WITH STEAM INJECTION CROSS-REFERENCE TO RELATED APPLICATION This application claims benefit under 35 U.S.C. § 119(e) to U.S. Provision Patent Application Ser. Nr. 61/395,256, filed on 05/11/2010 which is incorporated in its entirety by reference herein and in the name of the present inventor.

FIELD OF THE INVENTION

This invention relates in general to new and improved devices used for reducing air pollution but more particularly pertains to a little known staged combustion apparatus, respectively, which when installed onto a pollution source, such as onto an existing smokestack, any type of exhaust vent including engine exhausts, or the like, provides reduction and/or complete combustion of harmful emissions generated there from. Such emissions including but not limited too compounds such as oxides of nitrogen, hydrocarbons, carbon monoxide, odors, organic and inorganic particulates. The combustion apparatus is of very simple construction as it is basically formed from one elongated tube having six internal compartments that are partitioned by baffle plates therein and which when combined with heating provide the unusual end results. The apparatus is extremely energy efficient, is maintenance free, respectively and it does not require any moving parts.

BACKGROUND OF THE INVENTION

The present invention is functional for use in numerous fields of choice. Including any application wherein liquid and/or gaseous fuel is utilized to convert the liquid and/or gaseous fuel into useful energy derived from heat. Some examples include exhaust re- burner apparatuses which burn the exhaust from engines and recover the hydro carbons energy normally exhausted into the atmosphere. The apparatus will function with only the excess fuel and air from the pollution source. Any and all known pollution prevention methods and/or Co-generation apparatuses, of which use the exhaust of a diesel engine to burn and produce heat and convert the heat into steam for generating electricity. This invention is also functional as a quiet steam power generator that is cleaner, more functional and much more economically feasible. The present invention is further applicable for use within the home heating field. The current way of heating a house is inefficient. The process is to spray diesel fuel into a cavity, ignite it and then use some type of heat transfer apparatus to force hot fresh air through the house. The spraying of fuel into a cavity is a notoriously unproductive way of extracting heat from the fuel. Up to 50% of the fuel or more can be wasted and go up the chimney as un- burnt hydrocarbons and soot. Furthermore, hot water heaters, house and industrial heating of water is about the same as the home heating apparatus and just as inefficient. Spraying the diesel type fuel into a cavity around where tubing is positioned to soak up the heat. The heat is then transferred to the water. As in home heating the waste energy in the form of heat, soot, and un-burnt hydrocarbons are all exhausted up the chimney of the water heater apparatus. Other applications of use for the present invention are numerous and the noted applications are only exemplary of some possible fields of use.

This invention has been derived from building and testing numerous Thermal Oxidizer and heat reactors over the past several years. Originally conceived and tested to mitigate all types of pollution exhausts in the form of carbon monoxide, carbon dioxide Nitrous Oxides (NOx) and Volatile Organic Compounds (VOC's). It has now proven to be an excellent source of uncontaminated high temperature combustion to take apart and destroy pollution molecules that are exhausted through smoke stacks, exhaust vents and the like. The same basic design has now proven to be an energy efficient and economical way to eliminate pollutants from home and commercial heating applications.

Reducing air pollution, particularly emissions from heating devices and engines, harmful fuel odors and particulates has become a strong environmental objective both in the United States and around the world. Because of worldwide tightening of pollution emission standards, inventors have continually tried to invent devices and methods that will meet these increasingly stringent standards. This device does the job very simply with no moving parts, which is most advantageous and cost effective.

There remains a continuous need for a device that can always eliminate virtually all compounds such as, hydrocarbons, carbon monoxide, odors and organic and inorganic particulates from pollution exhausted from a pollution source such as a household chimney, smokestack, or any type of exhaust vent and still be energy efficient and significantly reduce oxides of nitrogen and Carbon Monoxide (CO ₂ ).

