Process and Apparatus for Combusting Hydrogen and Recycling Combustion Products

The present disclosure relates to heat exchanger systems for generating heat for heating fluids, such as air, by combusting gaseous molecular hydrogen.

Existing heat exchanger systems, such as furnaces, typically rely on hydrocarbon materials as a combustible fuel for generating the desired heat energy. Hydrocarbon-based fuels are typically expensive. Also, combustion of hydrocarbon fuels generates carbon dioxide which is detrimental to the environment.

In one aspect, there is provided a process for heating ambient air, comprising: emplacing a reaction zone material within a reaction zone, wherein the reaction zone material includes gaseous molecular hydrogen and an oxidant; igniting the reaction zone material, with effect that the reaction zone material is converted to reaction products via a reactive process, wherein the reaction products include a post-reactive process gaseous material; wherein: the reactive process generates heat energy, wherein a first portion of the generated heat energy heats the reaction products such that heated reaction products are produced; and emplacing the heated reaction products in heat transfer communication with ambient air, such that the ambient air is heated by the reaction products, such that heated ambient air and cooled reaction products are produced, wherein the cooled reaction products include a cooled post-reactive process gaseous material; emplacing the cooled post-reactive process gaseous material in heat transfer communication with the reaction zone such that, while the heat energy is being generated in response to the conversion of the reaction zone material to the reaction products, the cooled post-reactive process gaseous material is heated by a second portion of the generated heat energy, such that a re-heated post-reactive process gaseous material is produced; and admixing the re-heated post-reactive process gaseous material with the heated ambient air such that a heated gaseous mixture is obtained.

In another aspect, there is provided a system for producing heat energy comprising: a source of gaseous molecular hydrogen; a manifold, comprising: a gas-receiving chamber disposed in flow communication with the gaseous molecular hydrogen source for receiving the gaseous molecular hydrogen; and a manifold-defined heat exchanger; a nozzle for discharging the gaseous molecular hydrogen that is received by the gas-receiving chamber; an igniter for effecting ignition of reaction zone material within a reaction zone, wherein the manifold-defined heat exchanger and the reaction zone are emplaced in heat transfer communication; a heat exchanger; and wherein: the source of gaseous molecular hydrogen, the gas-receiving chamber, the nozzle, the igniter, and the reaction zone are co-operatively configured such that, while: (i) the gaseous molecular hydrogen is being received by the gas-receiving chamber and discharged via the nozzle to the reaction zone, and (ii) oxidant is also being supplied to the reaction zone, such that the reaction zone material includes the gaseous molecular hydrogen and the oxidant: in response to ignition of the reaction zone material within the reaction zone by the igniter, the reaction zone material is converted to reaction products via a reactive process, wherein the reaction products include a post-reactive process gaseous material; and the reactive process generates heat energy, wherein a first portion of the generated heat energy heats the reaction products such that heated reaction products are produced; the reaction zone and the heat exchanger are co-operatively configured such that, while: (i) the heated reaction products are produced, and (ii) ambient air is emplaced in heat transfer communication with the heat exchanger: the heated reaction products become emplaced in heat transfer communication with the heat exchanger, such that the ambient air is heated by the heated reaction products via the heat exchanger, such that heated ambient air and cooled reaction products are produced, wherein the cooled reaction products include a cooled post-reactive process gaseous material; the reaction zone, the heat exchanger, and the manifold-defined heat exchanger are co-operatively configured such that, while: (i) the cooled post-reactive process gaseous material is produced, (ii) the heated ambient air is produced, and (iii) the heat energy is being generated in response to the conversion of the reaction zone material to the reaction products: the cooled post-reactive process gaseous material becomes emplaced in heat transfer communication with the manifold-defined heat exchanger, with effect that the cooled post-reactive process gaseous material is emplaced in heat transfer communication with the reaction zone via the manifold-defined heat exchanger; the cooled post-reactive process gaseous material is heated by a second portion of the generated heat energy, such that a re-heated post-reactive process gaseous material is produced; the re-heated post-reactive process gaseous material is admixed with the heated ambient air such that a heated gaseous mixture is obtained.

