Combustion product condensing water heater

Abstract

In a water heating system, vapor in the products of combustion gases is condensed in a secondary heat exchanger positioned in a housing with the primary heat exchanger and combustion chamber. The two heat exchangers are coaxial coils with the secondary coil positioned below the primary. Gases flow radially through the primary coil and then axially through the secondary coil at an increased velocity. The gases are then used to pre-heat a gas/air mixture in a third heat exchanger within the secondary heat exchanger. The pre-heated gas/air mixture is burned in a burner within the primary heat exchanger and the gas products are drawn through the exchangers by a blower. A water storage tank is designed to enhance stratification of hot water over cooler water. The cooler water is used to condense vapor in the secondary heat exchanger.

We claim: 
     
       1. A method of heating water and storing the hot water in an insulated storage vessel comprising: permitting natural stratification of the water within the vessel such that cooler water collects at the bottom of the vessel;   withdrawing cooler water from the bottom of the vessel and passing that water in heat exchange relationship with combustion gases from a burner assembly to cool those gases below their dew point temperature so as to extract some of the latent heat of vaporization from the gases and to heat the water;   returning the thus heated water to the storage vessel at a location in the storage vessel above the cooler water and in a manner as to avoid mixing with the cooler water, the volume of the cooler water below the location at which hot water is returned to the vessel being sufficiently large to provide for condensation of the combustion gases through substantially the entire heating cycle of the burner.   
     
     
       2. A water heating system comprising: a water-walled combustion chamber defined by a primary heat exchanger, the products of combustion gas flow path past the primary heat exchanger providing for a first gas velocity through the primary heat exchanger;   a secondary heat exchanger for receiving gases cooled by the primary heat exchanger, the secondary heat exchanger providing for a second gas velocity substantially greater than the first;   a water storage assembly including a tank having a baffle to separate a volume of hot water from a smaller volume of cooler water at the bottom of the tank in communication with the hot water and a diffuser positioned over a cold water inlet into the bottom of the tank;   means for circulating the cooler water through the secondary heat exchanger in counterflow heat exchange relationship with the combustion gases to cool the gases below their dew point temperature and condense water vapor from the gases; and   means for directing the water from the secondary heat exchanger through the primary heat exchanger to cool the combustion gases to a temperature which is above the dew point temperature.   
     
     
       3. A water heating assembly comprising: a heat exchanger and combustion chamber housing;   a water-walled combustion chamber within the housing surrounded by a primary heat exchanger, the products of combustion gas flow path past the primary heat exchanger providing a first gas velocity through the primary heat exchanger;   a secondary heat exchanger within the housing for receiving gases cooled by the primary heat exchanger providing for a second combustion gas velocity substantially greater than the first;   a cool water inlet;   means for circulating cool water from the cool water inlet through the secondary heat exchanger at a first flow rate in heat exchanger relationship with the combustion gases to cool the gases below their dew point temperature and condense water vapor from gases; and   a water flow path from the output of the primary heat exchanger to its input for recirculating water in the primary heat exchanger, said water flow path and the primary heat exchanger forming a primary heat exchanger loop;   means for mixing water from the secondary heat exchanger with a portion of the water from the output of the primary heat exchanger and a pump in said primary heat exchanger loop for pumping the water mixture through the primary heat exchanger at a flow rate greater than first flow rate to cool the combustion gases to a temperature which is above their dew point temperature.   
     
     
       4. A water heating system comprising: a water-walled combustion chamber surrounded by a primary heat exchanger, the product of combustion gas flow path past the primary heat exchanger providing for a first gas velocity through the primary heat exchanger;   a secondary heat exchanger for receiving gases cooled the primary heat exchanger, the secondary heat exchanger providing for a second gas velocity substantially greater than the first;   water storage assembly including a volume of hot water and a smaller volume of cooler water in communication with the hot water;   means for circulating the cooler water from said smaller volume of cooler water through the secondary heat exchanger in heat exchange relationship with the combustion gases to cool the gases below their dew point temperature and condense water vapor from the gases;   means for directing the water from the secondary heat exchanger through the primary heat exchanger to cool the combustion gases to a temperature which is above the dew point temperature; and   means for directing heated water from the primary heat exchanger to said volume of hot water in such a manner as to avoid mixing with the smaller volume of cooler water.   
     
