US 5,032,230 AGrant
Vacuum Draft Submerged Combustion Separation System
Issue Date:1991-07-16
•11 Claims
•10 Drawing Sheets
Abstract
A vacuum draft submerged combustion system and method for separating combustible hydrocarbons and other components or liquid solutions from their solvents, usually water, includes evaporating volatile components by a submerged combustion burner and condensing the vaporized volatile components under a partial vacuum. The hot gases from the burner are injected under partial vacuum into the first tank. The hot gases bubbled through the solution cause volatile components in the liquid to be evaporated and collected above the level of the liquid. The collected gasses are drawn into a condensing tank where the condensable particulates are condensed and collected.
Metadata
Assignee
- Deep Woods, Inc.
Inventor
- Richard C. Shepherd
Application Information
Application Number:US 2346389
Filing Date:1988-08-22
Priority Date:1988-08-22
Art Unit:138
Classifications
IPC:
B01D 114C02F 110
Field of Search:
202203159210126205;176;202;200;234;203;182;181;185.2;185.3;185.110;11;1;41;49;100;50;3916.2;47.3;905708;198.1368;360 A
Patent Drawings (10 sheets)
Description
Field of the Invention
This invention relates to a vacuum draft submerged combustion system and more particularly to a vacuum draft submerged combustion system having greater efficiency than heretofore known submerged combustion systems and which is readily adaptable for use in a variety of industrial processes where it may be desirable to remove dissolved solids from liquids.
Description of the Prior Art
Toxic waste and the separation of impurities from contaminated liquids is a major problem in most industrialized countries. Groundwater is easily contaminated by hydrocarbons and chlorinated solvents. Other sources of contamination include leaking tanks, accidental spills, dumping of solvents and even natural rainfall which is a major carrier of pollutants discharged as vapor into the atmosphere.
Recent emphasis by environmentalists has created a public awareness and concern in pollution problems and the attendant dangers therefrom confronting industrialized nations. Throughout the world, the resources of governments have been polarized to attack these problems. Legislation in many countries has made dumping of waste illegal. Pollutant controls have been required with respect to discharge of industrial waste in both liquid and gas form. Because of the tremendous efforts and attention being paid to waste disposal and toxic waste management controls, a need exists for reliable, cost efficient systems for removing impurities form water.
Various systems have been devised in the past for handling toxic waste and removing impurities from water. Typical of such systems are the methods of desalinization illustrated and described in U.S. Pat. No. 3,933,600; the process for reconditioning spent brine for recycling illustrated and described in U.S. Pat. No. 3,732,911 and the system and method for removing dissolved organic impurities from groundwater illustrated and described in U.S. Pat. No. 4,713,089.
The latter patents identify many problems confronting industry, but none is perhaps more important than that recognized in the '911 patent. As stated therein at column 2, lines 3-9, "Because of the present emphasis by federal State, and local government on pollution control, processors who rely on the procedure in question (discharge of waste onto a ground site) are facing a crisis-they must devise a disposal system which not only meets anti-pollution standards, but also does the job economically. A failure to meet these criteria means that the operation must be shut down".
A review of the aforementioned patents shows three different approaches to deal with three specific problems. Each of these approaches has a common drawback. They each require a high level of energy input for treating liquid, and thus are designed each in their own way to minimize energy consumption. In the '911 patent a submerged combustion unit evaporator is used for a brine solution with vapors being passed to a scrubber while liquids slurry concentrate is passed to an incinerator which is heated internally to temperatures between 1000.degree. F. and 1400.degree. F. In the desalinization process of the '600 patent, the intake water is preheated in preheating stages to a temperature preferably above 130.degree. F. before being processed in the form of a spray onto a flat flame to cause partial vaporization.
In the '089 patent, a stripper column is used wherein steam generated in a boiler is passed counter current to the contaminated water being treated, the scrubber being operated at a reduced pressure so that the feed water enters the column at its boiling point. The vapor exiting from the scrubber is compressed to reduce its condensation temperature, passed through a boiler where it is condensed and the condensed and noncondensed phase; passed into a receiver where they are separated.
