WO2025062285A1

WO2025062285A1 - Fully mechanical boiler without using electricity

Info

Publication number: WO2025062285A1
Application number: PCT/IB2024/059017
Authority: WO
Inventors: Hamid POURMOHAMMADI BALTORKI
Original assignee: Individual
Current assignee: Individual
Priority date: 2024-09-17
Filing date: 2024-09-17
Publication date: 2025-03-27
Anticipated expiration: 2027-03-17

Abstract

A fully mechanical boiler device generates steam without electricity. It comprises a first water tank (3) with a mechanical float (1) to regulate water level, and a one-way valve (2) connecting it to a steam-generating tank (11). A non-electrical heater (17) heats the water to produce steam. The device features a mechanical pressure gauge (5), a steam release valve (6), and a pressure differential mechanism that uses atmospheric pressure changes to move water without an electric pump. A mechanical gas control valve (16) regulates the heater based on pressure readings. Safety is ensured with a safety valve (4). The heat transfer system includes spiral tubes (12) and cross-flow tubes (13) to enhance efficiency. Claims include additional features like a three-layered steam-generating tank (11), various types of pressure gauges, an automatic water stop mechanism, and a heat transfer wall for preheating water.

Description

Fully mechanical boiler without using electricity

The present invention relates to a boiler, and more particularly, to a non-electrical boiler capable of generating and circulating warm liquid.

Non-electrical, mechanically operated boilers have a rich history dating back to ancient times, with significant advancements during the industrial revolution, particularly through the work of James Watt and later innovations in high-pressure boilers by Richard Trevithick and George Stephenson. These boilers are crucial in various applications, including industrial processes like chemical manufacturing and food processing, historical and modern transportation such as locomotives and ships, central heating systems in buildings, and power generation in thermal power plants. Their evolution has significantly impacted industrial efficiency and transportation, making them indispensable in many sectors.

There are some patents which address the non-electrical or non-powered boiler, for example:

The Korean Pat.App.No.KR20160131376 is a non-powered hot water boiler that circulates hot water using steam pressure generated by an electric heater. Key components include an external casing that houses the boiler, a heating chamber that heats cold water to form steam and hot water (discharged by steam pressure) with a cold water supply pipe at the top and a hot water discharge pipe at the bottom, an electric heater that is cylindrical and horizontally arranged to heat water, and an evaporation plate positioned below the cold water supply pipe to form steam by heating the cold water. Additional features include a tapered lower part of the heating chamber for higher pressure discharge, a corrugated evaporation plate, and a booster pressure stage with a heat-resistant rubber blade and nitrogen system to increase hot water discharge pressure.

Korean Pat.No. KR101477074B1 discloses a hot water discharge system featuring a hot water discharge pipe connected to a cold water supply pipe with a check valve, a heating chamber divided into a heating and a pressurizing chamber, and an electric heater to heat the cold water. The system includes partition walls with steam and hot water flow holes, level sensors to monitor water levels, and a pressure sensor to regulate internal vapor pressure and control the hot water discharge pipe. The automatic valve ensures water flow is managed based on sensor readings, preventing discharge when water levels are too low. This system aims to efficiently heat and discharge hot water while maintaining precise control over water levels and pressure, enhancing safety and performance.

The PCT.App.No.WO2016170080A1 discloses a boiler system, designed to be significantly more fuel-efficient than existing boilers, comprising a first and second reservoir that together define a combustion enclosure, a storage tank positioned to define an upper wall of the enclosure and in fluid communication with the first reservoir, a heat exchange tube located in the storage tank and in fluid communication with the second reservoir, and a burner arranged to directly heat atmospheric gases within the enclosure to indirectly heat the walls. The burner issues a flame that does not directly heat any wall of the enclosure, with the first reservoir defining the first, second, and third walls, and the second reservoir defining the fourth and fifth walls. The storage tank, thermally insulated except for the portion defining the wall of the enclosure, has a concave lower end made of copper, and the heat exchange tube comprises a finned coil. The system includes an exhaust manifold with ports for extracting combustion gases, an exhaust flue with a water-retaining sleeve in fluid communication between the second reservoir and the heat exchange tube, and a first pump for circulating water in a closed circuit. Additionally, the system features a heat damper, a flue gas condenser, a radiator with a heat exchange unit and thermostat-controlled fan, and a control system with sensors and actuators for automatic operation.