     
       5. In a liquid heater comprising an insulated storage vessel and a fuel-fired heat exchanger assembly in which liquid is circulated from the storage vessel to the heat exchanger assembly to be heated, and then returned to the storage vessel, the liquid heater characterized in that: the heat exchanger assembly comprises a primary heat exchanger consisting of cylindrical finned tubing coils surrounding a central burner, the flow of combustion products from said burner being essentially radially outward through the surrounding coil at a first velocity, the partially cooled combustion products being directed to flow in an axial direction at a second velocity substantially greater than the first over a secondary heat exchanger coil in which said gases are cooled below their dew point temperature so as to extract some of the latent heat in said flue gases;   liquid is withdrawn from the bottom of said storage vessel to be circulated first through said secondary heat exchanger at a first flow rate in heat exchange relationship with products of combustion, then mixed with a portion of the liquid issuing from the outlet of said primary heat exchanger, and then caused, by action of a circulating pump placed in a primary heat exchanger loop, to flow through said primary heat exchanger at a flow rate greater than said first rate; and   the thus heated liquid is returned to an upper section of the storage vessel in such a manner as to avoid mixing with the liquid stored in the bottom of the storage vessel.   
     
     
       6. A water heating assembly as claimed in claim 3 wherein: the primary heat exchanger is a coil of tubing surrounding the combustion chamber and combustion gases flow radially over that tubing; and   the secondary heat exchanger is a coil of tubing and gases from the primary heat exchanger flow axially over the secondary coil.   
     
     
       7. A water heating assembly as claimed in claim 6 wherein the primary and secondary coils are coaxial. 
     
     
       8. A water heating assembly as claimed in claim 7 further comprising a tertiary heat exchanger located concentrically within the secondary heat exchanger wherein an unburned fuel/air mixture is pre-heated by the combustion gases from the secondary heat exchanger. 
     
     
       9. A water heating assembly as claimed in claim 3 or 4 further comprising means for pre-mixing fuel gas and an amount of air sufficient for complete combustion of the gas. 
     
     
       10. A water heating assembly as claimed in claim 9 wherein the flow of the gas/air mixture into the burner is induced by a blower positioned downstream from the secondary heat exchanger. 
     
     
       11. A water heating system as claimed in claim 4 wherein: the primary heat exchanger is a coil of tubing surrounding the combustion chamber and combustion gases flow radially over that tubing; and   the secondary heat exchanger is a coil of tubing and gases from the primary heat exchanger flow axially over the secondary coil.   
     
     
       12. A water heating system as claimed in claim .[.1.]. .Iadd.4 .Iaddend.wherein the primary and secondary coils are coaxial. 
     
     
       13. A water heating system as claimed in claim 12 further comprising a tertiary heat exchanger located concentrically within the secondary heat exchanger wherein an unburned fuel/air mixture is pre-heated by the combustion gases from the secondary heat exchanger. 
     
     
       14. A water heating system as claimed in claim 4 or 13 further comprising means for pre-mixing fuel gas and an amount of air sufficient for complete combustion of the gas. 
     
     
       15. A water heating system as claimed in claim 14 wherein the flow of the gas/air mixture into the burner is induced by a blower positioned downstream from the secondary heat exchanger. 
     
     
       16. A water heating system as claimed in claim 4 wherein the water storage assembly is a tank separated into hotter water and cooler water volumes by a baffle. 
     
     
       17. A water heating system as claimed in claim 16 further comprising a diffuser positioned over a cold water inlet into the bottom of the tank. 
     
     
       18. A water heating system as claimed in claim 4 further comprising a water flow path from the output of the primary heat exchanger to its input for recirculating water in the primary heat exchanger, said water flow path and the primary heat exchanger forming a primary heat exchanger loop, and means, including a pump in said primary heat exchanger loop, for recirculating hot water through the primary heat exchanger mixed with water from the secondary heat exchanger to raise the temperature of mixed water to a temperature above the dew point temperature of the combustion gases. 
     