SUMMARY OF THE INVENTION

It is therefore a primary object of the present invention to provide a recuperated combustion apparatus having six sequential chambers of varying sizes and lengths which function in combination as a staged combustion apparatus to reduce pollution via fuel staging, air staging, and selective noncatalytic reduction that are techniques for reducing the associated pollutions in a combustion apparatus. The following is a general explanation as to function for the apparatus. Namely, between each of the six combustion chambers is a stationary bladed baffle plate that causes a vortex to be generated within each chamber. This vortex is the same type of a vortex that is found in nature in the form of tornadoes on land and water spouts over water. As the gases flow between each of the combustion chambers, the stationary vortex generating blades of the baffle plate cause a vortex to be generated in each chamber. The faster the gases in the combustion chamber rotate the tighter the vortex tube. This action makes for total and complete mixing of all the gases as the gases go through each of the six combustion chambers and reduces combustion instability.

Each one of the six sequential combustion chambers has a distinct process to perform in overall sequence in the Staged Combustion Apparatus. The sequential combustion chambers will cause the gases in the chamber apparatus to go from a fuel rich environment to a stoichiometric condition (Correct Air/fuel ratio) and then on to a fuel-lean or excess air condition that warrants complete combustion in the last two chambers (chambers ch-5 and ch-6). Accordingly there are three zones in the apparatus, namely a primary combustion zone, a re-burn zone and burnout zone. The function and the zones are more fully described within the detailed description of the drawings.

Another important object of the present invention is to provide a recuperated combustion apparatus that is versatile and is functional for use with any type of liquid or gaseous fuel of choice.

Yet another object of the present invention is to provide a recuperated combustion apparatus that is functional for reduction of any type of pollution exhausted from any environmentally unfriendly source. Such as but not limited to, incinerators, land-fills, internal combustion engines, or any other type of an exhaust that needs to have the pollutants eliminated there from.

It is therefore an object of the present invention to provide a recuperated combustion apparatus that overcomes the drawbacks and disadvantages associated within the known prior art. The present invention is generally 50% more efficient than current external combustion methods as the heat generated by the apparatus consumes all hydrocarbons and/or anything with caloric value. Furthermore, the present invention has been simplified and accomplishes unusual results heretofore not achieved. The apparatus itself includes an elongated tube that is internally partitioned forming interconnected multiple compartments that are individually partitioned by baffle plates having stationary vortex generating blades for controlling velocity and swirling of the gases.

Another object of the present invention is to provide a pollution combustion apparatus that requires little or no maintenance resultant from no moving parts in all of the combustion apparatus.

Still another object of the present invention is to provide a pollution combustion apparatus that can be easily manufactured, is extremely cost effective, very efficient and marketable.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic overview depicting the general components and construction for the preferred embodiment of the present combustion apparatus assembly.

FIG. 2 is a side view depicting shape for the preferred embodiment for each of the baffle plates associated with the apparatus.

FIG. 3 is a top view depicting shape for the preferred embodiment for each of the baffle plates associated with the apparatus.

FIG. 4 is a top view depicting a different shape for each of the baffle plates. FIG. 5 is a top view depicting a different shape for each of the baffle plates. DETAILED DESCRIPTION OF THE DRAWINGS

Referring now in detail to the drawings wherein like characters refer to like elements therein. As depicted in figure 1 , the present invention is a recuperated combustion apparatus assembly (10) and the new, novel and unique qualities of the present invention are achieved because of the shape, size, internal structure and components of the recuperated combustion apparatus assembly (10), which in combination provide unusual results theretofore not taught.

The recuperated combustion apparatus assembly (10) is formed from an external elongated cylindrical container (12) made from any suitable material of choice, such as stainless steel or the like. The external elongated cylindrical container (12) having a pollution inlet duct (14) for receiving an exhausted pollutant therein and a hot gas exhaust outlet duct (16) for expelling hot gases there from. The external elongated cylindrical container (12) further includes an internal heat transfer cylinder (18) of which is substantially segregated into a first section and a second section. The first section is in open communication with the pollution inlet duct (14) via a pollution directional passage (20). The directional pollution passage (20) contains heat transfer fins (22) therein for receiving and directing the exhausted pollutant there through and outwardly there from into the second section. The second section contains an elongated internal tube which functions as the combustion chamber (24). The elongated internal tube/combustion chamber (24) having inlet ports (25) there about for further receiving the exhausted pollutant there through and directing the exhausted pollutant inward into the interior of the elongated internal tube/combustion chamber (24) and the elongated internal tube/combustion chamber (24) is partitioned internally by multiple baffle plates (26). The second section directs the incoming exhausted pollutant via the inlet ports (25) through the baffle plates (26) and forward into a third section having steam generation tubes (28) and the internal tube/combustion chamber (24) and the steam generation tubes (28) are in open communication with a reaction chamber (30). The reaction chamber (30) further directs the exhausted pollutant into and throughout additional baffle plates (26) and then outward there from into the hot gas exhaust outlet duct (16). Furthermore, the elongated internal tube/combustion chamber (24) is interconnected with an igniter-fuel-air delivery assemblage (32). It is to be understood these are the general components of the entire recuperated combustion apparatus assembly (10). To further improve operational parameters numerous variations of materials of engineering choice may be incorporated. For example, the assembly (10) may also include ceramic insulation (34), or the like for heat reduction purposes, etc.