The summary of disclosed invention is intended to provide an overview of the subject matter of the invention, and is not intended to identify essential elements or key elements of the subject matter, nor is it intended to be used to determine the scope of the claimed implementations.

The invention is a fully mechanical, electricity-free boiler that uses a non-electrical heat source, such as a flame, to heat water and convert it into steam. Water is introduced into a water tank via a mechanical float, then flows through a one-way valve into the steam tank. The boiler features cross-flow and spiral heat exchangers to enhance heat transfer efficiency. Once the water in the steam tank is heated and turned into steam, the pressure is monitored with a gauge, and when the steam is released, the pressure in the steam tank drops below atmospheric pressure. This pressure difference enables water to be suctioned from the water tank into the steam tank without the need for an electric pump. A mechanical gas control valve regulates the flame based on pressure, while a safety valve prevents over-pressurization. The system also includes insulation and pre-heating mechanisms to increase overall efficiency. The valve connected to the mechanical float of the water level is opened until the water tank reaches a certain level. Then, the water enters the main tank from the water tank. In the next step, the flame is turned on, and the water in the main tank starts to heat up. According to the pressure measurement on the device, when it reaches a certain pressure, the steam outlet valve on the device can be opened to release the required steam. This cycle runs continuously, producing the required steam without needing to close the valves. Additionally, the output steam pressure can be adjusted to the required value using the mechanical thermocouple.

Other key features include:

Cross-flow pipes as heat exchangers: Gas-to-water and gas-to-steam heat exchangers improve heat exchange efficiency by ensuring perpendicular flow between gas and fluids (water or steam).

Spiral pipe or spiral heat exchangers: These direct combustion gases upwards, extending the heat transfer path for better efficiency.

Mechanical pressure control: A mechanical gas control valve adjusts the flame based on pressure readings to manage steam tank pressure. A safety valve prevents over-pressurization.

Efficiency improvements: The steam tank has a three-layer construction with insulation, and heat transfer between the steam tank and water tank pre-warms the water, reducing heat requirements.

Steam generation cycle: As steam is generated, the pressure is monitored by a gauge. When steam is released, pressure drops, allowing water to be drawn into the steam tank without needing an electric pump.

Steam boilers have evolved over time in response to the need for a more powerful and efficient source of mechanical energy production. Traditional steam boilers required electrical energy to control the system or pump, which led to issues such as sensor failures or electrical component malfunctions. Modern steam boilers are designed to minimize energy consumption and eliminate dependence on electrical energy and its components.

The mechanical boiler offers several advantages over its electric or semi-electric counterparts. It utilizes a mechanical suction system instead of an electric pump, and employs mechanical floating level control and a mechanical thermocouple flame control system, replacing electronic components. This design ensures uniform heating of water inside the tank, thanks to the presence of spiral and cross pipes. Additionally, the mechanical boiler is easy to set up and operate, providing continuous and instantaneous steam production. Its high safety standards significantly reduce the risk of explosion.

illustrates a perspective view of the boiler and main parts of the boiler.

illustrate a side view of the boiler.

illustrate the section view of the boiler and its internal components.

shows the details of the main tank layers.

illustrates the details of channel and the passage of the heat transfer pipes on it.

The present document discloses a fully mechanical boiler device operates without using electricity. By connecting a water hose to the mechanical float (1) located in tank (3), water enters the tank up to the predetermined level. Then, the water flows from the one-way valve (2) to tank (11). The water inside tank (11) is heated using a non electrical heater(17) for example a flame . The non electrical heater are included bun not restricted to gas-fired, oil-fired, biomass-fired flames and other combustible fuel source. It is also necessary to mention that the spiral tube (12) and two cross tubes(13) which passes through and around of a channel(7) circulate the heated water in tank (11) for better heat transfer.In one embodiment of invention channel(7) is a hollow vertical pipe on which holes or clamps (13a, 13b, 13c, 13d) are installed for passage or hold of the spiral tube (12) and at least one cross tube(13) .