All of the above identified systems and methods require substantial amounts of energy input into their systems for their operation. The substantial energy input required in such systems contributes to a significant portion of the operating expense for operation of the systems, and contributes to their inefficient operation. It is noted that the operating expense of such systems will increase with higher fuel prices and be subject to shortage of fuel. Moreover, as recognized, the separation of constituent impurities from a solution requires their safe disposal without harming the environment.
Submerged combustion systems such as disclosed in the '911 patent have been recognized as an efficient method of distillation because the partial pressure of the water vapor in the rising bubbles is less than the atmosphere so that boiling takes place at a temperatures below 212.degree. F. Previous use of submerged combustion in distillation systems has required that the back pressure of the displaced water from the combustion chamber be overcome with the use of a blower operating with positive pressure. This approach suffers from several disadvantages. For example, gasketing at the burner is critical to prevent escape of very hot gases from the combustion chamber. Also, heavy construction of the combustion chamber is necessary and high and low air pressure instrumentation as well as emergency gas escape valves are needed. Other problems arise in the use of positive pressure. For example, the effect of the partial pressure of the rising vapor bubbles is reduced as in the size of the bubbles which in turn reduces the heat transfer rate from bubble surface to liquid. As a result, more time is required, restricting the introduction of the flame to the lowest levels. This in turn may require elevated fuel pressures for heat transfer.
Summary of the Invention
These and other disadvantages of conventional submerged combustion systems are overcome by the present invention which provides a unique and novel submerged combustion system which operates with a vacuum throughout the system. In this manner the fuel and air are drawn into and through the combustion chamber where combustion takes place and the hot gases are drawn into and passed through the liquid or solution while condensed gases are drawn into a second condensing stage and through the vacuum pump. By operating the submerged combustion burner under vacuum, the relative bubble size of the bubbles passing through solution is increased over that which would be available under atmospheric or pressurized conditions, thus increasing the available surface area for heat transfer. This in turn increases the heat transfer rate which improves efficiency and provides several advantages over the prior arrangements.
Accordingly, a primary object of the present invention is to provide a vacuum draft submerged combustion system which provides for efficient and easy separation of constituent portions of a solution.
Another object of the present invention is to allow for separation and disposal of various constituent components of solutions safely and efficiently in the environment or at remote waste disposal sites.
Another object of the present invention is to provide a means for purifying contaminated liquids or solutions having unwanted dissolved solids.
Another object and distinct feature of the present invention is to provide a system for and a method of separating undesirable dissolved components of a solution.
A further feature and distinct advantage of the present invention is the ability to utilize a vacuum draft submerged combustion system for effective removal of components from a solution which requires a separation of the constituent portions of the solution.
The following is a list of some of the advantages of the present invention over conventional systems:
Liquids and solutions introduced into the negative pressure of the vacuum draft system have substantially lower boiling points.
The system of the present invention offers an increased heat transfer rate from bubble surface to the bath because the vacuum allows the bubbles to expand and thereby provide more surface area for heat transfer.
Gases may be introduced at a shallower point in the water as a result of the more rapid heat transfer and less residence time necessary for the bubbles to pass through solution.
Gasketing around the combustion chamber is minimized.
The need for heavy construction metals or exotic metals in the combustion chamber are minimized.
Fuel pressures can be reduced.
The vacuum draft submerged combustion system of the present invention is much safer than positive pressure systems because any leaks of the hot gases in the combustion chamber or tanks(s) will be directed inward instead of outward.
Back pressure on the combustion process is eliminated.
Fuel is conserved due to the lower boiling points achieved.
Some of the Objectives Achieved by the Present Invention Include
Purifying liquids or solutions which have unwanted dissolved solids such as salt, and condensing the steam back, or other undesirable components with different boiling points which may be subject to distillation with this process.
The ability to utilize a vacuum system for the more efficient distillation and removal of components from a solution which requires a separation of the constituent portions of that solution.
Blending or mixing of various solutions at differing temperatures.
The capacity to homogenize into jell form solutions of seemingly immiscible materials such as water and oil, for such uses as lubricants and blending solutions for cosmetic purposes.
Vacuum distillation of a solution providing for more efficient and easier separation of constituent portion of the solution.
