Apparatus and method to optimize the functioning of a boiler to heat water

FIELD OF THE INVENTION

The present invention concerns an apparatus and a method to optimize the functioning of a boiler, or heat generator, particularly of the solid biomass fuel type, such as pellets or suchlike or similar to pellets, chip or similar solid biomass fuel in the form of particulate, granules or similar, to heat water for a user machine, such as a heating plant of the domestic type, a tank to accumulate water, or other.

BACKGROUND OF THE INVENTION

An apparatus to regulate a boiler using solid biomass fuel, such as pellets or suchlike or similar to pellets, chip or similar solid biomass fuel in the form of particulate, granules or similar, to heat water, which comprises a pump to circulate the water, a three-way valve, a device to regulate the thermal power of the boiler, a temperature sensor at exit from the boiler, and an electronic control unit connected to the temperature sensor.

In general it must first be considered that boilers using solid biomass fuel in question, unlike wood burners, gas burners or liquid fuel burners, have a very long transitory switch-on and switch-off time, in the range of half an hour; that is, they do not have an on/off behavior where the generation of heat, and hence the heating of the water, is almost instantaneous. On the contrary, they have long waiting times until they reach normal operating temperature conditions, and therefore, in said transitory times, the water heating is not optimal.

One disadvantage of such boilers using solid biomass fuel to heat water, connected to the long switch-on and switch-off times described above, is that if the water is too cold, condensation forms in the combustion chamber and the drops of condensation, together with the combustion fumes, cause unwanted compounds, such as creosote and tar, which are deposited on the walls of the heat exchanger.

Generally speaking, known boilers comprise a delivery pipe, which conveys the hot water toward the outside, and a return pipe, which returns the water back inside the boiler. The three-way valve is located on the return pipe and is connected, by means of a by-pass pipe, to the delivery pipe, in order to possibly mix a certain quantity of hot water with the return water. In this way the return water can be heated before returning inside the boiler. In order to perform this mixing, the valve is commanded by the electronic control unit when the temperature detected by the sensor goes below a determinate value. Alternatively, the system may be managed by a thermostatic member with a predefined and constant set point.

In this way, the pre-heated water entering into the boiler allows to keep the heat interchange wall between the water and the combustion fumes at a temperature such as to prevent the formation of condensation. Condensation, as we said, which mixing with the soot, would form creosote and tar that would cause the formation of incrustations and hence occlusions.

The pump, controlled by the electronic control unit, is only able to function in the so-called "on/off' mode, and therefore is switched on and works at maximum power, or is switched off. The alternation of these two time phases allows to vary the flow rate of the hot water sent to the user machine and consequently the heat load used thereby.

The known apparatus functions according to a method that provides to set a reference value of the water temperature, which must possibly be maintained at exit from the boiler and precisely in the delivery pipe. If the temperature value detected by the temperature sensor is less than the one set, the electronic control unit commands both the device to regulate the boiler so that the maximum thermal power is produced, and also commands the pump to switch on. If, on the contrary, the temperature value detected by the temperature sensor is more than or equal to the one set, the electronic control unit commands the boiler to turn itself down, or even to temporarily switch off.

One disadvantage of the known apparatus is the presence of the three-way valve, which increases the hydraulic load losses for which the pump has to compensate. Furthermore, the known apparatus does not guarantee that the water temperature at exit from the three-way valve and entering into the boiler is high enough to prevent the formation of condensation inside the boiler.

Another disadvantage is that the hydraulic pump with an on/off functioning increases the consumption of electric energy, since it cannot function, when switched on, at other operating conditions other than maximum. Consequently, the pump cannot convey water flow rates other than maximum.

Another disadvantage is that detecting only one temperature value does not allow to regulate the functioning of the boiler precisely, and it is therefore not very adaptable to the different types of user machines to which the boiler is associated. Indeed, with this type of management, no information is provided concerning what happens downstream of the hot water generator. The prior art documents DE-A-19956222, EP-A-0.816.766, DE-A-102006009047 and DE-C-19710905 are known, which generally describe known control apparatuses applicable to boilers for heating water associated with a user machine, the main purpose of which is to guarantee the heat requirements of the user machine and not to optimize the functioning of the heat generator itself.

In particular, DE-A-19956222 describes a known control apparatus which provides a by-pass valve to mix a part of heated water at exit from the delivery pipe with cold water entering the boiler from a return pipe, a temperature sensor associated with the delivery pipe, a temperature sensor associated with the return pipe and a temperature sensor of the outside environment. The known control apparatus uses the data detected by the sensors to command the switching on and off of the pump and the heater at specific intervals according to a predetermined algorithm.

