Dr. Allan Inovius
RCWO, Reactor Combustion World Organization S.A.

Carlo P.A. Inovius
CCB Kft., Complete Combustion Bureau Kft. of Hungary

KEYWORDS: Complete Combustion Reactor - Flue-Gas Condensing - Flue-Gas Acid to Gypsum - Recycling of Clean CO2 - Nitrified SiC, SiSiC Ceramic

.....The Patent for the complete combustion reactor, with an always clean burnt flue-gas, is based in Hungary with EPC for 100 countries.

.....Smoke and smell of all kind of unburnt hydrocarbons from gaseous, liquid and solid fuels and wastes are lost energy, increasing the air and water pollution. It results in high costs and lost money.

.....A boiler/incinerator, equipped with the CCR, produces hot water/steam or hot air for heating premises, running power plants and dryers. CCR units are in Nitrified SiC of SiSiC ceramic available in a diameter range from Ø165mm to Ø950mm in various length according to the needed capacity from 16kW to 44MW/unit.

.....The big hot surfaces of the glowing CCR, Complete Combustion Reactor, bring 80% of all produced heat value directly by radial infrared radiation to always clean surfaces of the burning chamber. The resting 20% energy is absorbed in the boiler giving after this very special combustion process an always clean burnt and dryer flue-gas to a temperature as low as around 120°C.

.....Without a Complete Combustion Reactor, the CO₂ in the flue-gas is a barrier preventing the radiation from the core of the burner flame to reach the walls of the burning chamber.

.....The sparks from the flame pattern over win after few minutes the CO₂ barrier around the flame and reach some of the millions of facets o the CCR's SiC ceramic inner walls, starting a ping-pong effect like a laser principle with the continuously accelerating sparks from the flame pattern. At only 1,000°C the process reaches a frequency able to crack the moisture of the overheated water steam in the burning process to hydrogen energy H₂ and oxygen O₂ which in the process goes to ozone O₃.

..... In the process, produced required ozone guaranties a safe end-combustion of the VOC (Volatile Organic Carbons) such as Benzopyren, Formaldehydes, CO etc. to a very low oxygen rate in the flue-gas.

.....This process is of importance by use of low-grade fuels, heavy fuels and other fuels or wastes rich in not oxidated sulfuric or other acid contents - partly separated to the ashes in a dry form easy to collect from an always soot free boiler.

.....This opens, through condensation, the way to collect sulfur, acids, and micro particles passing the flue-gas through a dry bed of lime stone (calcium) which turns into gypsum. The cleaned water from the flue-gas-condensing is treated as rainwater.

.....An always cleaned flue-gas, containing mainly CO₂ at a temperature after the condenser of 20-30°C gives the opportunity to bubble industrial recycled CO₂ into a lake or other growing system to produce rice, algae, biomasses.

Dr. Allan Inovius
RCWO, Reactor Combustion World Organization S.A.

S. Dubovskoy
Institute of Engineering Thermophysics, Ukrainian Academy of Science

KEY WORDS: Boiler - Waste Fuels - Electricity - Cogeneration - Thermoelectricity - Semi-conductor Materials.

.....CCR is a well-known combustion device, which has more than 150 different practical application. Special property of CCR is its ability to burn gaseous, liquid or solid fuel and waste, such as rubber tires, waste oil and others without any visible injurious pollution. All combustion by the CCR technology has to be done in following stages. The First stage is to use good common technology for Boiler, Stoves and Incinerators completed with... Stage two - the missing link between the burner and the boiler. Here is the key function for an always complete burnt combustion gas without PAH, polyaromatic hydrocarbons, and VOC, light gasformed carcinogen/cancer causing hydrocarbons as CO, formaldehydes, benzpyrenes and dioxines.

..... First now the process is entering stage Tree to condense the always clean burnt flue- gas to remove the acids from sulphur, chlorine, etcetera and to separate all micro particles down into the calcium filter-cake neutralizing sulphur into gypsum.

..... At stage Four, for complete recycling of the total combustion process the clean flue gas with its CO₂ leads into a lake/water system bubbling up CO₂ as a fertilizer able to grow rice and algae to give good protein.