Steam Vapor Generation for use as a steamer or a humidifier.
Hydronic heating system for uses such as heating homes, swimming pools or industrial heater.
Distillation of whiskey.
Distillation processes and treatment of waste streams in general such as toxic dissolved solids in water or raw sewerage.
The capacity for use as a laundering system or for dyeing or bleaching textiles.
Used to separate oil and water or briny water with the use of de-emulsification chemicals such as one manufactured by Emulsions Control, Inc. 829 Hooven Avenue, National City, Calif. the brand name E.C.I. to produce the light ends hydrocarbons on the surface of water after being condensed.
In accordance with the present invention, in one embodiment thereof, a high intensity flame is used to heat gases directed into a solution maintained in a tank which is under partial vacuum. Due to direct contact with the hot gases entering the solution which are ar a temperature in the order of 1200.degree. F., the solution is rapidly raised to and stabilized at about 160.degree. F. with the hot gas bubbles flowing upwardly through the solution causing evaporation. Due to the vacuum, the volume of the bubbles tends to expand over that of a pressurized system giving an increased surface area of contact and improved heat transfer and efficiency. The gas bubbles containing undesirable constituents of the liquid are drawn upward and outward to a condenser where the unwanted constituents are collected by condensation of the gases, the uncondensed portions of the vapor phase being vented to atmosphere after preferably passing through a filter.
The vacuum draft submerged combustion system of the present invention provides an improved and efficient method of separating components portions of a solution. A partial vacuum is maintained in a vaporizing and condensing tank connected to each other to reduce the boiling point of the liquid and to increase the volume of the hot gas bubbles introduced drawn through the solution the bubbles containing the vaporized components of the solution are passed into the condenser which may be either a shell and tube or plate and frame form. Alternatively, the heat exchanger or condenser may be of the submerged system type. In that event, the gases are introduced into a tank below the level of a relatively cool condensing liquid to bubble the components through the cool liquid which condenses the volatile components. Any uncondensed components may be vented to the atmosphere with or without filtering and the condensate is recovered for possible or waste disposal as the case may be.
Brief Description of the Preferred Embodiments Drawings
Further objects of the invention and a better understanding thereof will be obtained from the following drawings and accompanying description. In the drawings, like parts throughout the several views are represented with like reference characters.
FIG. 1 is graphical representation contrasting heating efficiency of a liquid vs. efficiency for submerged combustion systems with and without vacuum draft;
FIG. 2 is a diagrammatic representation of the present invention employing a shell in tube type condensing heat exchanger;
FIG. 3 is a diagrammatic view of the representation of the present invention employing a submerged combustion condenser; and
FIG. 4 illustrates in diagrammatic form of another embodiment of a submerged system according to the present invention.
Description of the Invention
Before describing the invention in the preferred embodiments, reference should be made to FIG. 1 which graphically depicts the advantages achieved by comparing the heating efficiency of and vaporization efficiency of a vacuum draft submerged combustion system with that of a conventional submerged combustion system. The graphs represent measurements taken in a 100 gallon tank using a 100,000 B.T.U.H. burner having a 6 inch diameter by 30 inch long combustion chamber connected to a six inch diameter, 36 inch long bubble distributor shown more clearly in FIG. 2. The combustion chamber and distributor were submerged in tank with the distributor arranged cross wise of the chamber which was positioned vertically. For vacuum operation, a lid was provided on the tank and sealed. A pipe was installed opposite the combustion chamber and connected to a vacuum pump to draw a vacuum of approximately 4 inches Hg with the flame ignited.
The x axis of FIG. 1 represents the temperature of the liquid and they y axis represents efficiency in percent. With stoichiometric gas/air ratios, the maximum temperatures attainable in the submerged combustion system at atmospheric pressure is approximately 195.degree. F. This is represented by solid line A and is believed due to the great affinity and capacity of moisture which the spent combustion gases have at the higher temperatures and the natural partial pressure of the water vapor in the rising bubbles. Thus, at 195.degree. F., substantially all of the heat goes into vaporizing or steaming and the heating efficiency (Line A) of the water is zero. Conversely, steaming off or evaporation at 195.degree. F. under atmospheric pressure is 100%. This is represented by Line B comprising long and short dashes.