     
       19. A liquid heater according to claim 5 in which partially cooled products of combustion are directed from said secondary heat exchanger to flow axially through a tertiary heat exchanger located concentrically within said secondary heat exchanger, product of combustion in said tertiary heat exchanger being in heat transfer communication with the unburned fuel/air mixture flowing towards said fuel burner. .Iadd. 
     
     
       20.  A method as claimed in claim 1 further comprising returning the water to the storage tank at a flow rate and temperature controlled by a thermostatic valve. .Iaddend. .Iadd.21. A method as claimed in claim 1 further comprising varying the input to the burner to maintain a steady 
     
     
        temperature of water returned to the storage vessel. .Iaddend. .Iadd.22. A liquid heating assembly comprising: a combustion chamber;   a primary heat exchanger in the gas flow path of products of combustion from the combustion chamber;   a secondary heat exchanger for receiving gases cooled by the primary heat exchanger;   a cool liquid inlet to the secondary heat exchanger;   means for circulating cool liquid from the cool liquid inlet through the secondary heat exchanger at a first flow rate in heat exchange relationship with the combustion gases;   a liquid flow path from the output of the primary heat exchanger to its input for recirculating liquid in the primary heat exchanger, said liquid flow path and the primary heat exchanger forming a primary heat exchanger loop;   a pump in the primary heat exchanger loop for pumping liquid from the secondary heat exchanger and a portion of the liquid from the output of the primary heat exchanger through the primary heat exchanger at a flow rate greater than said first flow rate to cool the combustion gases to a temperature which is above their dew point temperature. .Iaddend.   
     
     
        .Iadd.     A liquid heat assembly as claimed in claim 22 further comprising a thermostatic valve for controlling the flow rate through the heat exchangers. .Iaddend. .Iadd.24. An apparatus as claimed in claim 22 wherein the gas flow path past the primary heat exchanger provides a first gas velocity through the primary heat exchanger and the combustion gases then flow past the secondary heat exchanger at a second gas velocity substantially greater than the first. .Iaddend. .Iadd.25. An apparatus as claimed in claim 24 further comprising a thermostatic valve to control the flow rate of liquid withdrawn from and returned to the storage vessel. .Iaddend. .Iadd.26. An apparatus as claimed in claim 24 wherein: the primary heat exchanger surrounds the combustion chamber and combustion gases flow radially through that heat exchanger; and   a secondary heat exchanger in which gases from the primary heat exchanger flow in an axial direction sequentially past multiple liquid flow paths of the secondary heat exchanger. .Iaddend. .Iadd.27. A liquid heating assembly as claimed in claim 22 further comprising a liquid storage tank having a naturally stratified upper zone of heated liquid and a lower zone of cooler liquid, the volume of the lower zone of cooler liquid and the flow rate through the primary and secondary heat exchangers being such that the liquid provides for condensation of the combustion gases in the secondary heat exchanger through substantially the entire heating cycle of   
     
     
        the burner. .Iaddend. .Iadd.28.  An apparatus as claimed in claim 22 wherein: the primary heat exchanger is tubing surrounding the combustion chamber and combustion gases flow radially over that tubing; and   a secondary heat exchanger is a coil of tubing and gases from the primary   
     
     
        heat exchanger flow axially over the secondary coil. .Iaddend. .Iadd.29. A method of heating liquid comprising: in a secondary heat exchanger passing liquid in heat exchange relationship with combustion gases that have been cooled by a primary heat exchanger to further cool those gases below their dew point temperature so as to extract some of the latent heat of vaporization from the gases and to heat the liquid;   passing the liquid heated in the secondary heat exchanger into a primary heat exchanger in heat exchange relationship with gases from the burner assembly to cool those gases to a temperature above their dew point temperature to further heat the liquid but avoid condensation of the flue gases in the primary heat exchanger; and   mixing a portion of the liquid from the output of the primary heat exchanger with the liquid from the secondary heat exchanger and recirculating that liquid through the primary heat exchanger to provide a flow rate in the primary heat exchanger greater than the flow rate in the   
     
     
        secondary heat exchanger. .Iaddend. .Iadd.30.  A method as claimed in claim 29 further comprising returning the liquid to a storage tank at a flow rate and temperature controlled by a thermostatic valve. .Iaddend. 
     