The lower cross-flow tube is a gas-to-water cross-flow heat exchanger. The upper cross-flow heat exchanger is a gas-to-steam heat exchanger. It is used to reduce the moisture content of the steam. Spiral heat exchangers actually move the combustion products upwards from inside it. It is a cross flow heat exchanger.

Gas-to-water cross-flow heat exchanger, facilitates the transfer of heat from a gas to water. In the cross-flow configuration, the gas and water flow perpendicular to each other. This arrangement enhances the heat exchange efficiency by maximizing the contact surface area between the gas and water. Gas-to-steam heat exchanger, transfers heat from a gas to steam, primarily to reduce the moisture content in the steam. Similar to the gas-to-water heat exchanger, the gas and steam flow perpendicular to each other. The heat from the gas helps to evaporate any remaining water droplets in the steam, ensuring it is dry and superheated. Spiral heat exchanger move combustion products(gases) upwards through a spiral path. The spiral design ensures a longer path for the gases, which can enhance heat transfer and allow for more efficient combustion product movement. This is also a type of cross-flow heat exchanger, meaning the fluids (gas and another medium) flow perpendicular to each other

To carry out the process in the first cycle, the heat of the flame increases to such an extent that the water in tank (11) turns into steam. The pressure inside tank (11) can be measured using the mechanical pressure gauge (5). The pressure gage (5) is in the form bourdon tube pressure gauge, diaphragm pressure gauge, bellows pressure gauge, or other type of mechanical pressure gauge.

By opening valve (6), the steam created in tank (11) is released. This causes the pressure inside tank (11) to drop drastically, becoming lower than the ambient atmospheric pressure. Now, without using any electric pump, the water in tank (3) is pumped into tank (11) using the pressure difference, performing suction operations on one side.

Additionally, by using a mechanical gas control valve (16), the heater (17) can be controlled based on the pressure results from pipe (15), allowing the pressure in tank (11) to be managed according to its usage. A safety valve(4) is also installed to prevent excessive pressure increase in tank (11).

Tank (11) consists of three layers: aluminum covers (8), insulation layer(9), and a tank sheet (10). It should also be noted that when tank (11) is heated, the wall in contact with tank (3) becomes hot. This causes the water in tank (3) to be heated, and the warmer water enters tank (11), reducing the required heat received by the water and thus increasing the efficiency of the boiler. In the main embodiment of the invention, insulation layer(9) is in the form of mineral wool insulation, and specially the stone wool insulation. Other type of insulation layer which can be used is, fiberglass Insulation and polystyrene insulation.

Mechanical float (1) regulates the water level in tank (3). When the water reaches a predetermined level, the float(11) stops the flow, ensuring the tank doesn’t overflow.

Tank (3) is the initial water reservoir. It holds the water before it is transferred to tank (11) for heating.

One-way valve (2) allows water to flow from tank (3) to tank (11) but prevents it from flowing back, ensuring a one-directional flow.

Tank (11) is the main heating tank where water is converted into steam. It is designed to withstand high temperatures and pressures.

The heat source(17) heats the water in tank (11). It is controlled to ensure the water reaches the necessary temperature to turn into steam.

Spiral Tube (12) and cross tubes (13) passes through channel (7) and help circulate the heated water within tank (11). This circulation improves heat transfer efficiency.

Channel (7) houses the spiral and cross tubes, facilitating the circulation of heated water.

Pressure gauge (5) measures the pressure inside tank (11), allowing for monitoring and ensuring the pressure remains within safe limits.

Valve (6) releases steam from tank(11) when opened, reducing the pressure inside the tank.

Mechanical valve(16) controls the flame (17) based on the pressure readings from pipe (15), ensuring the pressure in tank (11) is maintained according to the required usage. In the main embodiment of invention the mechanical valve(17) is a gas control valve.

Safety valve (4) prevents excessive pressure buildup in tank(11) by releasing pressure if it exceeds safe levels.

Covers (8) in the outer layer of tank (11), provide structural support.

The insulation layer(9) between the covers and the tank sheet helps retain heat within tank (11), improving efficiency.