In another aspect, there is provided a kit of components for retrofitting a furnace that includes a conventional burner assembly and a heat exchanger, comprising: a source of gaseous molecular hydrogen; a gaseous hydrogen-compatible burner assembly, comprising: a manifold, comprising: a fluid conductor for receiving and conducting a reaction zone supply to a reaction zone such that a reaction zone material, within the reaction zone, is obtained, a manifold-defined heat exchanger, and an igniter for igniting the reaction zone material emplaced within the reaction zone; wherein: the source of gaseous molecular hydrogen, the gaseous hydrogen-compatible burner assembly, and the heat exchanger are co-operatively configured such that while: (i) the gaseous hydrogen-compatible burner assembly is replacing the conventional burner assembly, (ii) the gaseous hydrogen-compatible burner assembly is receiving a reaction zone supply; (iii) the gaseous hydrogen-compatible burner assembly is disposed in flow communication with the source of gaseous molecular hydrogen, such that the received reaction zone supply includes at least the gaseous molecular hydrogen of the source of gaseous molecular hydrogen: the received reaction zone supply is conducted to the reaction zone, such that the reaction zone material includes the gaseous molecular hydrogen; in response to ignition of the reaction zone material within the reaction zone by the igniter, the reaction zone material is converted to reaction products via a reactive process, wherein the reaction products include a post-reactive process gaseous material; the reactive process generates heat energy, wherein a first portion of the generated heat energy heats the reaction products such that heated reaction products are produced; the reaction zone and the heat exchanger are co-operatively configured such that, while: (i) the heated reaction products are produced, and (ii) ambient air is emplaced in heat transfer communication with the heat exchanger: the heated reaction products become emplaced in heat transfer communication with the heat exchanger, such that the ambient air is heated by the heated reaction products via the heat exchanger, such that heated ambient air and cooled reaction products are produced, wherein the cooled reaction products include a cooled post-reactive process gaseous material; the reaction zone, the heat exchanger, and the manifold-defined heat exchanger are co-operatively configured such that, while: (i) the cooled post-reactive process gaseous material is produced, (ii) the heated ambient air is produced, and (iii) the heat energy is being generated in response to the conversion of the reaction zone material to the reaction products: the cooled post-reactive process gaseous material becomes emplaced in heat transfer communication with the manifold-defined heat exchanger, with effect that the cooled post-reactive process gaseous material is emplaced in heat transfer communication with the reaction zone via the manifold-defined heat exchanger; the cooled post-reactive process gaseous material is heated by a second portion of the generated heat energy, such that a re-heated post-reactive process gaseous material is produced; the re-heated post-reactive process gaseous material is admixed with the heated ambient air such that a heated gaseous mixture is obtained.

Other aspects will be apparent from the description and drawings provided herein.

There is provided a heat exchanger system. The heat exchanger systemis provided and configured to generate heat, from combustion of a gaseous fuel within a reaction zone, for heating ambient air for climate control of an interior space.

In some embodiments, for example, a first gaseous material supply sourceis provided and functions to provide a source of first gaseous material. The first gaseous material includes a gaseous fuel. The sourceis for supplying the first gaseous materialto the reaction zonefor combustion of the gaseous fuel. In some embodiments, for example, the gaseous fuel includes gaseous molecular hydrogen.

In some embodiments, for example, the first gaseous materialis combined with second gaseous material, such that a combined fluid materialis produced and supplied to the reaction zone. In some embodiments, for example, the second gaseous materialincludes an oxidant, and, in this respect, within the reaction zone, combustion of the gaseous fuel of the first gaseous materialis effected by the oxidant of the second gaseous material. In some embodiments, for example, the second gaseous materialincludes ambient air, such that the oxidant includes molecular oxygen. The oxidant of the second gaseous materialis adscititious to any oxidant that is part of the first gaseous material. In some embodiments, for example, the second gaseous materialincludes return air. In some embodiments, for example, the second gaseous materialincludes fresh air. In some embodiments, for example, the second gaseous materialincludes a mixture of return air and fresh air.

In some embodiments, for example, an eductor(also sometimes referred to as a “venturi mixer”) is provided for inducing flow of the first gaseous materialwith a flow of second gaseous material, in response to the venturi effect, with effect that at least the first gaseous materialand the second gaseous materialare combined such that a combined fluid material flowis obtained, at least a fraction of which is supplied to the reaction zone.

In some embodiments, for example, the eductorincludes a motive fluid receiver, a converging nozzle flow passage, a suction fluid receiver, a mixing zone, a diverging nozzle flow passage, and a combined fluid material discharge communicator. The motive fluid receiveris disposed in flow communication with the mixing zonevia the converging nozzle flow passage. The mixing zoneis disposed in flow communication with the combined fluid material discharge communicatorvia the diverging nozzle flow passage. The suction fluid receiveris disposed in flow communication with the mixing zone. The motive fluid receiver, the converging nozzle flow passage, the suction fluid receiver, the mixing zone, the diverging nozzle flow passage, and the combined fluid material discharge communicatorare co-operatively configured such that, while: (i) the motive fluid receiveris receiving a flow of the second gaseous materialat a sufficiently high pressure, and (ii) the suction fluid receiveris disposed in flow communication with the first gaseous materialand the first gaseous materialis disposed at a sufficiently low pressure:

The flow of the combined fluid material, including the first gaseous material, is discharged from the eductor, via the combined fluid material discharge communicator, at a pressure that is higher than the pressure of the first gaseous materialupstream of the suction fluid receiverof the eductor. In this respect, this increase in pressure of the gaseous fuel, effected by the venturi effect, enables flow of the gaseous fuel (as part of the combined fluid material flow) through a heat exchanger, for effecting heating of ambient air, as described below.