     
        .Iadd.31.  A liquid heater as claimed in claim 5 wherein the liquid is water heated solely by the burner assembly to a temperature of at least about 140° F. .Iaddend. .Iadd.32. A liquid heating assembly as claimed in claim 22 wherein the liquid is water heated solely by products of combustion of the combustion chamber to a temperature of at least about 140° F. .Iaddend. .Iadd.33. A method as claimed in claim 29 wherein the liquid is water to be heated solely by the combustion gases to a 
     
     
        temperature of at least about 140° F. .Iaddend. .Iadd.34.  An apparatus for heating liquid in a burner assembly and storing the heated liquid comprising: a burner assembly;   a heat exchanger assembly;   an insulated storage vessel having a naturally stratified upper zone of heated liquid and a lower zone of cooler liquid separated by a baffle;   withdrawing means for withdrawing cooler liquid from the lower zone of cooler liquid and passing the withdrawn liquid through the heat exchanger assembly in heat exchange relationship with combustion gases from the burner assembly to cool those gases below their dew point temperature so as to extract some of the latent heat of vaporization from the gases to heat the withdrawn liquid; and   returning means for returning the thus heated liquid to the storage vessel at a return location in the storage vessel above the lower zone of cooler liquid and so as to avoid mixing with the cooler liquid, the return location being such that the volume of cooler liquid below it is large enough to provide for condensation of the combustion gases through a substantial portion of the heating cycle of the burner assembly. .Iaddend.   
     
     
        .Iadd.35.  An apparatus for heating liquid in a burner assembly and storing the heated liquid comprising: a burner assembly;   a heat exchanger assembly;   an insulated storage vessel having a naturally stratified upper zone of heated liquid and a lower zone of cooler liquid;   withdrawing means for withdrawing cooler liquid from the lower zone of cooler liquid and passing the withdrawn liquid through the heat exchanger assembly in heat exchange relationship with combustion gases from the burner assembly to cool those gases below their dew point temperature so as to extract some of the latent heat of vaporization from the gases to heat the withdrawn liquid; and   returning means for returning the thus heated liquid to the storage vessel at a return location in the storage vessel above the lower zone of cooler liquid and so as to avoid mixing with the cooler liquid, the return location being such that the volume of cooler liquid below it is large enough to provide for condensation of the combustion gases through a substantial portion of the heating cycle of the burner assembly; and   a thermostatic valve to control the flow rate of liquid withdrawn from and   
     
     
        returned to the storage vessel. .Iaddend. .Iadd.36.  An apparatus for heating liquid in a burner assembly and storing the heated liquid comprising: a burner assembly;   a heat exchanger assembly;   an insulated storage vessel having a naturally stratified upper zone of heated liquid and a lower zone of cooler liquid;   withdrawing means for withdrawing cooler liquid from the lower zone of cooler liquid and passing the withdrawn liquid through the heat exchanger assembly in heat exchange relationship with combustion gases from the burner assembly to cool those gases below their dew point temperature so as to extract some of the latent heat of vaporization from the gases to heat the withdrawn liquid; and   returning means for returning the thus heated liquid to the storage vessel at a return location in the storage vessel above the lower zone of cooler liquid and so as to avoid mixing with the cooler liquid, the return location being such that the volume of cooler liquid below it is large enough to provide for condensation of the combustion gases through a substantial portion of the heating cycle of the burner assembly; and   the heat exchanger assembly comprising a primary heat exchanger and a secondary heat exchanger for receiving gases cooled by the primary heat exchanger, the apparatus further comprising a liquid flow path from the output of the primary heat exchanger to its input for recirculating liquid in the primary heat exchanger, said liquid flow path and the primary heat exchanger forming a primary heat exchanger loop, and a pump in the primary heat exchanger loop for pumping liquid from the secondary heat exchanger and a portion of the liquid from the output of the primary heat exchanger through the primary heat exchanger. .Iaddend. .Iadd.37. An apparatus as claimed in claim 36 further comprising a thermostatic valve to control the flow rate of liquid withdrawn from and returned to the storage vessel. .Iaddend. .Iadd.38. An apparatus as claimed in claim 36 wherein the flow path of combustion gases past the primary heat exchanger provides a first gas velocity through the primary heat exchanger and the combustion gases then flow past the secondary heat exchanger at a second gas velocity substantially greater than the first. .Iaddend. .Iadd.39. An apparatus as claimed in claim 38 further comprising a thermostatic valve to control the flow rate of liquid withdrawn from and returned to the storage vessel.   
     