..... The level of burning temperature in CCR is quite high and the temperature of its ceramic shell reaches 1000 1100°C. Thus, CCR is a good emitter of intensive infrared radiation (IR). The radiation heat flow rate is close to 80% of the total heat production of combustion chamber and only 20% goes out with flue gases.

..... The density of IR results to the small dimensions of apparatus, assembled with CCR. But being absorbed on the wall of boiler, the high temperature IR becomes heat upon quite low temperature.

..... According to the point of view of the Second Law of Thermodynamics Analyses the temperature drop between the boiler and the reactor must be regarded as a loss of the temperature potential. This loss can be reduced by transformation of the heat into another kind of energy, in particular, into electricity. It is rather desirable from the practical point of view.

..... When a boiler with CCR is powered with a device for electricity production it becomes a power plant for combined production of heat and power. In this case, the efficiency of heat's transformation into electricity determines only the value of the electricity part of total energy output, but doesn't influence the value of specific fuel expenditure for getting electricity. It gives the possibility to get relatively cheap electricity even with a rather low efficiency of heat's conversion into power, especially when CCR burns waste fuel.

..... The direct conversion of heat by means of thermoelectricity phenomena is not the only and the most effective way to do it. But this technology seems to be the simplest and the most suitable for CCR among all the available ones.

..... The advantages of the thermoelectric transformers, such as absence of any mechanical motion, noise and high-pressure equipment, high reliability, absence of service, seem to be a good addition to the advantages of CCR technology, which does not break it's ecological cleanliness and simplicity.

..... The inclusion of TPG into CCR boiler for domestic water heating with total heat capacity of about 2 MW is schematically shown at the Fig. below. There are also presented the major parameters of the boiler. They should be taken into account when TPG is calculated.

CCR equipped with TPG.

..... In the calculations, TPG is supposed to consist of one or two different cascades, each of which being formed by a number of semiconductor thermopiles that are joined together electrically. Connection is determined by electrical parameters of useful needed load. On its hot junction, each thermopile of the first (upper) cascade has a receiver plate which absorbs the IR of the CCR. Cold thermojunctions of thermopiles in the second (lower) cascade are assembled on the inner wall of the boiler.

..... Efficiency of TPG is firstly determined by the properties of thermoelectrical materials that are used. At the same time, the right choice of the materials depends on thermal regime of working of the cascades. It is determined by conditions of optimal accordance of TPG with IR emitter.

..... In the case of CCR NOCO-reactors, these materials are found by taking into consideration the thermal interaction between the reactor and the receiver plates of thermopiles. The higher the receiver plate's temperature, the bigger the electrical output of TPG, but so is its thermal resistance. Therefore, if the temperature of the CCR is constant, its heat power falls as the electrical output of TPG increases. This is the reason why there is an optimal temperature of thermopile receivers at which the electrical output of TPG reaches its maximum value. According to our calculation, the optimal temperature of the receiver is around 800 K to 900 K. This region assumes the optimal application of middle- and low - temperature materials in one or two cascades.

..... The results of more detailed calculations of TPG, which were held for CCR with the heat capacity of 2 MW (the IR capacity - 1.6 MW) in accordance with the traditional method of " average properties" [1], are presented in the table below. The calculations were held by taking into account the properties of easy available materials, such as low temperature triple alloys of Bi, Sb and Te, and middle temperature alloys of Pb and Te. The thermal leakage and contact electrical losses of TPG were determined as shown in [2,3]. According to the presented results, and using the single cascade low temperature, TPG (in 2 MW boiler) permits to obtain 115 kW of electricity production and does not visibly influence the CCR's work. The use of the double cascade increases the electrical output up to 196 kW, but makes the heat capacity of the reactor fall down to 12.5%. Therefore, any increase of working temperature to get more electricity must be accompanied by special measures directed to the intensification of heat transfer between the reactor and the TPG.

..... If the measures are successful, the efficiency of the TPG will go up to 20 %.

References
1. Thermoelements and thermoelectric devices. Reference book. L. Anatichuk . Kiev, Naukova dumka ,1979- 768 p.
2. Calculation and design of thermoelectrical generators and heat pumps. G. Kotirlo, G. Lobunech. Kiev, Naukova dumka, 1980 - 327 p.
3. B. Pozdniakov, E. Koptelov. Thermoelectric energetics. Moscow, Atom izdat, 1979.

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