Still further it is to be understood that it is contended that the overall improved apparatus is most functional not only because of the structural arrangement but more importantly to the shape of the baffle plates (26). It is to be understood there are numerous designs for construction of the different baffle plates (26). Thus the following description is only exemplary for some possible variations but the invention is not to be limited to any specific type of shape of size for the baffle plates.

As depicted in figures 2-5, the baffle plates (26) include a continuous outside edge (26-A) and a continuous inside edge (26-B) which in combination form a rim (37). The rim (37) is divided into multiple sections which are defined by equally spaced apart integrally formed tabs (39). Each of the tabs (39) extends inward from the rim (37) toward a centralized circular solid center section (42). The interconnecting area between each of the tabs (39) and the centralized circular solid center section (42) is enlarged and cut into multiple blades (40) which when bent at an angle function as vanes. The vanes and/or blades (40) direct exhausted pollutant and/or gas to flow in a controlled angular manner outwardly there from. It is to be noted the centralized circular solid center section (42) is very important as this does not allow the exhausted pollutant and/or gases to escape there through, rather the exhausted pollutant and/or gases are substantially restricted, blocked, and deflected which results in increased dwell time for further conditioning of the exhausted pollutant and/or gases. The gases are therefore spread out before going through the next stage where they are again formed into a vortex in the center of the chamber. All of the gases and hydro carbons are mixed and combusted.

Whereby, due to use of the baffle plates (16) the apparatus provides a vortex flame that greatly increases dwell and/or burn time and this is the key to total combustion. Along with dwell time, the exhausted pollutant and/or gases are concentrated in the center of the vortex flame where combustion takes place more readily. This is easily accomplished due to the angle of the vanes (45 degrees) on the baffle plates that set the direction and velocity of the swirling vortex gases. This allows the exhausted pollutant and/or heated gases to be retained inside the elongated internal tube/combustion chamber (24) and the reaction chamber (30) and elevated to a high temperature for a period of time instead of being immediately exhausted throughout the outlet duct (16). This process is continued throughout each of the compartments until there is nothing left but purified gases, thus no C _x H _x fuels, etc. Thereafter the heated gases are expelled from within the apparatus via the outlet duct (16), respectively.

The following further defines the unusual operational characteristics for the present invention. Chamber (52) is the first chamber where auxiliary air, auxiliary fuel, and the first of the exhausted pollutant gases are mixed and combustion process is started. Chamber (52) is the apparatuses primary combustion zone. The second chamber (54) is a continuation of the mixing and burning that was started in the first chamber (52). These two chambers start the primary combustion of the exhausted pollutant coming into the apparatus and this is a fuel rich area. Also at this time the heat generated by combustion along with the excess fuel will start to brake- down the pollution in the apparatus and primarily NOx. Chamber (54) is the apparatuses secondary combustion zone.

The third chamber (56) is where all of the auxiliary fuel and incoming pollution gases are thoroughly mixed with auxiliary air. This chamber is where the re-burning process starts to takes place.

The gases now transition onward into the fourth combustion chamber (30) "previously referred to as reaction chamber" where all of the hydrocarbon fuel, no matter what state or condition it is in will be oxidized and consumed because of the oxygen rich, fuel lean condition in the fourth chamber. Also a part of the forth combustion chamber is item 28, steam generating coils that inject steam into the chamber and this brings down the overall combusting temperature in that particular chamber and stabilizes the combustion process at a lower temperature, thus helping to prevent the reformation of NOx molecules.