EP-A-0.816.766, DE-A-102006009047 and DE-C-19710905 describe similar control apparatuses which provide a temperature sensor associated with the delivery pipe and a temperature sensor associated with the return pipe and able to transmit coordinated electric signals associated with the temperatures detected, according to which the functioning of the pump is commanded on each occasion so as to define a desired water flow rate.

One purpose of the present invention is to obtain an apparatus for the functioning of a boiler using solid biomass fuel, such as pellets or suchlike or similar to pellets, chip or similar solid biomass fuel in the form of particulate, granules or similar, which allows to prevent condensation inside the boiler in a simple and safer way, and to reduce the load losses for which the pump has to compensate.

Another purpose of the present invention is to obtain an apparatus that reduces electric consumption of the pump.

Another purpose of the present invention is to perfect a functioning method of the boiler that is accurate, precise and easily adaptable to different types of user machine.

The Applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages.

SUMMARY OF THE INVENTION

The present invention is set forth and characterized in the independent claims, while the dependent claims describe other characteristics of the invention or variants to the main inventive idea.

In accordance with the above purposes, an apparatus according to the present invention can be used to optimize the functioning of a boiler or heat generator, suitable to heat water for a user machine and having a delivery pipe, a return pipe, and a heat exchanger comprising a heat interchange wall between the water to be heated and the combustion fumes.

The present invention is particularly advantageous to optimize the functioning of a boiler or heat generator using solid biomass fuel, such as pellets or suchlike or similar to pellets, chip or similar solid biomass fuel in the form of particulate or granules or suchlike.

The apparatus according to the present invention comprises pumping means suitable to make the water circulate in the boiler, between the return pipe and the delivery pipe, and a first temperature sensor to detect a first temperature of the water in the delivery pipe.

According to one feature of the present invention, a second temperature sensor is associated to the return pipe to detect a second temperature of the water in the return pipe, and adjustment means are associated to the pumping means, to selectively vary the flow rate of the pumping means depending on the temperature detected by at least one of either the first temperature sensor or the second temperature sensor.

According to the present invention, the adjustment means comprise an electronic control unit provided with a memory and associated to at least the first temperature sensor and to the second temperature sensor and power varying means in order to selectively vary the flow rates of the pumping means depending on at least the first and second temperature, detected by at least the first temperature sensor and the second temperature sensor.

According to the present invention, the electronic control unit is configured to compare the difference in the values of the first and second temperatures with a maximum temperature difference value between the first and the second temperature and with a minimum temperature difference value between the first and the second temperature: the maximum and minimum values are predetermined and memorized in the memory of the electronic control unit.

Moreover, according to the present invention, the electronic control unit is also configured to carry out a comparison of an actual average value of the values of the first and second temperatures with a first predetermined value, indicative of the start-up temperature of the pumping means, and with a second predetermined value indicative of the temperature of the interchange wall of the heat exchanger of the boiler, both memorized in the memory.

With the present invention it is therefore possible to easily and automatically vary the flow rate of the hot water exiting and therefore to vary, in particular, to slow down the flow of heat to the outside, in order to raise the temperature of the boiler, in particular of the interchange walls of the heat exchanger of the boiler, and therefore eliminate the undesirable phenomenon of condensation.

Moreover, with the present invention it is possible to make the boiler work in optimal heat exchange conditions, reducing electricity consumption, particularly deriving from the pumping means. According to the present invention the pumping means are controlled in their functioning to maintain optimal the heat difference represented by the maximum value of temperature difference between the first temperature and the second temperature.

According to another feature of the present invention, the electronic control unit is also associated to means to feed the solid fuel toward the combustion chamber of the boiler in order to regulate the thermal power delivered.

According to another inventive feature of the present invention, the method to optimize the functioning of a boiler suitable to heat water for a user machine comprises a first step in which a first temperature of the water in the delivery pipe is measured, and a second step in which a second temperature of the water in the return pipe is measured.

According to another feature of the present invention, the method also comprises a third step in which the flow rate of the pumping means is regulated depending on at least one of the two temperatures measured in the first and the second step.

According to another feature of the present invention, the third step of the method, carried out according to a first work program of an electronic control unit, comprises a first sub-step of comparing the difference of the values of the temperatures with a maximum temperature difference value and with a minimum temperature difference value predetermined and memorized in a memory of the electronic control unit connected to the pumping means.