When operating the tank under a vacuum of approximately 4 inches Hg the surprising and unexpected result of a maximum solution temperatures of 160.degree. F. is observed. This is represented by Line C comprising short dashes. Line D comprising large dashes shows the evaporation efficiency which reaches 100% at approximately 160.degree. F., the maximum temperature attainable at 4 inches Hg. While the reason and the effects of the combined vacuum draft and submerged combustion are not entirely understood, it is believed that the result are attributable to the larger volume of air bubbles which are obtainable under vacuum. To this end, the percent volume expansion (based on volume of one cubic foot of dry air) ratio of a gas force draft system and a vacuum draft system can be shown to be:
The latter Computations show that at 60.degree. F. there is no substantial expansion of bubble size up to 6 inches of vacuum, but that there should be a dramatic 50% increase in bubble size with 6 inches of vacuum at 1200.degree. F. Inasmuch as the rate of the heat transfer is dependent on the area of surface contact of the bubble with the solution, the larger bubbles serve to increase the rate of heat transfer and thus improve the efficiency of the system.
With reference to FIG. 1, it can be seen that with a maximum temperature of 160.degree. F. and a heat input of 100,000 BTUH, the bath or solution has an evaporation rate of approximately 100 lbs./hr. With an input of 1,000,000 BTUH, distillation rate of 1000 lbs. of water per hour may be reached. With a forced draft system, the BTUH requirement of 195.degree. F. would be 35 times that, i.e. 350,000 BTUH heat input would be necessary to evaporate 100 lbs. of water/hr. The vacuum draft submerged combustion system according to the invention provides approximately a 30% increase in performance over a forced draft system. While further testing and evaluation need to be done to determine the effects of air in the combustion process as used in the vacuum draft system of the invention and the effect on rate of temperature rise and maximum temperatures attainable at different vacuums, there seems little doubt that the vacuum draft submerged combustion process synergistically effects the efficiency of the system and dramatically reduces the cost of distillation of water on terms of BTUH per pound so as to provide significant cost savings not heretofore attainable with forced draft systems.
FIG. 2 shows in diagrammatic form the essential elements of an embodiment of the present invention. The system of the embodiment shown in FIG. 2 is generally indicated by reference character 10 and includes a first tank 12 enclosed and substantially sealed to the environment and having a burner 14 disposed through an aperture 16 in the top of the tank 12 and supported in a known manner internally of the tank 12. Burner 14 includes conventional fuel inlet and air inlets 18, 20 respectively, suitably valved as at 21 for providing a proper fuel and combustion air mixture, to the burner 14. The mixture when ignited provides a direct flame 22 into a combustion chamber 23 disposed below the level 30 of the solution to be treated. Level 30 may be maintained by suitable float controls arranged to automatically control the liquid input so that a substantially constant level is maintained with a space maintained between the top of tank 12 and level 30. First tank 12 has a conical bottom which collects a slurry or sludge of solid particulates. The concentrated slurry may be removed through slurry outlet 76.
Burner 14 may take the form of any of a number of conventional dispersing or atomizing burners having a flame jet 22 emitted from its burner opening. Combustion chamber 23 is conventionally arranged to feed into bubble distributor 24, which may take any of a various number of forms, but which in one preferred form is a perforated cylindrical tube 24 disposed crosswise to combustion chamber 23 and having a plurality of openings 25 disposed in the lowermost surface of the chamber 25. Air or combustion gases are heated and forced into the distribution tube 24 and through openings 25 thereafter traveling upward in the solution 26 as shown by the arrows. For convenience, the exhaust gases from the combustion chamber 25 and the resultant gas bubbles may be referred to as exhaust air or air bubbles. Of course, distribution tubes 24 may take any shape (e.g. S-shape, cross shape, etc . . . ) to facilitate distribution of the bubbles throughout the solution. Distributor 24 should preferably be disposed at the lowermost portion of the tank for maximum contact of the bubbles as they rise through solution 26 to level 30. However, it has been found that due to efficiency of the system, the hot gases from distributor 24 can be allowed to enter at a shallow level above the midpoint of the tank. This indicates that a relatively long shallow tank can be used, i.e. one whose length is at least twice its height. This is important where weight distribution of equipment is of particular concern.
