Sensor-Driven Variable Gas Flow Burner System

Abstract

A gas destruction system using a gas destroying device communicatively coupled to an electronic controller subsystem for neutralizing unwanted gas emissions. The system includes a gas destruction device and method and can be customized to variable conditions by way of controlling available flow area. The disclosed gas destruction device includes multiple combustion manifolds separated by valves, which allow gas to flow to sets of nozzles as needed to maintain stable combustion. The system consists of multiple nozzles for gas flow, a main shutoff valve, a flow measurement sensor, and an igniter and power source. The combustion products are allowed to flow through the exhaust outlet attached to the combustor. A communicator device is included in the system to send system information, preferably wirelessly. The system can operate autonomously via local or remote controllers, or manually via local or remote commands.

What is claimed is: 
     
         1 . A gas destruction apparatus for the destruction and neutralization of gas from a source, the apparatus comprising:
 a. a chimney ( 125 );   b. at least one vent ( 107 ) within said chimney;   c. at least one manifold ( 101 ) within a burner enclosure ( 131 ), said burner enclosure extending from said chimney ( 125 ) and said at least one manifold ( 101 ) has manifold openings ( 101 A) configured for the distribution of the source gas;   d. at least one igniter ( 106 ) to ignite said source gas upon distribution from said at least one manifold ( 101 );   e. at least one flow control valve ( 102 ), said at least one flow control valve ( 102 ) connected to the at least one manifold ( 101 ) to control flow of source gas into the at least one manifold;   f. a length of piping ( 118 ) extending from said at least one manifold ( 101 ) to said gas source, said piping configured to transport said source gas;   g. an electronic controller subsystem ( 111 ) having at least one processor running a software program;   h. a flame arrestor ( 116 ) within said piping ( 118 ) proximate said at least one manifold ( 101 );   i. at least one shutoff valve ( 113 ) within said piping ( 118 ) upstream from said flame arrestor ( 116 ) and said flow control valves ( 102 );   j. a gas concentration sensor subsystem ( 105 ) attached to the piping ( 118 ), said gas concentration sensor subsystem ( 105 ) configured to receive a sample of source gas from said piping ( 118 ) and to communicate with the electronic controller subsystem ( 111 );   k. a power source ( 109 ) powering the apparatus; and   l. at least one sensor, each of said at least one sensor configured to monitor at least one process variable of the gas source;
 wherein said at least one process variable comprises gas pressure, gas flow, gas concentration, gas temperature, exhaust temperature, thermal flux, and humidity; 
 wherein said at least one sensor generates values; 
 wherein said sensor-generated values are sent to the electronic controller subsystem ( 111 ) for analysis by the software program; 
 wherein the electronic controller subsystem generates output triggering at least one action to actuate at least one system element. 
   
     
     
         2 . The apparatus of  claim 1  wherein said at least one system element is one of: the at least one shutoff valve, the at least one flow control valve, and the igniter. 
     
     
         3 . The apparatus of  claim 1  wherein said at least one manifold ( 101 ) further comprises flow control valves ( 102 ) between manifold openings ( 101 A) and said pipe ( 118 ), said control valves ( 102 ) being in communication with said controller subsystem ( 111 ) to control gas distribution through said openings ( 101 A) and being powered by said power source ( 109 ). 
     
     
         4 . The apparatus of  claim 1  further comprising at least one converging-diverging housing ( 112 ) adjacent to the at least one of the manifold to entrain combustion air. 
     
     
         5 . The apparatus of  claim 1  further comprising at least one flame holder device ( 114 ) adjacent to the at least one of said manifold to improve combustion stability. 
     
     
         6 . The apparatus of  claim 1  wherein said gas concentration sensor subsystem ( 105 ) comprises:
 a. a bypass having inlet ( 259 A,  309 A) configured to receive the sample of said source gas from the piping  118 ; 
 b. a process valve ( 266 ,  308 ) configured to control flow of said source gas through said bypass; 
 c. a conditioner element ( 253 ,  303 ) configured to receive the sample of said source gas from the piping  118  through the bypass; 
 d. a gas concentration sensor ( 252 ,  302 ) configured to measure said sample passed through the conditioner element, said gas concentration sensor ( 252 ,  302 ) continuously monitoring said sample and communicating measurements to said electronic controller subsystem; 
 e. an outlet ( 259 B,  309 B) for egress of the sample from the gas concentration sensor subsystem. 
 