In some embodiments, for example, the first gaseous feed materialis supplied from an electrolyzer, such that the sourceincludes the electrolyzer. The electrolyzeris configured for effecting electrolysis of water with effect that reaction products are obtained. In this respect, in some embodiments, for example, the electrolyzerincluding an anode, a cathode, an electrolysis chamber containing an aqueous electrolyte solution. The anode, the cathode, and the electrolyte are co-operatively configured such that application of an electrical potential difference between the anode and the cathode effects electrolysis of water of the aqueous solution such that the reaction products, including gaseous molecular hydrogen and gaseous molecular hydrogen, are produced. The first gaseous feed materialis recovered from the reaction products, such that the first gaseous feed materialincludes the produced gaseous molecular hydrogen and the gaseous molecular hydrogen of the reaction products. In this respect, in some embodiments, for example, the gaseous fuel of the first gaseous materialincludes the produced gaseous molecular hydrogen that is recovered from the reaction product.

In some embodiments, for example, the sourceof the first gaseous materialis fluidly coupled to the suction fluid receiverof the eductorvia a first gaseous material conductor. In some embodiments, for example, the first gaseous material conductorincludes a flame arrestor(for example, a composite metal foam material flame arrestor, such as a hastelloy flame arrestor) for interfering with potential flashback from the reaction zone. In some embodiments, for example, the first gaseous material conductorincludes a check valvefor further interfering with potential flashback from the reaction zone. In this respect, in some embodiments, for example, the check valve is a floating ball check valve. The floating ball check valveincludes a ball(it is understood that the ballis not necessarily spherically-shaped or otherwise ball-shaped), whose movement is constrained within a chamber, and a valve seatconfigured for receiving the ballfor effecting closure of a flow communicator(e.g. a port) that is effecting flow communication between the sourceand the suction fluid receiverof the eductor. In this respect, sufficient downstream pressure effects seating of the ballon the valve seat, thereby effecting closure of the flow communicator, and thereby mitigating potential flashback from the reaction zone. In some embodiments, for example, the first gaseous material conductorincludes a sightglassfor providing visibility of the balland, thereby, amongst other things, enabling visual confirmation of flow of the first gaseous material. In some embodiments, for example, the ballis a flame retardant foam ball, such as a flexible polyimide foam body. A suitable flexible polyimide foam body is made from SOLVER PI-Flexible Foam manufactured by SOLVER POLYIMIDE of Room 1401, Peninsula International Mansion, Jiande City, 311600 Zhejiang Province, China.

In some embodiments, for example, the flow of the second gaseous materialis supplied to the eductorat a pressure of between 2 psig and 12 psig and at a velocity of at least 0.021 metres per second. In some embodiments, for example, the first gaseous material, which is disposed in flow communication with the suction fluid receiver, is disposed at a pressure of atmospheric pressure.

In some embodiments, for example, the second gaseous material, which is supplied to the eductor, is ambient air that is supplied by an air pumpwhich draws from ambient air.

In some embodiments, for example, the source(for example, the air pump) of the second gaseous material, which is being supplied to the motive fluid receiverof the eductor, is fluidly coupled to the motive fluid receiverby a second gaseous material conductor. In some embodiments, for example, the second gaseous material conductorincludes a flame arrestor(for example, a composite metal foam material flame arrestor, such as a hastelloy flame arrestor) for interfering with potential flashback from the reaction zone. In some embodiments, for example, the second gaseous material conductorincludes a check valvefor further interfering with potential flashback from the reaction zone. In this respect, in some embodiments, for example, the check valve is a floating ball check valve. The floating ball check valveincludes a ball(it is understood that the ballis not necessarily spherically-shaped or otherwise ball-shaped), whose movement is constrained within a chamber, and a valve seatconfigured for receiving the ballfor effecting closure of a flow communicator(e.g. a port) that is effecting flow communication between the sourceand the motive fluid receiverof the eductor. In this respect, sufficient downstream pressure effects seating of the ballon the valve seat, thereby effecting closure of the flow communicator, and thereby mitigating potential flashback from the reaction zone. In some embodiments, for example, the second gaseous material conductorincludes a sightglassfor providing visibility of the balland, thereby, amongst other things, enabling visual confirmation of flow of the second gaseous material. In some embodiments, for example, the ballis a flame retardant foam ball, such as a flexible polyimide foam body. A suitable flexible polyimide foam body is made from SOLVER PI-Flexible Foam manufactured by SOLVER POLYIMIDE of Room 1401, Peninsula International Mansion, Jiande City, 311600 Zhejiang Province, China.