In operation, tank 12 is partially filled with a solution such as water 26, which is continuously decanted into tank 12 through solution inlet means 28 and valve 20. Regulating means may be utilized to maintain solution 26 at a level 30 by monitoring the level of the solution 26 in tank 12 and regulating the amount of solution decanted into the tank through valved solution inlet means 28. Burner 14 has disposed around the burner opening 16 a baffled combustion tube 23 which normally extends to the base of the tank where it connects to distributor 24. Perforations or openings 25 in bubble distributor 24 may be in a prearranged pattern to help distribute the bubbles evenly throughout the solution for maximum evaporation rate of the solution due to contact between the surface area of the bubbles and the solution 26.
Due to evaporation, the bubbles are saturated with volatile components of the solution. As bubbles break the surface so, the vapor collects in the area or space and is drawn through an outlet 37 in tank 12 via a connecting duct 38 to tank 40. Duct 37 connects the space 31 of first tank 12 with the interior 36 of second tank 40 which contains a heat exchanger condenser 41. Condenser 41 may be of conventional design such as a shell-in tube type comprising an insulated plurality of tubes supported in an outer shell. Chill water is fed into the tubes 42 which are interconnected such that chill water fed into the condenser inlet 43 passes through the tubes and exits through a condensate discharge 44. A pump not shown in FIG. 3 may be provided to circulate the spent chill water and pass it to a cooler. Each of the condenser tubes is arranged to allow maximum contact between the evacuated gas from tank 10 and the surface are of the tubes. As the gases pass over and contact the tube skin, the gases are condensed and the condensate collected at 46 and drawn off via pump 45 and collected at 47.
Any volatile components having boiling points below that of the condensing liquid boiling point are thus separated and collected as a condensing liquid 47. The vapor phase in the meantime is collected in an exhaust collecting area 48 above the level of the condenser 41 and drawn out through vacuum pump 49.
The gas collected in area 48 has been mostly cleansed of particulates dissolved in the starting solution. Its condensate may contain, for example light hydrocarbons components, such as the light end oils which will float to the surface of the liquid 46, to create a second predetermined level 47'. Particulates, such as tars or heavier oils, tend to sink to the bottom of the condensed liquid and can be collected by conventional heavy component removal members illustrated diagrammatically at 76'. For a more efficient separation of the heavier components from the condensing or solution liquids, a deemulsifier 51, such as one manufactured by Emulsions Control Co. under the brand name of ECO RECOVERALL, may be added to either of the liquids in the tanks. The de-emulsifier may be an additive provided to the solution 26 before or after it is decanted into tank 12 or a de-emulsifier additive device may be disposed within the vapor collecting area to release deemulsifier into the condensate liquid in measured doses.
Vacuum draft pump 49, is arranged to create a partial vacuum in the second tank 40. A partial vacuum in a range of from about 2.0 to about 10.0 inches Hg (about 50 to about 260 millibars) is established in the second tank 40. Preferably a partial vacuum pressure of approximately 4.5 inches Hg (115 millibars) is utilized. A partial vacuum will also be drawn in tank 12 through connecting duct 38. The vacuum pump 49 may alternatively be disposed between tanks 12 and 40, particularly where its desired to draw a higher vacuum in tank 12. The partial vacuum in tank 12 is maintained in the range between 0.1 to 4.0 inches Hg (about 2 to about 90 millibars) during operation. This range has been found to produce good results with optimum results being achieved with a partial vacuum pressure of approximately 2.5 inches Hg (60 millibars).
The partial vacuum pressure in each of the of the tanks is the amount of pressure in the appropriate units below ambient atmospheric pressure. For instance, a partial vacuum pressure of 4.5 inches Hg tank 40 means a pressure in tank 40 which is 4.5 inches Hg less than atmospheric pressure, or about 25.5 inches Hg at sea level.