Moreover, according to another feature of the present invention, the third step of the method also comprises a second sub-step of comparing an actual average value of the values of the temperatures with a first predetermined value, indicative of the start-up temperature of the pumping means, and with a second predetermined value indicative of the temperature of the interchange wall of the heat exchanger of the boiler, both memorized in the memory of the electronic control unit.

According to a variant, the method comprises a third sub-step in the third step, carried out according to a third work program of the electronic control unit, which compares the value of the first temperature with a third predetermined temperature value, memorized in the memory of the electronic control unit.

According to a further feature of the present invention, in the third step, the electronic control unit regulates the thermal power of the boiler acting on means to feed a solid fuel toward a combustion chamber of the boiler.

According to one feature of the present invention, in the third step, adjustment means vary the flow rate of the pumping means, in a linear manner between a minimum value and a maximum value.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other characteristics of the present invention will become apparent from the following description of a preferential form of embodiment, given as a non-restrictive example with reference to the attached drawings wherein:

• fig. 1 is a schematized perspective view of an apparatus according to the present invention;
• fig. 2 is a schematized view of the apparatus and boiler in fig. 1, connected to a first user machine;
• fig. 3 is a schematized view of the apparatus and boiler in fig. 1, connected to a second user machine;
• fig. 4 is a schematized view of the apparatus and boiler in fig. 1, connected to a third user machine;
• fig. 5 is a schematized view of the apparatus and boiler in fig. 1, connected to a fourth user machine.

To facilitate comprehension, the same reference numbers have been used, where possible, to identify identical common elements in the drawings. It is understood that elements and characteristics of one form of embodiment can conveniently be incorporated into other forms of embodiment without further clarifications.

DETAILED DESCRIPTION OF SOME PREFERENTIAL FORMS OF EMBODIMENT

With reference to fig. 1, an apparatus 10 according to the present invention is shown installed in a boiler or heat generator 11 of a known type, in this case using solid biomass fuel, for example pellets or suchlike or similar to pellets, chip or similar solid biomass fuel in the form of particulate, granules or similar, suitable to heat hot water to be conveyed to a user machine 12, which can be for example a heating plant, a tank to accumulate water, or other.

The apparatus 10 comprises a pump 13 (figs. 1 and 2), a device 14 to regulate the thermal power of the boiler 11, an electric power variator 21 of the pump 13, a first temperature sensor 16a, a second temperature sensor 16b and an electronic control unit 15 connected to them.

The boiler 11 comprises a combustion chamber 22, fed with solid fuel, in this case pellets, by means of an Archimedes screw 23 driven by an electric motor 24, controlled by the device 14 to regulate the thermal power. The boiler 11 also comprises a heat exchanger 19 having a heat interchange wall 19a between the water circulating in a first zone 19b and the fumes F, produced by combustion, circulating in a second zone 19c. The boiler 11 also comprises a delivery pipe 17 for the hot water and a return pipe 18 for the cold water, connected to the user machine 12.

The temperature sensor 16a is mounted on the delivery pipe 17 to detect a first temperature T1 of the water in the delivery pipe 17, while the second temperature sensor 16b is mounted on the return pipe 18 to detect a second temperature T2 of the water in the return pipe 18.

According to a variant, shown in figs. 3, 4 and 5, the apparatus 10 also comprises a third temperature sensor 16c, which is positioned near the user machine 12 (fig. 3), or inside it (figs. 4 and 5).

The disposition of the temperature sensors 16a and 16b allows to detect the water temperature both at inlet and at outlet of the boiler 11, so that it is also possible to estimate, with sufficient approximation, the value of the water temperature inside the boiler 1 l, which is substantially equal to the temperature of the interchange wall 19a of the heat exchanger 19.

The pump is disposed in series on the return pipe 18 and, by means of the power variator 21 connected to it, is able to vary the flow rate of the water from a minimum value (Q_min) to a maximum value (Q_max), as will be described in more detail hereafter.

The sensors 16a, 16b and 16c are connected to the electronic control unit 15 which comprises a memory 25 and is programmed to control, in response to the signals from the sensors 16a, 16b and possibly 16c, both the electric power variator 21 of the pump 13, and also the device 14 which regulates the thermal power of the boiler 11, so as to satisfy the heat requirements of the user machine 12.

The apparatus 10 as described heretofore functions as follows.