The fifth and sixth chambers (58) and (60) will allow for the cooling of all gases and the recombining into more mundane compounds such as H ₂ 0 and N ₂ . Here again the rotating gases caused by the vortex generating stationary blades and the resulting tornado in the combustion chambers facilitate the mixing of the gases and the formation of new compounds gases.

Referring now to the igniter-fuel-air delivery assemblage (32), of which is illustrated in figure 1. The igniter-fuel-air delivery assemblage (32) includes a spark/igniter device (44), a fuel delivery input conduit (46) and a fresh air input conduit (48). It is to be noted the igniter-fuel-air delivery assemblage (32) is operated and controlled by any suitable apparatus controller (not shown) of engineering choice. There are numerous types of apparatus controllers available within the known prior art thus there is no need to teach their function and/or components herein. Also, any type of spark/igniter and/or fuel can be utilized dependent upon engineering choice.

Referring again to figure 1 , wherein the general concept and functioning parameters are illustrated as follows. (Note) arrows depict directional flow. Upon initial startup, the exhausted pollutant (not shown) is introduced into the pollution inlet duct (14) and then forcibly directed into the pollution directional passage (20). Within the pollution directional passage (20) the exhausted pollutant is deflected and re-directed by 180 degrees into the heat transfer fins (22) wherein the exhausted pollutant is heated to a useful temperature. This is beneficial as heated exhausted pollutant requires less fuel during the combustion process than cold exhausted pollutant. The now heated exhausted pollutant is further directed onward and circulated around the external surface of the internal tube/combustion chamber (24) and forcibly introduced into the interior of the internal tube/combustion chamber (24) via the inlet ports (25). The heated exhausted pollutant upon entering the interior of the internal tube/combustion chamber (24) is then subjected to the igniter-fuel-air delivery assemblage (32) thus resulting in combustion. It is to be noted the amount of fuel and air is adjustable and controlled by the apparatus controller as regulated by engineering choice. However, it is to be understood that the fresh air serves two purposes; first to cool the fuel injector apparatus and secondly to provide oxygen for combustion.

Upon combustion of the exhausted pollutant within the internal tube/combustion chamber (24), the resultant combusted gases are further detained by the baffle plates (26) and due to their construction cause the combusted gases to rotate in a coherent manner forming an intense vortex rotational flame (like a small tornado) within the combustion chamber. The faster the gases move through each dwell cell the tighter and/or smaller the vortex flame will be and the better the mixing/air/fuel will be. It is to be understood each additional baffle plate (26) intensifies the density of the vortex flame and increases the temperature. Whereby, resulting in increased dwell time and intense heat which significantly reduces the NOx count in the combustion process as well as reducing the NOx in the exhaust gases. During the combustion process the NOx are broken down into nitrogen and oxygen, respectively. Thus, the remaining gases are predominantly nitrogen and H ₂ O.

Thereafter, when water has been injected into the steam generation tubes (28) via the water inlet conduit (5) the now substantially NOx-free nitrogen and H ₂ O gases are directed into the steam generation tubes (28) resulting in production of steam (not shown). The steam is most beneficial as this reduces the temperatures and prevents the formation of any new NOx production. This area is oxygen deprived therefore the nitrogen within the apparatus has fewer oxygen atoms to bond with, thus less NOx is formed.

Upon the NOx-free nitrogen and H ₂ O gases entering the reaction chamber (30) the remaining mixture is now depleted of oxygen as most of the available oxygen has been used up combusting all carbon and hydrocarbons in the combustion chamber. Thereafter, the pollution reduced hot gases and/or hot air is further directed onward throughout the reaction chamber (30) into additional baffle plates (26) and finally exhausted outward from the apparatus via hot gas exhaust outlet duct (16). Resulting in clean hot gas that may be used for energy purposes in an environmentally friendly manner, such as for heating or the like, if desired. It can now be seen I have herein provided a combustion apparatus that is of simple construction, is environmentally friendly, economical to produce and manufacture, and is extremely efficient and adaptable for numerous uses of choice.

Although the invention has been herein shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made there from within the scope and spirit of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the specification and claims so as to embrace any and all equivalent devices and apparatuses.