     
     
         7 . The apparatus of  claim 1  further comprising a recalibration system ( 250 ) for monitoring drift in one of said at least one sensor, said recalibration system ( 250 ) comprising:
 a. a bypass having inlet configured to receive a sample of said source gas from the piping  118  and pass the source gas sample to said one of said at least one sensor for monitoring; 
 b. a process valve configured to control flow of said source gas through said bypass; 
 c. an outlet for egress of the sample from the recalibration system; 
 d. at least one compressed gas cylinder ( 268 A,  268 B); 
 e. pressure regulators ( 265 A,  265 B,) affixed to each of said at least compressed gas cylinders ( 268 A,  268 B); 
 f. at least one calibration control valve ( 251 A,  251 B), said at least one calibration control valve ( 251 A,  251 B) closed during normal monitoring operation; 
 wherein when recalibration is triggered, process gas valve  266  is closed and each of said at least one calibration control valve  251 A and  251 B are opened sequentially, 
 wherein upon opening of each of said at least one calibration control valves, calibration gas within one of said at least one compressed gas cylinders ( 268 A and  268 B) corresponding to the opened calibration control valve flows to said one of the at least one sensor; 
 wherein said calibration gas is measured and continues to flow through said one of the at least one sensor until a measured value is within a pre-determined range, with measured calibration gas passing to the egress outlet; and 
 wherein upon detecting the measured value in the pre-determined range, said at least one calibration valve is closed, process gas valve is opened, and recalibration system ( 250 ) is returned to normal monitoring operation. 
 
     
     
         8 . The apparatus of  claim 7  wherein said recalibration system is integrated with the gas concentration subsystem ( 105 ) to monitor and recalibrate the gas concentration sensor. 
     
     
         9 . The apparatus of  claim 1  wherein one of said at least one sensors comprises at least one exhaust temperature sensor ( 115 ) within said chimney ( 125 ), said exhaust temperature sensor ( 115 ) monitoring temperature within said chimney ( 125 ) and reporting said temperature to said controller subsystem ( 111 ). 
     
     
         10 . The apparatus of  claim 1  further comprising at least one thermal flux sensor ( 115 ) within said chimney ( 125 ), said thermal flux sensor ( 115 ) quantifying gas destruction within said chimney ( 125 ) and reporting said temperature to said controller subsystem ( 111 ). 
     
     
         11 . The apparatus of  claim 1  further comprising at least one thermal mass device ( 117 ) within said chimney ( 125 ), said thermal mass device ( 117 ) being placed to reignite said source gas after an interruption. 
     
     
         12 . The apparatus of  claim 1  further comprising multiple burner enclosures, each of said burner enclosures having at least one manifold connected to said piping. 
     
     
         13 . A method for destructing gases to neutralize emissions, the method comprising:
 a. causing gas to flow from a gas source to a monitoring and destruction path of a gas destruction system having a controller subsystem, said controller subsystem having at least one processor running a state machine program in communication with at least one circuit to operate the destruction system;   b. loading system parameters to the controller subsystem;   c. generating by each of a plurality of sensors along the monitoring and destruction path a value transmitted to the controller subsystem, one or more of the plurality of sensor-generated values indicative of measurements of continuously monitored process variables within the system;   d. controlling by the at least one circuit at least one gas destruction element and at least one actuator of the system based on the loaded parameters and sensor-generated values, wherein said control subsystem analyzes the loaded parameters and sensor-generated values, implements control logic, and generates output triggering at least one system operating action to promote stable functionality of the system;   e. controlling by the at least one circuit a safety operating loop wherein one or more of the sensor-generated values falling outside a pre-determined process variable threshold triggers a system safety action; and   f. storing sensor-generated values and system actions in a storage database;   wherein, loaded parameters and process variable measurements customize the destruction of gases under variable conditions.   
     
     
         14 . The method of  claim 12  wherein said state machine program comprises at least a first state, a second state, and a third state, with each state including entry actions, an operating loop, and exit actions, said program configured to:
 a. upon entering said first state, execute entry actions comprising loading parameters, monitoring system sensors, configuring instruments, sending operator notifications, actuating closure of all valves, and confirming blowers are powered off; 
 b. upon detection of a transition trigger, execute exit actions then transitioning to the second state, said transition trigger comprising pre-set conditions and external commands; 
 c. upon entering said second state, execute entry actions comprising opening main shutoff valve, powering igniters, and starting an ignition timer, and commanding operation of system elements and entering a second state operating loop comprising checking temperatures, temperature rates, and timeout status of the ignition timer and implementing control algorithms to promote stable ignition; 
 d. upon detection of a transition trigger comprising a timeout or ignition, execute exit actions comprising sending operator notifications then transitioning to the third state if temperature measurements meet threshold levels or back to the first state if a timeout is reached without ignition; 
 e. upon entering said third state, execute entry actions comprising sending operator notifications and commanding blower run speeds and entering a third state operating loop comprising checking temperatures to confirm burning, monitoring process variables, and implementing control algorithms to maintain stable burning and promote complete gas destruction; and 
 f. upon detection of a transition trigger comprising detection of out of bounds process variables, execute exit actions comprising sending operator notifications, closing valves, and shutting down operation of system elements, then transitioning back to the first state or initiating system shutdown. The method of  claim 1  wherein said parameters comprise variable thresholds, safe bound for sensor readings, telemetry reporting frequency, presence/absence of a blower motor, desired operating speed of the blower motor during the ignition state, and desired operating speed of the blower during the burn state, wherein said parameters are determined by system site requirements, reporting requirements, and system instrumentation. 
 
     
     
         15 . The method of  claim 1  wherein said process variables comprise at least one of: pressure, flow, gas concentration, gas temperature, flame temperature, and thermal flux. 
     
