HVAC furnace condensate removal system

Patent metadata

Field	Value
Publication number	US-10584896-B2
Application number	US-201715640240-A
Country	US
Kind code	B2
Filing date	Jun 30, 2017
Priority date	Aug 1, 2016
Publication date	Mar 10, 2020
Grant date	Mar 10, 2020

Abstract

A heating, ventilating, and air conditioning (HVAC) furnace includes a condensing furnace and a condensate removal system associated with the condensing furnace. The condensate removal system includes an electrolyzer having a container that may collect a condensate generated from an exhaust gas produced in the condensing furnace and an electrode disposed within the container and that may apply an electric current to the condensate to electrolyze the condensate and thereby generate condensate gases.

First claim

The invention claimed is:

1. A heating, ventilating, and/or air conditioning (HVAC) system, comprising:
a condensing furnace; and
a condensate removal system associated with the condensing furnace, wherein the condensate removal system comprises an electrolyzer comprising:
a container configured to collect a condensate generated from an exhaust gas produced in the condensing furnace;
an electrode disposed within the container and configured to apply an electric current to the condensate to electrolyze the condensate and thereby generate condensate gases including oxygen and hydrogen; and
a vent configured to direct the condensate gases including oxygen and hydrogen from the container toward atmosphere.

2. The HVAC system of claim 1 , wherein the condensate removal system comprises a switch electrically positioned between the electrode and a power source configured to generate the electric current.

3. The HVAC system of claim 2 , wherein the switch comprises a mechanical or electrical float device disposed within the container and configured to close an electric circuit between the power source and the electrode when the condensate is in contact with the mechanical or electrical float device.

4. The HVAC system of claim 1 , wherein the condensate removal system comprises a heater disposed within the container and configured to heat the condensate.

5. The HVAC system of claim 1 , wherein the container comprises a valve coupled to the vent and configured to release the condensate gases including oxygen and hydrogen from the container and through the vent, wherein the valve controls release of the condensate gases including oxygen and hydrogen based on a pressure within the container.

6. The HVAC system of claim 1 , wherein the condensate removal system comprises a temperature sensor coupled to the container to indirectly measure a temperature of the condensate.

7. The HVAC system of claim 6 , wherein the temperature sensor is positioned on the container such that the temperature sensor does not contact the condensate.

8. The HVAC system of claim 6 , wherein the temperature sensor is positioned adjacent to an inlet of the electrolyzer.

9. The HVAC system of claim 1 , wherein the condensing furnace comprises a first heat exchanger and a second heat exchanger disposed downstream from the first heat exchanger, wherein the condensate removal system is disposed downstream from the second heat exchanger, and wherein the second heat exchanger is configured to generate the condensate.

10. The HVAC system of claim 1 , comprising a controller configured to control operation of the HVAC system, wherein the controller comprises:
one or more tangible, non-transitory, machine-readable media collectively storing one or more sets of instructions; and
one or more processing devices configured to execute the one or more sets of instructions to:
monitor a temperature of the condensate, the container, or both, using a temperature sensor coupled to the electrolyzer; and
activate a heater disposed within the container and configured to heat the condensate in response to determining that the temperature of the condensate is below a temperature threshold.

11. The HVAC system of claim 1 , comprising a controller configured to control operation of the HVAC system, wherein the controller comprises:
one or more tangible, non-transitory, machine-readable media collectively storing one or more sets of instructions; and
one or more processing devices configured to execute the one or more sets of instructions to:
monitor a pressure within the electrolyzer using a pressure sensor coupled to the container; and
open a valve disposed on a vent of the container in response to determining that the pressure within the container is above a pressure threshold.

12. The HVAC system of claim 1 , wherein the condensate removal system is diposed disposed within the condensing furnace.

13. The HVAC system of claim 1 , wherein the HVAC system comprises a rooftop unit, and wherein the condensate removal system is disposed within the rooftop unit.

14. A heating, ventilating, and/or air conditioning (HVAC) system, comprising:
a condensate removal system associated with a condensing furnace of the HVAC system and comprising an electrolyzer, wherein the electrolyzer comprises:
a container having an inlet and an outlet, wherein the inlet is configured to receive and enable the container to collect a condensate generated within a section of the condensing furnace having a heat exchanger; and
an electrode disposed within the container and configured to apply an electric current to the condensate, wherein the electric current is configured to decompose the condensate to generate condensate gases including oxygen and hydrogen, and wherein the outlet of the container is fluidly coupled to a vent configured to direct the condensate gases including oxygen and hydrogen toward atmosphere.

15. The HVAC system of claim 14 , comprising a switch electrically coupled to the electrode and a power source configured to generate the electric current, wherein the switch is configured to transmit the electric current from the power source to the electrode in its closed state.

16. The HVAC system of claim 15 , wherein the switch comprises a mechanical or electrical float device disposed within the container and configured to detect a threshold level of the condensate within the container and to close an electric circuit between the power source and the electrode when the threshold level of the condensate is reached.

17. The HVAC system of claim 14 , comprising a heater disposed within the container and configured to heat the condensate when a temperature of the condensate, the container, or both is below a threshold temperature.

18. The HVAC system of claim 14 , comprising a temperature sensor coupled to the container to indirectly measure a temperature of the condensate.

19. The HVAC system of claim 14 , comprising a pressure sensor coupled to the container and configured to measure a pressure within the container.

20. The HVAC system of claim 14 , comprising a valve configured to control release of the condensate gases including oxygen and hydrogen via the outlet based on a pressure within the container.

21. The HVAC system of claim 20 , wherein the valve is a check valve set to a threshold pressure that is at or above an atmospheric pressure.

22. A method, comprising:
directing a condensate to a condensate removal system associated with a condensing furnace of a heating, ventilating, and/or air conditioning (HVAC) rooftop unit, wherein the condensate is generated from cooling an exhaust gas produced from combustion of a fuel within a burner of the condensing furnace, wherein the condensate removal system comprises an electrolyzer comprising a container, an electrode, and a vent, and wherein the container is configured to collect the condensate;
applying an electric current to the condensate in the container using the electrode to decompose the condensate and thereby generate condensate gases including oxygen and hydrogen; and
releasing the condensate gases including oxygen and hydrogen through the vent and into atmosphere.

23. The method of claim 22 , wherein applying electric current comprises activating a switch via a mechanical or electrical float device responsive to a level of the condensate in the container, wherein the switch is configured to communicatively coupled to a power source configured to generat

Assignees

• Johnson Controls Tech Co

Inventors

• Wilson Stephen C
• Knight John T

Classifications

• F24F13/22

  Means for preventing condensation or evacuating condensate · CPC title

• F24H9/16

  Arrangements for water drainage · CPC title

• F24D5/00

  Hot-air central heating systems (district heating systems F24D10/00; central heating systems using heat accumulated in storage masses F24D11/00; air conditioning F24F); Exhaust gas central heating systems · CPC title

• F24F3/001 Primary

  in which the air treatment in the central station takes place by means of a heat-pump or by means of a reversible cycle (reversible cycle for humidifying and drying air F24F3/147) · CPC title

• F24D2200/123

  Compression type heat pumps · CPC title