     
        .Iaddend. .Iadd.40.  An apparatus as claimed in claim 38 wherein: the primary heat exchanger surrounds the combustion chamber and combustion gases flow radially over that heat exchanger; and   gases from the primary heat exchanger flow in an axial direction sequentially past multiple liquid flow paths of the secondary heat exchanger. .Iaddend. .Iadd.41. An apparatus for heating liquid in a burner assembly and storing the heated liquid comprising:   a burner assembly;   a heat exchanger assembly comprising a primary heat exchanger and a secondary heat exchanger, wherein the flow path of combustion gases past the primary heat exchanger provides a first gas velocity through the primary heat exchanger and the combustion gases then flow past the secondary heat exchanger at a second gas velocity substantially greater than the first;   an insulated storage vessel having a naturally stratified upper zone of heat liquid and a lower zone of cooler liquid;   withdrawing means for withdrawing cooler liquid from the lower zone of cooler liquid and passing the withdrawn liquid through the heat exchanger assembly in heat exchange relationship with combustion gases from the burner assembly to cool those gases below their dew point temperature so as to extract some of the latent heat of vaporization from the gases to heat the withdrawn liquid; and   returning means for returning the thus heated liquid to the storage vessel at a return location in the storage vessel above the lower zone of cooler liquid and so as to avoid mixing with the cooler liquid, the return location being such that the volume of cooler liquid below it is large enough to provide for condensation of the combustion gases through a substantial portion of the heating cycle of the burner assembly. .Iaddend. .Iadd.42. An apparatus for heating liquid in a burner assembly and storing the heated liquid comprising:   an insulated liquid storage assembly including a naturally stratified volume of hot liquid in communication with a volume of cooler liquid, the volumes of hot liquid and cooler liquid being separated by a baffle;   a heat exchanger assembly for passing liquid, withdrawn from the volume of cooler liquid, in heat exchange relationship with combustion gases from the burner assembly to cool those gases below their dew point temperature so as to extract some of the latent heat of vaporization from the gases to heat the withdrawn liquid; and   circulating means for circulating the liquid from the volume of cooler liquid through the heat exchanger and returning the liquid to the volume of hot liquid, the volume of cooler liquid and the flow rate established by the circulating means being such that the circulated liquid provides for condensation of the combustion gases through a substantial portion of   
     
     
        the heating cycle of the burner. .Iaddend. .Iadd.43.  An apparatus for heating liquid in a burner assembly and storing the heated liquid comprising: a liquid storage assembly including a volume of hot liquid and a volume of cooler liquid in communication with the volume of hot liquid;   a heat exchanger assembly for passing liquid, withdrawn from the volume of cooler liquid, in heat exchange relationship with combustion gases from the burner assembly to cool those gases below their dew point temperature so as to extract some of the latent heat of vaporization from the gases to heat the withdrawn liquid;   circulating means for circulating the liquid from the volume of cooler liquid through the heat exchanger and returning the liquid to the volume of hot liquid, the volume of cooler liquid and the flow rate established by the circulating means being such that the circulated liquid provides for condensation of the combustion gases through a substantial portion of the heating cycle of the burner; and   the heat exchanger assembly comprising a primary heat exchanger and a secondary heat exchanger for receiving gases cooled by the primary heat exchanger, the apparatus further comprising a liquid flow path from the output of the primary heat exchanger to its input for recirculating liquid in the primary heat exchanger, said liquid flow path and the primary heat exchanger forming a primary heat exchanger loop, and a pump in the primary heat exchanger loop for pumping liquid from the secondary heat exchanger and a portion of the liquid from the output of the primary heat exchanger   
     
