the liquid filtration cum storage system 113 can be located at the upper side of the vehicle, at any convenient position, causing easy accessible to maintenance point of view for 113 without affecting the functional quality.

Figure 3 to Figure 11 - shows the preferred embodiments of the device as discussed in figure 1 . The device as discussed is made compact by introducing the separating chamber and homogenous mixing chamber in a single compartment, compact. However, the flow of the flue gases and filtration process is the same as the device discussed in figure 1. The figure shows various modifications in the design of the device 100. Mainly the design of the device can be varied in accordance with an application of the device and required performance of the device. Likewise, the perforation structure may be changed and the shape and diameter of the perforations may decrease and increase on the basis of the requirement.

For example, likely in figure 3 multiple liquid spraying arrangement provided after perforated structure this arrangement enables the flue gases get mixed with liquid after releases from the perforated structure.

Likely in figure 4, the device by different perforated structure liquid spraying feature is not required here. Preferred for light duty application. Like in figure 5, the perforations to be changed to the maximum level and liquid spraying may be provided at perforated structure instead of the homogenous mixing chamber. It will help to achieve maximum filtration of the flue gases and heavy duty application. Like in figure 6, by changing the inlet pipe of flue gases in angular and conical form. The perforation structure is different to achieve fine performance. Single spraying of liquid is provided. Preferred for light and medium duty applications. Also in figure 7 and 8, by changing the inlet pipe of flue gases in angular and conical form. The perforation structure is different to achieve fine performance. Multiple spraying of liquid in open area is provided for getting better homogeneous mixing of flue gases after flue gases pass through perforated structure and before getting passes from the gas preamble and liquid impermeable membrane. Preferred for light and medium duty applications. In figure 8, by changing the inlet pipe of flue gases in angular and conical form. The perforation structure is different to achieve fine performance. Multiple spraying of liquid in an enclosed area is provided for getting a better homogeneous mixture. Preferred for light and medium duty applications. Figure 9 shows an intermediate perforation structure which is a very simple construction device. Figure 10, a larger perforation structure with longer, higher and angular inlet pipe construction device. Figure 11, shows a compact size of the device by a change in design features for low space application.

These devices may be used for all fossil fuel 1C engine/automobile vehicles exhaust systems such as fossil fuel, diesel pumps & generators for the exhaust system, for diesel, fossil fuel trains, ships, for all fossil fuel combustion systems i.e. industrial boilers, Industrial furnaces, etc.

Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It is, therefore, contemplated that such modifications, improvements can be made without departing from the spirit or scope of the present invention as defined.