Vacuum draft means 49 may be a conventional, commercial vacuum pump. The output gases from pump 49 may be vented directly to the atmosphere or through an exhaust pipe 50. If desired they may first be filtered through a suitable filter such as a charcoal high efficiency particle air (H.E.P.A.) filter before being vented to the atmosphere. In that event another optional blower may be utilized. The filter removes any odors that may remain in the exhaust as well as any smoke or other particulates and to this end the filter may be disposed in the flow line directly after the vacuum pump 49.
FIG. 3 illustrates an alternative system of the present invention employing a submerged condenser.
A combustion chamber 23 in the form of a cylindrical pipe encloses flame 22 and directs the flame from burner 14 into a one shaped bubble distributor 24 having a plurality of apertures 25. As shown, at least two annular rows of apertures are utilized; however, the apertures may also be randomly spaced and more or less these two rows may be used. The lower end of distributor 24 is closed off with a plate to ensure that all the air is forced through the apertures on all sides in this form of bubbles through the solution 26 in tank 12. Tank 12 has a conical bottom 72 which collects a slurry or sludge of solid particulates 74. Slurry collects as a result of the natural tendency of the concentration of a solute in a solvent as the solvent is boiled or evaporated and of heavier matter to sink as it precipitates out of solution. In the present case, slurry 74 collects as the air heated by the flame jet 22 passes through the solution in the form of hot air bubbles causing the solvent of solution 26 to vaporize. The constituent portions of slurry 74 may include heavy tar-like oils or solid particulate matter such as dirt or other impurities which are not easily vaporized. The agitation of the water due to the bubbling enhances the rate of dropout. The concentrated slurry may be removed through outlet 76 and then transferred to a safe disposal site or other appropriate area. Such transfer avoids the expense of transferring the solvent in the solution, which normally requires special equipment and special handling.
Gas collected above the surface 30 of the solution in area 31 of tank 12 is drawn into condenser 40 through insulated connecting conduct 38 as shown by the directive arrows.
Cooling of the condensing liquid may be affected by any of a number of means such as a cooling tank 60, as shown, or a refrigeration system, cooling tower, heat exchanger or a combination of cooling systems. Cooling tank 60 includes a lower inlet 63 connected by a pipe 62 to an outlet 65 of tank 41 for transferring condensing liquid to the cooling tank 60 where it is maintained and cooled until it is ready for use in the condensing tank. A second insulated return duct or pipe 64 is used of for returning cooled condensing liquid to the condensing tank 40, the direction of flow being shown by arrows. Pipe 64 may include radiating or heat sink means 66 and fan means 68 for directing air over the radiator 66 for carrying away heat and thereby further cooling the condensing liquid before returning it to the condensing tank 40. Fan 68 may be a conventional electric fan connected to an electric motor (not shown) and disposed to cause air to pass over heat sink means 66 so as to cool the liquid contained in the pipes and passing through the radiator.
Tank 40 includes a cylindrical feed tube 55 having a conical gas dispersing apertured head disposed in the solution 56. The conical head of tubes 55 includes annular spaced rows of apertures 57 to facilitate gas dispersion. Tank 40 also includes particulate collecting and removal members illustrated diagrammatically at 76'. Tank 50 is connected to a vacuum draft pump 49 which establishes the partial vacuum in tanks 40 and 12 as herein before described.
The partial vacuum in the tanks provides several advantages. For example, the partial vacuum results in the reduced boiling point of the solution, including both the solute and the solvent, to about 160.degree. F. as shown in FIG. 1. Also the condensation point of the gaseous exhaust injected into the liquid 56 in tank 40 is reduced. Another advantage of maintaining a partial vacuum in tanks 12 and 40 is that it allows for the hot gases to be drawn into and through the solution 26 more efficiently. As previously noted, the bubble size is larger than in non-vacuum systems. This enables a larger surface area of the bubbles to contact the solution 26 causing more rapid evaporation. More of the solvent and solute in thus carried by the gas which rise through the solution 26 before being drawn to condensing tank 40.
The exhaust system for the gases being drawn off by a vacuum pump 49 further includes an exhaust duct 58 within which may be disposed a charcoal filter 53 and high-efficiency particulate air (H.E.P.A) filter 54. The exhaust vented out through the exhaust duct 58 thus is cleansed by the filters which minimize the possibility of pollution of the environment. Filters 53, 54 may alternatively be disposed in line before vacuum means 49 at the outlet from tank 40 or in conduit 38.