     
        through the primary heat exchanger. .Iaddend. .Iadd.44.  An apparatus as claimed in claim 43 further comprising a thermostatic valve to control the flow rate of liquid withdrawn from and returned to the storage vessel. .Iaddend. .Iadd.45. An apparatus as claimed in claim 43 wherein the gas flow path past the primary heat exchanger provides a first gas velocity through the primary heat exchanger and the combustion gases then flow past the secondary heat exchanger at a second gas velocity substantially greater than the first. .Iaddend. .Iadd.46. An apparatus as claimed in claim 45 further comprising a thermostatic valve to control the flow rate of liquid withdrawn from and returned to the storage vessel. .Iaddend. 
     
     
        .Iadd.47.  An apparatus as claimed in claim 45 wherein: the primary heat exchanger is tubing surrounding the combustion chamber and combustion gases flow radially over that tubing; and   gases from the primary heat exchanger flow in an axial direction sequentially past multiple liquid flow paths of the secondary heat exchanger. .Iaddend. .Iadd.48. An apparatus for heating liquid in a burner assembly and storing the heated liquid comprising:   a liquid storage assembly including a volume of hot liquid and a volume of cooler liquid in communication with the volume of hot liquid;   a heat exchanger assembly for passing liquid, withdrawn from the volume of cooler liquid, in heat exchange relationship with combustion gases from the burner assembly to cool those gases below their dew point temperature so as to extract some of the latent heat of vaporization from the gases to heat the withdrawn liquid;   a heat exchanger assembly comprising a primary heat exchanger and a secondary heat exchanger, wherein the gas flow path past the primary heat exchanger provides a first gas velocity through the primary heat exchanger and the combustion gases then flow past the secondary heat exchanger at a second gas velocity substantially greater than the first; and   circulating means for circulating the liquid from the volume of cooler liquid through the heat exchanger and returning the liquid to the volume of hot liquid, the volume of cooler liquid and the flow rate established by the circulating means being such that the circulated liquid provides for condensation of the combustion gases through a substantial portion of the heating cycle of the burner. .Iaddend. .Iadd.49. In a liquid heater, a heat exchanger assembly comprising:   a central burner;   a primary heat exchanger surrounding the central burner, the flow of combustion products from the burner being essentially radially outward through the surrounding heat exchanger at a first velocity; and   a secondary heat exchanger which is coaxial with the primary heat exchanger, the partially cooled combustion products from the primary heat exchanger being directed to flow in an axial direction sequentially past multiple liquid flow paths in the secondary heat exchanger at a second velocity substantially greater than the first; and   a tertiary heat exchanger located coaxially within the secondary heat exchanger wherein an unburned fuel/air mixture is preheated by the   
     
     
        combustion gases from the secondary heat exchanger. .Iaddend. .Iadd.50. In a liquid heater, a heat exchanger assembly comprising: a central burner;   a primary heat exchanger surrounding the central burner, the flow of combustion products from the burner being essentially radially outward through the surrounding heat exchanger at a first velocity; and   a secondary heat exchanger which is coaxial with the primary heat exchanger, the partially cooled combustion products from the primary heat exchanger being directed to flow in an axial direction sequentially past multiple liquid flow paths in the secondary heat exchanger at a second velocity substantially greater than the first;   wherein the combustion products are diverted from a radial flow path to an axial flow path in an annulus surrounding the primary heat exchanger and are then directed into the secondary heat exchanger which is axially displaced from the annulus. .Iaddend.