In a first form of embodiment according to the present invention, when the user machine 12 consists of a hydraulic heating plant (fig. 2), the control unit 13 executes a first work program, memorized in its memory 25, both to optimize the functioning of the plant 12 and also to prevent condensation inside the boiler 11.

In this case the method provides that a first reference temperature P1 is set in the memory 25, to start up the pump 13, for example 30°C, and a second temperature P2 of the interchange walls 19a, for example 45°C.

When the boiler 11 is functioning, the control unit 15 continuously calculates the real value Tc of the temperature of the heat interchange walls 19a. The value Tc is an average weighted between a temperature value T1 of the water in the delivery pipe 17, detected by the first sensor 16a, and a temperature value T2 of the water in the return pipe 18, detected by the second sensor 16b.

If the Tc value calculated is equal to or less than value P2, there is a danger of condensation on the heat interchange walls 19a; in particular, if the Tc value calculated is also less than value P1, there is a risk of excessive cooling of the heat interchange walls 19a and hence of reducing the performance of the boiler 11.

In this case, in order to prevent the formation of condensation on the heat interchange walls 19a, the control unit 15, to control the temperature value Tc, keeps the boiler 11 in conditions of nominal power, which correspond to conditions of maximum efficiency, by means of the device 14 to regulate the thermal power. To do this, it acts on the pump 13 by means of the power variator 21, so that a greater delivery of cold water is conveyed to the boiler 11 when it is necessary to lower the temperature value Tc and a lower delivery when it is necessary to increase the temperature value Tc.

In particular, in this case the following three conditions may arise, which have corresponding actions of the electronic control unit 15:

• a1) if Tc<P1, the pump functions at minimum flow rate Q_min.
• b1) if Tc=P2, the pump functions at maximum flow rate Q_max.
• c1) if P1<Tc<P2, the pump functions and modulates the flow rate linearly between the minimum flow rate Q_min and the maximum flow rate Q_max.

On the contrary, if Tc is greater than P2, there is no danger of condensation in the heat exchanger 19, and therefore in a second mode of the method, able to ensure an efficient and accurate functioning of the boiler 11, the control unit 15 compares the difference in temperature, called ΔT, between the temperature values T1, detected by the first sensor 16a, and T2, detected by the second sensor 16b, with two reference values memorized in the memory 25 and called ΔT_max and ΔT_min. In particular ΔT_max refers to the maximum value of ΔT acceptable, for example 8°C, whereas ΔT_min refers to the minimum value of ΔT, for example 3°C. In this other case the control unit 15 is set to keep the value of ΔT as near as possible to the optimum value of heat exchange ΔT_max, and in any case to keep this value greater than ΔT_min so as to prevent the water from passing inside the boiler 11 without acquiring the maximum possible quantity of heat. In order to do this, the control unit 15 acts on the pump 13 by means of the power variator 21, so that a greater quantity of cold water is conveyed, if the ΔT value detected is near to or greater than the value of ΔT_max, and a smaller quantity of cold water if the ΔT value detected is near to or less than the value ΔT_min. The thermal power of the boiler 11 is instead kept at the nominal value by means of the device 14 to regulate the thermal power.

In this other case the following other three conditions may arise, which have corresponding actions of the control unit 15:

• d1) if ΔT <ΔT_min, the pump functions at minimum flow rate Q_min.
• e1) if ΔT >ΔT_max, the pump functions at maximum flow rate Q_max.
• f1) if ΔT_min<ΔT<ΔT_max, the pump functions and modulates the flow rate linearly between the minimum flow rate Q_min. and the maximum flow rate Q_max.

This method ensures an efficient functioning of the boiler 11, which thus minimizes the heat consumption of the pump 13, so as to minimize the electric consumption of the corresponding motor and to respond quickly to the requirements of the user machine 12.

In a second form of embodiment of the present invention, shown schematically in fig. 3, there is the third temperature sensor 16c in the environment heated by the heating plant 12. In this configuration the control unit 15 executes a second work program memorized in the memory 25.

In this case, the method provides that a temperature T_A is set, to be maintained in the environment heated by the user machine 12, the actual value T3 of which is measured by the third temperature sensor 16c. In the memory a hysteresis temperature value I_A is also memorized, relating to T_A, and a temperature value Tw, relating to the temperature of the water exiting from the boiler 11, the actual value T1 of which is measured by the first temperature sensor 16a. The control unit 15 acts on the pump 13, in the same way as described above for the first work program and on the boiler 11, by means of the device 14 to regulate the thermal power, so as to make the boiler 11 function in conditions of maximum power, or respectively minimum power, if T3 is lower than the difference between T_A and I_A or respectively above T_A. The boiler 11 is instead made to function in power modulation if the value of T3 is comprised between T_A and the difference between T_A and I_A.