In some embodiments, for example, the combined fluid material discharge communicatorof the eductoris fluidly coupled to the burner assemblyvia a bubbler. The bubblerincludes a combined fluid material receiver, for receiving a flow of combined fluid materialflow from the venture mixer, and conducting the flow of the combined fluid materialinto a liquid mediumthat is contained within the bubbler, with effect that impurities are separated from the flow of the combined fluid material(such as, for example, by dissolution within the liquid medium), and such that a flow of purified combined fluid materialis obtained and discharged via a bubbler discharge communicator, of the bubbler, at least a fraction of which is supplied to the burner assembly. In some embodiments, for example, the impurities being separated include electrolyte that is carried over from the electrolyzer. In some embodiments, for example, the liquid medium further functions as a flame arrestor for mitigating flashback from the reaction zone.

In some embodiments, for example, the combined fluid material receiverincludes coiled tubingfor conducting the received combined fluid material. In some embodiments, for example, the coiled tubingfunctions to effect flow resistance to any flashback from the reaction zone, thereby interfering with its propagation to the sources,of the first and second gasesous materials, respectively. In some embodiments, for example, the coiled tubingis manufactured from heat conducting material (such as copper) for facilitating heat transfer from fluid being conducted through the coiled tubingto the liquid medium, and thereby further mitigating potential flashback.

In some embodiments, for example, the flow of the purified combined fluid material, being discharged from the bubbleris accelerated in response to a venturi effect that is obtained via conduction of a third gaseous material(e.g. ambient air that is supplied from an air pump) via a second venturi meter, with effect that at least the flow of the purified combined fluid materialand the third gaseous material floware combined such that a combined fluid material flowis obtained and discharged into the reaction zone.

In some embodiments, for example, the third gaseous materialincludes return air. In some embodiments, for example, the third gaseous materialincludes fresh air. In some embodiments, for example, the third gaseous materialincludes a mixture of return air and fresh air.

In some embodiments, for example, the second eductorincludes a motive fluid receiver, a converging nozzle flow passage, a suction fluid receiver, a mixing zone, a diverging nozzle flow passage, and a combined fluid material discharge communicator. The motive fluid receiveris disposed in flow communication with the mixing zonevia the converging nozzle flow passage. The mixing zoneis disposed in flow communication with the combined fluid material discharge communicatorvia the diverging nozzle flow passage. The suction fluid receiveris disposed in flow communication with the mixing zone. The motive fluid receiver, the converging nozzle flow passage, the suction fluid receiver, the mixing zone, the diverging nozzle flow passage, and the combined fluid material discharge communicatorare co-operatively configured such that, while: (i) the motive fluid receiveris receiving a flow of a third gaseous materialat a sufficiently high pressure, and (ii) the suction fluid receiveris disposed in flow communication with the purified combined fluid materialand the purified combined fluid materialis disposed at a sufficiently low pressure:

The flow of the combined fluid material, including the gaseous fuel, is discharged from the second eductor, via the combined fluid material discharge communicator, at a pressure that is higher than the pressure of the flow of the purified combined fluid materialat the suction fluid receiverof the second eductor. In this respect, this increase in pressure of the gaseous fuel, effected by the venturi effect, enables flow of the gaseous fuel (as part of the combined fluid material flow) through the heat exchanger, for combustion for effecting heating of ambient air.

In some embodiments, for example, the flow of the combined fluid materialis supplied to a burner assemblyfor effecting the combustion of the gaseous fuel of the first gaseous materialwithin the reaction zone. In some embodiments, for example, the combined fluid materialis a reaction zone material. In this respect, in some embodiments, for example, a burner assemblyis provided, and the burner assemblyincludes a manifoldand a plurality of nozzles. The manifolddefines a flow passage, for example, a manifold fluid passage networkfor receiving the flow of the combined fluid materialand distributing the received combined fluid material flow amongst the plurality of nozzles. Each one of the nozzles, independently, is configured for receiving the flow of the combined fluid materialand discharging a portion of the flow of the combined fluid materialto a respective reaction zone, such that the combined fluid material flow, including the first gaseous material and the second gaseous material, becomes disposed, for example, emplaced, within the reaction zone. In this respect, in some embodiments, for example, the emplacing of the combined fluid materialwithin the reaction zoneis effectuated by the flowing of the combined fluid materialvia the manifold fluid passage network.

In some embodiments, for example, the manifold fluid passage networkdefines a minimum cross-sectional flow area of at least 7.66×10square inches. In some embodiments, for example, the manifold fluid passage networkdefines a minimum cross-sectional flow area of between, inclusively, 7.66×10square inches and 1.23×10square inches.