     
         16 . The method of  claim 1  wherein said at least one operating action comprises actuating at least one system element to change process variable values. 
     
     
         17 . The method of  claim 1  wherein said safety action comprises at least one of: commanding the state machine program to an idle state, extinguishing at least one gas destructing element, or powering off the gas destructing system. 
     
     
         18 . The method of  claim 1 , further comprising exchanging information with an external electronic device communicatively coupled to the system, said information comprising sensor-generated values, updated parameters, and operator instructions. 
     
     
         19 . A gas destruction system using a gas destructing device communicatively coupled to an electronic controller subsystem for neutralizing gas emissions, the system comprising:
 a. the gas destructing device comprising:
 i. a chimney ( 125 ); 
 ii. at least one vent ( 107 ) within said chimney; 
 iii. at least one manifold ( 101 ) within a burner enclosure ( 131 ), said burner enclosure extending from said chimney ( 125 ) and said at least one manifold ( 101 ) has manifold openings ( 101 A) configured for the distribution of the source gas; 
 iv. at least one igniter ( 106 ) to ignite said source gas upon distribution from said at least one manifold ( 101 ); 
 v. at least one flow control valve ( 102 ), said at least one flow control valve ( 102 ) connected to the at least one manifold ( 101 ) to control flow of source gas into the at least one manifold; 
 vi. a length of piping ( 118 ) extending from said at least one manifold ( 101 ) to said gas source, said piping configured to transport said source gas; 
 vii. a controller subsystem ( 111 ) having at least one microcontroller with at least one microprocessor running a software program; 
 viii. a flame arrestor ( 116 ) within said piping ( 118 ) proximate said at least one manifold ( 101 ); 
 ix. at least one shutoff valve ( 113 ) within said piping ( 118 ) upstream from said flame arrestor ( 116 ) and said flow control valves ( 102 ); 
 x. a gas concentration sensor subsystem ( 105 ) attached to the piping ( 118 ), said gas concentration sensor subsystem ( 105 ) configured to receive a sample of source gas from said piping ( 118 ) and to communicate with the electronic controller subsystem ( 111 ); 
 xi. a power source ( 109 ) powering the apparatus; and 
 xii. at least one sensor, said at least one sensor configured to monitor process variables of the gas source; 
   wherein said at least one process variable comprises gas pressure, gas flow, gas concentration, gas temperature, exhaust temperature, thermal flux, and humidity;   wherein said at least one sensor generates values;   wherein said sensor-generated values are sent to the electronic controller subsystem ( 111 ) for analysis by the software program;   wherein the electronic controller subsystem generates output triggering at least one action to actuate at least one of the main shutoff valve, the flow control valve, the at least one igniter, and the power source; and   b. electronic controller subsystem comprising at least one processor running a state machine program, the program configured to:
 i. receive system parameter input; 
 ii. receive sensor-generated values from said sensors, the sensor-generated values indicative of measurements of continuously monitored process variables within the system; 
 iii. analyze the system parameter input and sensor-generated values; 
 iv. implement control algorithm to determine next steps to promote stable functionality of the system; 
 v. generate output triggering at least one system operating action; 
 vi. transmit operating action via circuits to actuate operating elements of the system to affect process variables; 
 vii. monitor sensor-generated values and rerunning control algorithm until stable functionality of the system is achieved; 
 viii. maintain stable process variables; and 
 ix. store sensor-generated values and system actions in a storage database. 
   
       wherein, loaded parameters and process variable measurements customize the destruction of gases under variable conditions. 
     
     
         20 . The apparatus of  claim 19  further comprising a recalibration system for monitoring drift in one of said at least one sensor, said recalibration system comprising:
 a. a bypass having inlet configured to receive a sample of said source gas from the piping  118  and pass the source gas sample to said one of said at least one sensor for monitoring; 
 b. a process valve configured to control flow of said source gas through said bypass; 
 c. an outlet for egress of the sample from the recalibration system; 
 d. at least one compressed gas cylinder ( 268 A,  268 B); 
 e. pressure regulators ( 265 A,  265 B,) affixed to each of said at least compressed gas cylinders ( 268 A,  268 B); 
 f. at least one calibration control valve ( 251 A,  251 B), said at least one calibration control valve ( 251 A,  251 B) closed during normal monitoring operation; 
 wherein when recalibration is triggered, process gas valve  266  is closed and each of said at least one calibration control valve  251 A and  251 B are opened sequentially, 
 wherein upon opening of each of said at least one calibration control valves, calibration gas within one of said at least one compressed gas cylinders ( 268 A and  268 B) corresponding to the opened calibration control valve flows to said one of the at least one sensor; 
 wherein said calibration gas is measured and continues to flow through said one of the at least one sensor until a measured value is within a pre-determined range, with measured calibration gas passing to the egress outlet; and 
 wherein upon detecting the measured value in the pre-determined range, said at least one calibration valve is closed, process gas valve is opened, and recalibration system ( 250 ) is returned to normal monitoring operation.