Tank sheet (10) is the innermost layer of tank (11), designed to withstand high temperatures and direct contact with the flame (17).

Pipe (15) transmits pressure readings to the mechanical gas control valve (16), helping regulate the flame.

Heat transfer wall in contact with tank (3) heats the water in tank (3) as tank (11) is heated, pre-warming the water before it enters tank (11) and increasing overall efficiency.

By connecting a water supply pipe to the mechanical float in the water tank, the device introduces water up to the predetermined level. The water then flows through a one-way valve into the steam tank. The water inside the tank is heated by a heat source. The heated water circulates within the tank through a spiral tube and two cross tubes, enhancing heat transfer efficiency.

In the first cycle, the flame's heat converts the water in the steam tank into steam. The pressure inside the steam tank is measured using a pressure gauge. When the desired pressure is reached, the outlet valve is opened to release the steam. This release causes the pressure inside the steam tank to drop significantly, falling below ambient atmospheric pressure. Consequently, without the need for an electric pump, water from the water tank is drawn into the steam tank through the one-way valve.

A mechanical gas control valve regulates the gas flame based on the pressure readings from the steam pressure receiving tube, allowing control over the steam tank's pressure according to its usage. A safety valve is installed to prevent over-pressurization of the steam tank.

The steam tank is constructed with three layers of aluminum and stone wool insulation. When the steam tank is heated, the wall in contact with the water tank also heats up, causing the water in the water tank to warm. This preheated water enters the steam tank, reducing the required heat input and thereby increasing the boiler's efficiency.

The boiler presented in this document is typically used in the industrial boiler sector, which serves various applications such as power generation, where boilers are essential in power plants for generating steam to drive turbines and produce electricity. In manufacturing, many processes require steam for heating, sterilization, and other purposes. In chemical processing, steam is used in chemical plants for reactions, distillation, and other processes. In the food and beverage industry, steam is crucial for cooking, sterilization, and other food processing activities especially production of tomato paste, milk and dairy products, candy, chocolate and cake. Additionally, industrial boilers provide heating for large buildings, facilities, and district heating systems.

Claims

A fully mechanical boiler device for generating steam without using electricity, comprising:
a first water tank (3) for storing water, equipped with a mechanical float (1) to regulate the water level;
a one-way valve (2) connecting the first water tank (3) to a steam-generating tank (11), allowing water to flow in only one direction;
a non-electrical heater (17) for heating the water inside the steam-generating tank (11) to produce steam;
a mechanical pressure gauge (5) for measuring the pressure inside the steam-generating tank (11);
a valve (6) for releasing steam from the steam-generating tank (11);
a pressure differential mechanism wherein upon release of steam from the steam-generating tank (11), lowers the pressure below atmospheric pressure, causing suction of water from the first water tank (3) into the steam-generating tank (11) without the need for an electric pump;
a mechanical gas control valve (16) that regulates the heater (17) based on pressure readings from the steam-generating tank (11);
a safety valve (4) to prevent over-pressurization; and
a heat transfer system comprising spiral tubes (12) and cross-flow tubes (13) inside the steam-generating tank (11), designed to circulate the heated water and enhance heat transfer efficiency.
The boiler device of claim(1), further comprises a channel (7) which houses the spiral and cross tubes, facilitating the circulation of heated water.
The boiler device of claim 1, wherein the steam-generating tank (11) comprising of at least three layers of an aluminum outer cover (8), some insulation layers (9), and an inner tank sheet (10).
The boiler device of claim 1, wherein the pressure gauge (5) is selected from the group consisting of a bourdon tube pressure gauge, diaphragm pressure gauge, or bellows pressure gauge.
The boiler device of claim 1, wherein the mechanical float (1) in the first water tank (3) automatically stops water flow when the water reaches a predetermined level.
The boiler device of claim 1, wherein the mechanical gas control valve (16) adjusts the flame (17) intensity based on pressure readings received through a pressure pipe (15) connected to the steam-generating tank (11).
The boiler device of claim 1, further comprising a heat transfer wall in contact with both the steam-generating tank (11) and the first water tank (3), whereby the heat from the steam-generating tank (11) preheats the water in the first water tank (3).