In some embodiments, for example, the nozzledefines a maximum cross-sectional flow area of less than 3.14×10square inches. In some embodiments, for example, the nozzledefines a maximum cross-sectional flow area of between, inclusively, 7.85×10square inches and 3.14×10square inches. In some embodiments, for example, such sizing of the maximum cross-sectional flow area of the nozzlemitigates potential flashback from the reaction zone.

The burner assemblyfurther includes, for each one of the nozzles, independently, an igniter(such as, for example, a surface igniter), for effecting ignition of the combined fluid materialwithin the respective reaction zone. While the combined fluid materialis disposed within the respective reaction zone, in response to ignition by the igniter(such as, for example, a surface igniter), combustion of the gaseous fuel, of the first gaseous material, is effected such that reaction products, for example, combustion products, are produced, and with effect that a gaseous flameis obtained. Upon establishing of the gaseous flame, gaseous fuel, present within the combined fluid materialwhich is continuing to be supplied to the reaction zone, becomes combusted, to thereby provide continuing production of combustion products. In some embodiments, for example, the combustion productsinclude a post-reactive process gaseous material.

The combustion also generates heat energy. In some embodiments, for example, the combustion is with effect that at least 25,000 BTUs, for example, 30,000 BTUs, of heat energy is generated. The generated heat energy heats the combustion products, and any unreacted gaseous material, such that heated combustion productsare produced. The heated combustion productsare conducted through the heat exchanger, such that the heated combustion productsbecomes disposed in heat transfer communication with the heat exchanger. While ambient airis emplaced in heat transfer communication with the heat exchanger, for example, while the ambient airis drawn across the heat exchangerby a circulating air fan, the heated combustion productsbecome disposed in heat transfer communication with the ambient air, via the heat exchanger, and, thus, heats the ambient air, such that heated ambient airand cooled reaction productsare produced. In some embodiments, for example, the disposition, of the heated reaction productsin heat transfer communication with the ambient air, is a disposition of the heated reaction productsin indirect heat transfer communication with ambient air, such that the heating of the ambient airby the heated reaction productsis effectuated by indirect heat transfer. In some embodiments, for example, at least 75%, for example, 80%, of the heat generated from the combustion of the combined fluid materialis transferred to the ambient airto produce the heated ambient air. In some embodiments, for example, the amount of heat energy that is received by the ambient air, to produce the heated ambient air, is based on the heat transfer efficiency of the heat exchanger.

In some embodiments, for example, the ambient airincludes return air. In some embodiments, for example, the ambient airincludes fresh air. In some embodiments, for example, the ambient airincludes a mixture of return air and fresh air.

In some embodiments, for example, the heat exchangerincludes a plurality of tubes, for example, longitudinally extending tubes, and each one of the longitudinally extending tubes, independently, is aligned with a respective one of the nozzles. In this respect, the heated combustion productsis conducted through the tubesof the heat exchanger, and the ambient air, which is drawn across the heat exchangerby the circulating air fan, is flowed as flowacross the outermost surface of the tubes. In some embodiments, for example, the tubesare coiled tubes, and each one of the coiled tubes, independently, includes a longitudinally extending portion that is aligned with a respective one of the nozzles. In some embodiments, for example, the heat exchangeris defined by a furnace.

In some embodiments, for example, the produced heated ambient airis then conducted to a space, for example, a space within a building, by a fluid communicator, for example, a duct, for heating the space. In some embodiments, for example, the heated ambient airis urged to flow through the fluid communicatorto the space via a fan.

In some embodiments, for example, the combustion of the combined fluid materialis with effect that water vapour is produced, such that the combustion productsinclude water vapour. In some embodiments, for example, the heating of the ambient airby the heated combustion productsis with effect that the water vapour of the heated combustion productsis condensed, such that liquid wateris produced, and such that the cooled reaction productsincludes the liquid water. In some embodiments, for example, as depicted in, the cooled reaction productsare conducted to a separatorthat is disposed in flow communication with the heat exchanger. The liquid wateris separated from the cooled reaction productsby the separatorand collected, and the collected liquid wateris conducted to a container, which functions as a source of water for the electrolyzer. Accordingly, in some embodiments, for example, the gaseous molecular hydrogen of the combined fluid material, which is received by the manifold, includes the produced gaseous molecular hydrogen. In some embodiments, for example, the collected liquid wateris conducted to the containervia an inducer motor or blower, such as the inducer motor or blower.

