Process heater system

Abstract

A process heater system ( 10 ) for an industrial envelope ( 11 ) comprises a main combustion chamber ( 20 ), an afterburner ( 30 ), and an exhaust stack ( 40 ). Retrofitted heat-recovery piping ( 50 ) receives combustion gas downstream of the afterburner ( 30 ) and uses it as a heat source for the industrial envelope. When the industrial load in the main combustion chamber ( 20 ) is paint, powder coating, varnish, epoxy, grease and/or oil, the secondary materials burned in the afterburner 30 can be considered alternative fuel, not solid wastes.

1 . A process heater system ( 10 ) for an industrial envelope ( 11 ), comprising:
 a main combustion chamber ( 20 ) wherein an industrial load is combusted;   an afterburner ( 30 ) comprising a supplemental combustion chamber ( 31 ) in communication with the main combustion chamber ( 20 ) and a second zone ( 33 ) in communication with the supplemental combustion chamber ( 31 );   an exhaust stack ( 40 ) receiving combustion gas from the second zone ( 33 ) of the afterburner ( 30 ) and exhausting it outside the industrial envelope ( 11 ); and   heat-recovery piping ( 50 ) receiving combustion gas downstream of the second zone ( 33 ) the afterburner ( 30 ) and transmitting it for use within the industrial envelope ( 11 ), whereby material combusted in the afterburner ( 30 ) is fuel used to provide energy for the industrial envelope ( 11 ).   
     
     
         2 . A process heater system ( 10 ) as set forth in  claim 1 , wherein the afterburner ( 30 ) is sized so that combustion gas dwells therein for at least half a second. 
     
     
         3 . A process heater system ( 10 ) as set forth in  claim 1 , wherein the industrial load in the main combustion chamber ( 20 ) is paint, powder coating, varnish, epoxy, grease and/or oil. 
     
     
         4 . A process heater system ( 10 ) as set forth in  claim 1 , wherein the material combusted in the afterburner ( 30 ) has a meaningful heating value and is without contaminants significantly higher in concentration than traditional fuel. 
     
     
         5 . A process heater system ( 10 ) as set forth in  claim 1 , wherein the main combustion chamber ( 20 ) volatizes the industrial load. 
     
     
         6 . A process heater system ( 10 ) as set forth in  claim 1 , wherein the main combustion chamber ( 20 ) has a gas burner ( 21 ). 
     
     
         7 . A process heater system ( 10 ) as set forth in  claim 1 , wherein the industrial purpose of the main combustion chamber ( 20 ) is to heat clean fixtures, parts, and/or equipment to remove non-hazardous material. 
     
     
         8 . A process heater system ( 10 ) as set forth in  claim 1 , wherein the afterburner ( 30 ) comprises a supplemental combustion chamber ( 31 ). 
     
     
         9 . A process heater system ( 10 ) as set forth in  claim 8 , wherein the supplemental combustion chamber ( 31 ) has its own gas burner ( 32 ). 
     
     
         10 . A process heater system ( 10 ) as set forth in  claim 8 , wherein the supplemental combustion chamber ( 31 ) is in communication with the main combustion chamber ( 20 ). 
     
     
         11 . A process heater system ( 10 ) as set forth in  claim 8 , wherein the supplemental chamber ( 31 ) is in the same package perimeter as the main combustion chamber ( 20 ). 
     
     
         12 . A process heater system ( 10 ) as set forth in  claim 8 , wherein the supplemental combustion chamber ( 31 ) combusts non-hazardous volatized organic material transported from the main combustion chamber ( 20 ). 
     
     
         13 . A process heater system ( 10 ) as set forth in  claim 1 , wherein the afterburner ( 30 ) comprises a second zone ( 33 ). 
     
     
         14 . A process heater system ( 10 ) as set forth in  claim 13 , wherein the second zone ( 33 ) is located downstream of a/the supplemental combustion chamber ( 31 ). 
     
     
         15 . A process heater system ( 10 ) as set forth in  claim 13 , wherein the second zone ( 33 ) is outside of the package perimeter of the main combustion chamber ( 20 ). 
     
     
         16 . A process heater system ( 10 ) as set forth in  claim 13 , wherein the second zone ( 33 ) is vertically aligned with the exhaust stack ( 40 ). 
     
     
         17 . A process heater system ( 10 ) as set forth in  claim 1 , wherein the heat-recovery piping ( 50 ) projects, turns, and extends to effectively cover the industrial envelope ( 11 ). 
     
     
         18 . A process heater system ( 10 ) as set forth in  claim 1 , wherein four pipes extend tangentially outward from the exhaust stack ( 40 ) at settings that are approximately 90° apart and wherein each pipe ( 50 ) includes an adapter region ( 51 ) connected to the exhaust stack ( 40 ) to receive combustion gas therefrom. 
     
     
         19 . A process heater system ( 10 ) as set forth in  claim 18 , wherein the exhaust stack ( 40 ) is retrofitted with the adapter region(s) ( 51 ). 
     
     
         20 . A process heater system ( 10 ) as set forth in  claim 18 , wherein the exhaust stack ( 40 ) is manufactured to include the adapter region(s) ( 51 ).