In operation of the system according to the present invention exhaust gases from the tank 12 are drawn through duct 38 and into pipe 55 which is disposed below level 50. The gases drawn through connecting duct 38 enter the submerged pipe 55 and are advantageously broken up into bubbles by the apertures 57 in the cone shaped head that act as a bubble dispersion mechanism. As the bubbles rise to the surface of the condensing tank 40, any gases having a boiling point less than the temperature of the condensing liquid 56 are condensed out of the bubbles and into the liquid 56. The gases which rise in bubble form through condensing liquid 56 rise above surface 50 and into the exhaust collecting area 36 where they are drawn off by the vacuum draft pump 49. Vacuum pump 49 draws off the exhaust gases through duct 58 and through filters 53, 54 as described above.
FIG. 4 shows another alternative embodiment of the present invention. A first tank 12, enclosed and substantially sealed to the environment contains the liquid to be treated. Burner 14 is supported in a known manner adjacent and above a combustion chamber 23. Burner 14 includes valved fuel and air inlets, for providing fuel and combustion air, respectively in the proper mixture to the burner 14. The output of burner 14 is flame 22 directed into chamber 23. Burner 14 may take the form of any of a number of conventional dispersing or atomizing burners.
In operation, tank 12 is partially filled with a solution 26 which is continuously decanted into tank 12 through inlet means 28. Regulating means may be utilized to maintain solution 26 at a predetermined level 30 by monitoring the level of the solution decanted into the tank 12 and regulating the amount of solution decanted into the tank through the inlet means 28. The baffled combustion chamber 23 of burner 14 takes the form of an "L", having a horizontally extending distributing section 24 disposed below the level 30 of the solution. The burner flame jet 22 projects below the level of the solution 30 and produces high temperature gases in distributor 24 which pass through apertures 25 and into the solution. Gases bubble upward into the upper vapor collecting area 37 of tank 12. Distributing section 24 extends substantially the entire length of tank 12 and includes apertures 25 along its length to distribute the bubbles evenly throughout the solution for increased evaporation of the solution due to contact with the surface area of the bubbles effects.
As the vapor collects in the vapor collecting area 31, it is drawn through an insulating connecting duct 38 which connects the outlet 37 of first tank 12 with the interior of second tank 40. Second tank 40 contains a condensing liquid 50 which is maintained at a predetermined level. Duct 38 forms an inlet conduit for tank 40 and is connected to a vertical apertured pipe 41 adapted to extend below level 56 of the condensing liquid 42. Pipe 41' preferably includes spaced apertures for dispersion of the vapor uniformly into the condensing liquid 50.
As the hot gas is injected into the second tank 40, through the pipe 41', the gases bubble up through the condensing liquid 50. The constituent elements of the exhaust gas are separated and any volatile components having boiling points below that of the condensing liquid boiling point are then condensed in condensing liquid 50. The dissolved gases are collected in an exhaust collecting area 48 above the level of the solution in tank 40.
The gas collected in area 48 is cleansed of particulates and components which have condensed out in either or both of the tanks. Light hydrocarbon components, such as the light end oils, if present, condense and float to the surface of the second tank adjacent forming a top level 47. Heavier particulates, such as tars or heavier oils, sink to the bottom of the either or both of the tanks and can be collected by conventional heavy component removal members.
For a more efficient separation of the heavier components from the condensing or solution liquids, a de-emulsifier, such as one manufactured by Emulsions Control Inc. under the brand name of ECI RECOVERALL, may be added to either of the liquids in the tanks. The de-emulsifier may be an additive provided to the solution 26 before it is decanted into tank 12 or a deemulsifier additive device 51 may be disposed within area 48 which releases de-emulsifier into condensing liquid in measured doses.
The gases removed from exhaust collecting area 48 may be vented directly to the atmosphere or, may first be filtered through a charcoal filter and a High Efficiency Particle Air (H.E.P.A) filter before being vented to the atmosphere to remove any odors that may remain in the exhaust. The H.E.P.A. filter also removes any smoke or other particulates which remain in the exhaust. Further filters 53, 54 may be disposed after the vacuum means in the system or alternatively in the duct between second tank 40 and vacuum means 49, at both locations.