Referring to, typically, a conventional heat exchanger system(such as a furnace) uses gaseous hydrocarbon material (such as, for example, natural gas) as the gaseous fuel. The gaseous fuel supply sourceincludes a source of pressurized gaseous fuel (such as, for example, a gaseous hydrocarbon material). The gaseous material-supplying conductorsupplies the gaseous fuel from the gaseous fuel supply sourceto a burner assemblyfor effecting combustion of the gaseous fuel within a reaction zone. In some embodiments, for example, the burner assemblyincludes a manifold, and the manifold includes a plurality of nozzles. Each one of the nozzles, independently, is configured to discharge a portion of the gaseous fuel into the reaction zonefor effecting combustion of the gaseous fuel, via the burner assembly. The burner assemblyincludes, for each one of the nozzles, independently, a respective flow mixer(such as, for example, a Venturi-type burner) igniter(such as, for example, a surface igniter). For each one of the igniters, independently, there is associated a respective reaction zone. The discharged gaseous fuel, and ambient air, whose flow is induced by the combustion air fan, are communicated from the manifoldto the reaction zonevia, and mixed within, the flow mixerto generate a gaseous fuel/air mixture. While the gaseous fuel/air mixture is disposed within the reaction zone, in response to ignition by the igniter, combustion of the gaseous fuel is effected such combustion products are produced. The combustion also generates heat energy, which heats the combustion products, and any unreacted gaseous material, such that a heated post-combustion gaseous materialis produced. The heated post-combustion gaseous material, whose flow is being induced by the combustion air fan, is flowed through the heat exchanger, such that the heated post-combustion gaseous materialbecomes disposed in indirect heat transfer communication with ambient airthat is drawn across the heat exchangerby the circulating air fan, and, thus, heating the ambient air. In some embodiments, for example, the heat exchangerincludes a plurality of longitudinally extending tubesand each one of the longitudinally extending tubes, independently, is aligned with a respective one of the nozzles. In this respect, the heated post-combustion gaseous material, whose flow is being induced by the combustion air fan, is flowed through the tubesof the heat exchanger, and the ambient air, which is drawn across the heat exchangerby the circulating air fan, is flowed across the outermost surface of the tubes, and then conducted to a predetermined space for heating the predetermined space.

In accordance with the present disclosure, the conventional heat exchanger systemis modified to enable use of gaseous molecular hydrogen as the gaseous fuel. In this respect, the conventional heat exchanger systemis modified to obtain the heat exchanger systemis provided for generating heat, via combustion of gaseous molecular hydrogen, for heating ambient air. To effect this modification, in some embodiments, for example, the burner assemblyof the conventional heat exchanger system is replaced by the burner assembly, such that gaseous fuel, in the form of gaseous molecular hydrogen, can be supplied for combustion within the modified heat exchanger system. In some embodiments, for example, a kit is provided for retrofitting a conventional heat exchanger system and includes the burner assemblyand the electrolyzer. In some embodiments, for example, the kit further includes the separator. In some embodiments, for example, the kit further includes the eductor. In some embodiments, for example, the kit includes the burner assembly, the eductor, as well as the bubblerand the second eductor. In some embodiments, for example, the kit further includes the separator. In some embodiments, for example, the kit further includes the electrolyzer. In some embodiments, for example, the kit includes the burner assemblyand the eductor, as well as the first gaseous material conductorand the second gaseous material conductor, and, in some of these embodiments, further includes the bubblerand the second eductor. In some embodiments, for example, the kit further includes the separator. In some embodiments, for example, the kit further includes the electrolyzer.

In some embodiments, for example, the electrolyzeris disposed in heat transfer communication with a heat sink, such that, while the electrolysis is being effected, heat is transferred from the electrolyte to the heat sink. In some embodiments, for example, the heat sink includes a chiller. In this respect, in some embodiments, for example, by effecting the heat transfer, the temperature within the electrolyte is sufficiently low such that vaporization of water, of the aqueous electrolyte, is mitigated, such that the presence of water within the first gaseous materialis mitigated. In some embodiments, for example, the sufficiently low temperature from 27 degrees Celsius to 32 degrees Celsius. In some embodiments, for example, temperature of the electrolyte is maintained at the sufficiently low temperature by controlling the rate of heat transfer from the electrolyte to the heat sink. Water that is present within the first gaseous material(and, therefore, the combined fluid material) may, undesirably, interrupt combustion, with effect that the gaseous flame within the furnace becomes extinguished. Once extinguished, the combustion of the gaseous fuel, continuing to be supplied to the reaction zonevia the combined fluid material, is suspended, such that the uncombusted gaseous fuel may accumulate within the furnace and potentially cause a backfire upon re-ignition of the igniter. Accordingly, the mitigation of the presence of water within the first gaseous material(and, therefore, the combined fluid material), mitigates extinguishment of the gaseous flame and conditions conducive for backfiring.

In some embodiments, for example, the system further includes a sensor for sensing extinguishment of the gas flame. In some embodiments, for example, the sensor is a photocell sensor. In this respect, in some embodiments, for example, the sensor co-operates with the power supply, that is establishing the electrical potential difference between the anode and the cathode of the electrolyzer, such that, in response to sensing of an absence of the gaseous flame by the sensor, power being supplied to the electrolyzeris suspended, with effect that the electrolysis is suspended.

In some embodiments, for example, the combustion of the gaseous fuel (e.g. hydrogen) of the first gaseous materialis effected via ambient air. In some embodiments, for example, the combustion of the gaseous fuel of the first gaseous materialis effected by return air, for improving the efficiency of the combustion of the gaseous fuel of the first gaseous material. In some embodiments, for example, return air is combined with the combined fluid materialor the combined fluid materialto change the stoichiometric combustion ratio of the combined fluid materialor the combined fluid material, to improve the efficiency of the combustion of the gaseous fuel (e.g. hydrogen) of the first gaseous material.

depicts a heat exchanger systemthat is an alternate embodiment of the heat exchanger system. As depicted in, the flow of the combined fluid materialis supplied to a burner assemblyof the heat exchanger system. The burner assembly, which is an alternate embodiment of the burner assembly, is configured to effect the combustion of the gaseous fuel of the first gaseous materialwithin the reaction zoneto heat ambient air, and to admix re-heated combustion products with the heated ambient airto obtain a heated gaseous mixture. In this respect, in some embodiments, for example, a burner assemblyis provided, and the burner assemblyincludes a manifold, which comprises a gas-receiving chamberand a manifold-defined heat exchanger, and a plurality of nozzlesas described with respect to the burner assembly.

As depicted inand, the gas-receiving chamberof the manifolddefines a flow passage, for example, a fluid passage network, similar to the fluid passage network, for receiving the flow of the combined fluid materialand distributing the received combined fluid material flow amongst the plurality of nozzles, as described with respect to the burner assembly. In some embodiments, for example, the disposition of the combined fluid materialwithin the reaction zoneis effectuated by flowing the combined fluid materialvia the fluid passage network. Each one of the nozzles, independently, is configured for receiving the flow of the combined fluid materialand discharging a portion of the flow of the combined fluid materialto a respective reaction zone, such that the combined fluid material flow, including the first gaseous material and the second gaseous material, becomes disposed within the reaction zone. In this respect, in some embodiments, for example, the emplacing of the combined fluid materialwithin the reaction zoneis effectuated by the flowing of the combined fluid materialvia the fluid passage network.

In some embodiments, for example, similar to the fluid passage network, the fluid passage networkdefines a minimum cross-sectional flow area of at least 7.66×10square inches. In some embodiments, for example, the fluid passage networkdefines a minimum cross-sectional flow area of between, inclusively, 7.66×10square inches and 1.23×10square inches.

As depicted inand, the manifold-defined heat exchangerand the reaction zoneare disposed in heat transfer communication. The manifold-defined heat exchangerdefines a flow passage, for example, a fluid passage network, for receiving a flow of the cooled post-reactive process gaseous material, to heat the cooled post-reactive process gaseous materialby the heat energy generated from the combustion of the combined fluid material, such that a re-heated post-reactive process gaseous materialis produced. In some embodiments, for example, the emplacement of the cooled post-reactive process gaseous materialin heat transfer communication with the reaction zoneis effectuated by flowing the cooled post-reactive process gaseous materialthrough the fluid passage network. In some embodiments, for example, the heating of the cooled post-reactive process gaseous materialincludes heating effectuated in response to heat conduction via the manifold. The fluid passage networkis further configured to distribute the re-heated post-reactive process gaseous materialamongst a plurality of discharge communicatorsdefined by the manifold-defined heat exchanger. Each one of the discharge communicators, independently, is configured for receiving the flow of the re-heated post-reactive process gaseous materialand discharging a portion of the flow of the re-heated post-reactive process gaseous materialout of the manifold-defined heat exchanger, for admixing the portion of the flow of the re-heated post-reactive process gaseous materialwith heated ambient airto obtain a heated gaseous mixture.

In some embodiments, for example, the fluid passage networkdefines a minimum cross-sectional flow area of at least 0.14 square inches. In some embodiments, for example, the fluid passage networkdefines a minimum cross-sectional flow area of between, inclusively, 0.14 square inches and 0.25 square inches.

In some embodiments, for example, the discharge communicatordefines a minimum cross-sectional flow area of at least 0.60 square inches. In some embodiments, for example, the discharge communicatordefines a minimum cross-sectional flow area of between, inclusively, 0.60 square inches and 1.2 square inches.

In some embodiments, for example, the discharge communicatoris a vent port.