Various modifications in the design and operation of the present invention will suggest themselves to those skilled in the art. The embodiment and methods described above are presented in all respects as illustrative and not restrictive and resort should be made to the appended claims which define the true spirit and full scope of the invention.
Claims
What is claimed is:
1. A vacuum draft submerged combustion system for separating unwanted constituents of liquid comprising: a first closed tank including fluid inlet means, means for introducing a liquid into the first tank and means for maintaining the liquid in the first tank at a predetermined level, said first tank having an exhaust outlet and a solid particulate collection section at a lowermost portion thereof and means for removing solid particulates collected therein, a burner for burning a combustible fuel and heating a source of air, a conduit combustion chamber connected to said burner and disposed in said first tank below the level of said liquid for supplying heated air to the liquid; a bubble distributing means connected to said combustion chamber for receiving said heated air and disposed along a lowermost portion of said first tank for distribution of heated air bubbles in said liquid in a predetermined pattern, a second closed tank for maintaining a liquid at a predetermined level, said second tank having an inlet and an exhaust outlet, insulating duct means connecting the inlet of said second tank to the exhaust outlet of said first tank, and bubble distributing means within said second tank, said bubble distributing means including a conduit extending from the inlet of said second tank to a portion below the level of the liquid and means disposed at the end of said conduit for distribution of air bubbles drawn from said first tank into said liquid in the second tank, said second tank further including a solids particulate collection section at a lowermost portion thereof and means for removing solid particulates collected therein, and vacuum pump means connected to the outlet of said second tank for simultaneously drawing a partial vacuum in said first tank in the order of approximately 0.1 to 4.0 inches Hg (2 millibars to 90 millibars) and in said second tank in the order of approximately 2.0 inches Hg (50 millibars) to 10.0 inches Hg (260 millibars) to thereby significantly reduce the boiling point of liquids in the tanks and causing the bubbles flowing upwardly through the liquid to expand to a degree greater than that of a pressurized system to thereby provide an increased surface area of contact of the bubbles with the liquid and be drawn upward and outward serially through the liquid in the first and the second tanks for condensing the separated constituents, and means for venting uncondensed vapor portions of the vapor phase of the bubbles being drawn through the pump to the atmosphere.
2. The system according to claim 1 wherein said first tank includes means for adding a deemulsifier to said liquid.
3. The system according to claim 1 wherein during operation, said partial vacuum in said first tank is approximately 2.5 inches Hg (62.5 millibars) and said partial vacuum in said second tank is approximately 4.5 inches Hg (115 millibars).
4. A combustion system as set forth in claim 1 wherein said bubble distributing means in the first tank is a conical head, said head being connected at one end to the combustion chamber in the first tank and closed off at an opposite end and having a plurality of spaced openings for discharge of air bubbles.
5. A combustion system as set forth in claim 4 wherein the openings are disposed in multiple rows peripherally about the head in a predetermined pattern.
6. A combustion system as set forth in claim 1 wherein said bubble distributing means in the second tank is a conical head, said head being connected at one end to the conduit in said second tank and closed off at an opposite end and having a plurality of spaced openings for discharge of air bubbles.
7. A combustion system as set forth in claim 6 wherein the openings are disposed in multiple rows peripherally about the head in a predetermined pattern.
8. A combustion system as set forth in claim 1 wherein the bubble distributing means in the first tank is a conduit disposed substantially horizontally along the length of the first tank, said conduit having a plurality of spaced openings for discharge of air bubbles into the first tank.
9. The system according to claim 1 further including means connected to said second tank for cooling the liquid in said second tank.
10. The system according to claim 1 including means for cooling liquid in said second tank.
11. A combustion system as set forth in claim 1 further including a cooling tank, first conduit means connected between said cooling tank and said second tank for transferring liquid to said cooling tank from said second tank, second conduit means connected between said cooling tank and said second tank for returning cooled liquid to said second tank and further including heat sink means connected to said second conduit for further cooling the liquid returning to said second tank.
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