The burner assemblyfurther includes, for each one of the nozzles, independently, an igniter(such as, for example, a surface igniter), for effecting ignition of the combined fluid materialwithin the respective reaction zone, as described with respect to the burner assembly. The combined fluid material, the gas receiving chamber, the nozzles, the igniter, and the reaction zoneare co-operatively configured such that, while the combined fluid materialis disposed within the respective reaction zone, in response to ignition by the igniter, combustion of the gaseous fuel, of the first gaseous material, is effected such that reaction products, for example, combustion products, are produced, and with effect that a gaseous flameis obtained. Upon establishing of the gaseous flame, gaseous fuel, present within the combined fluid material, which is continuing to be supplied to the reaction zone, becomes combusted, to thereby provide continuing production of combustion products. In some embodiments, for example, the combustion productsinclude the post-reactive process gaseous material.

The combustion also generates heat energy, for example, 30,000 BTUs of heat energy. A first portion of the generated heat energy heats the combustion products, and any unreacted gaseous material, such that heated combustion productsare produced. In some embodiments, for example, the first portion of the generated heat energy, for heating the combustion productsand producing the heated combustion products, is defined by at least 80% of the heat energy generated by combustion of the combined fluid material. The heated combustion productsare discharged through the nozzlesand conducted through the heat exchanger, for example, through the tubes, such that the heated combustion productsbecomes disposed in heat transfer communication with the heat exchanger. The reaction zoneand the heat exchangerare co-operatively configured such that, while the heated reaction productsare produced, and while ambient airis emplaced in heat transfer communication with the heat exchanger, for example, while the ambient airis drawn across the heat exchangerby a circulating air fan, the heated combustion productsbecome disposed in heat transfer communication, for example, indirect heat transfer communication, with the ambient air, via the heat exchanger, and, thus, heats the ambient air. In some embodiments, for example, at least 75% of the generated heat energy, for example, 80% of the generated heat energy via combustion of the combined fluid material, is received by the ambient airto produce the heated ambient air.

In some embodiments, for example, the heating of the ambient airby the heated combustion productsis such that heated ambient airand the cooled reaction productsare produced. In some embodiments, for example, the cooled reaction productsinclude a cooled post-reactive process gaseous material. In some embodiments, for example, as depicted in, the reaction zone, the heat exchanger, and the manifold-defined heat exchangerare co-operatively configured such that, while the cooled reaction productsare produced, the cooled reaction products, including the cooled post-reactive process gaseous material, is conducted to the manifold-defined heat exchanger, such that the cooled reaction productsbecomes disposed in heat transfer communication with the manifold-defined heat exchanger, which is with effect that the cooled reaction productsis disposed in heat transfer communication with the reaction zonevia the manifold-defined heat exchanger. While the heated ambient air is produced, and while the heat energy is being generated in response to the conversion of the combined fluid materialto the combustion products, the cooled reaction products, including the cooled post-reactive process gaseous material, is heated by a second portion of the generated heat energy, such that a re-heated reaction product, including a re-heated post-reactive process gaseous material, is produced, and is discharged through the discharge communicatorsand admixed with the heated ambient airsuch that a heated gaseous mixtureis obtained. In this respect, the ambient airis heated at least two times by the heat exchanger system, in particular, by heat transfer via the heat exchangerto produce heated ambient air, and then by admixing re-heated post-reactive process gaseous materialwith the heated ambient airto produce the heated gaseous mixture. In some embodiments, for example, the heated gaseous mixtureis then conducted to a space, for example, a space within a building, by a fluid communicator, for example, a duct, for heating the space. In some embodiments, for example, the heated gaseous mixtureis urged to flow through the fluid communicatorto the space via a fan.

In some embodiments, for example, the second portion of the generated heat energy, for heating the cooled reaction products, including the cooled post-reactive process gaseous material, and producing the re-heated reaction product, including the re-heated post-reactive process gaseous material, is defined by at least 5% of the heat energy generated by combustion of the combined fluid material.

In some embodiments, for example, the cooled combustion products, including the cooled post-reactive process gaseous material, is urged to flow to the manifold-defined heat exchangervia an inducer motor or blower. In some embodiments, for example, the bloweris powered by 110 V Ac/0.46 Amps, and has an output of at least 90 cubic feet per minute. In some embodiments, for example, the blowerhas an output of 100 to 150 cubic feet per minute.

In some embodiments, for example, the manifoldfurther comprises a blowout resisterinterposed between the gas-receiving chamberand the manifold-defined heat exchanger. The blowout resisteris configured to resist blowout of the gaseous flame, which is generated via combustion of the combined fluid material, by the cooled post-reactive process gaseous material. While the cooled post-reactive process gaseous materialis conducted to the manifold-defined heat exchangerfor emplacement in heat transfer communication with the reaction zone, an absence of flow communication, between the emplaced post-reactive process gaseous materialand the reaction zone, that is effective for stimulating blowout of the gaseous flameby the cooled post-reactive process gaseous material, is effected by the blowout resister. In some embodiments, for example, the blowout resisteris a plate.