In particular, the following five conditions may arise, which have corresponding actions of the electronic control unit 15:

• a2) if T3<(T_A _ I_A), the boiler 11 functions at maximum power.
• b2) if T3=T_A, the boiler 11 functions at minimum power.
• c3) if T3>T_A, the boiler 11 is switched off.
• d3) if (T_A- I_A)<T3 <T_A and T1 <Tw, the boiler 11 functions at maximum power.
• e3) if (T_A-I_A)<T3<T_A and T1>Tw,the boiler 11 modulates the power to keep T1 = Tw.

This functioning method reduces heat consumption of the boiler 11 and ensures a prompt and efficient response to the requirements of the user machine 12 and guarantees optimized electric consumption of the pump 13.

In a third form of embodiment of the present invention, shown schematically in fig. 4, when the user machine 12 consists of a tank 26 to accumulate hot water and it is provided that the latter is heated by an internal coil 27, and that the third temperature sensor 16c is located inside the tank 26, the control unit 15 is programmed to execute a third work program memorized in its memory 25. In this case, the method provides that the following are memorized in the memory 25: a temperature value T_ACC to be maintained in the tank 26, the actual value T3 of which is measured by the third temperature sensor 16c; a hysteresis temperature value I_ACC, relating to T_ACC; a temperature value Tw, relating to the temperature of the water exiting from the boiler 11, the actual value T1 of which is measured by the first temperature sensor 16a. The control unit 15, by means of the device 14 to regulate the thermal power, keeps the boiler 11 at its maximum power, so that temperature T3 is as equal as possible to the value T_ACC, and switches it off when temperature T3 is greater than temperature T_ACC. Furthermore, in order to eliminate the danger of condensation, the control unit 15 acts on the pump 13, by means of the power variator 21, as described in the first case of the first work program (Tc≤P2). On the contrary, if Tc>P2, the control unit 15 acts on the pump 13 so as to keep the water temperature value T1 equal to the reference value Tw. In particular, if T1 is less than Tw, the control unit 15 will reduce the flow rate of the pump 13 to convey less cold water to the boiler 11; on the contrary, if T1 is greater than Tw, the control unit 15 increases the flow rate of the pump 13, to convey more cold water to the boiler 11. In particular the following three work conditions may arise, corresponding to three conditions of the electronic control unit:

• a3) if T3<(T_ACC-I_ACC) and (T_ACC-I_ACC)<T3<T_ACC, the boiler 11 functions at maximum power and the pump 13 modulates the flow rate to keep T1 equal to Tw.
• b3) if T3>T_ACC, the boiler 11 is switched off and the pump modulates the flow rate to keep T1 equal to Tw.
• c3) if T3>T_ACC and T1<T2+1, the boiler 11 is switched off.

This method allows to optimize consumption of the boiler 11 and to respond promptly to the requirements of the user machine 12 by means of the pump 13.

In a fourth form of embodiment of the present invention, shown schematically in fig. 5, when the user machine 12 consists of a tank 28 to accumulate hot water directly arriving from the boiler 11 and the third temperature sensor 16c is located inside the tank 28, the control unit 15 is programmed to execute a fourth work program memorized in the memory 25.

In this case, the method is similar to the one executed by the third work program of the control unit 15 previously described. In fact, by means of the device 14 that regulates the thermal power, the control unit 15 makes the boiler 11 function at its maximum power until the temperature value T3, measured by the third sensor 16c, is less than or equal to the temperature value T_ACC, as happened in the third work program. It switches it off when the temperature value T2 is greater than or equal to the reference temperature value T_ACC, and not when the temperature value T3 is greater than the value T_ACC.

This way of making the boiler 11 function is due to the fact that the water in the tank 28 is hotter in the upper part, where the sensor 16c is positioned, and is colder in the lower part from which the water entering into the boiler 11 exits, and the temperature T2 of which is detected by the second temperature sensor 16b. In this way the control unit 15 switches on the boiler 11 when the temperature T3 detected by the third sensor 16c is lower than the reference value T_ACC, and switches it off when the temperature T2 detected by the second temperature sensor 16b is equal to or greater than the reference value T_ACC. In this way it is guaranteed that the water contained in the tank 28 remains above the reference temperature T_ACC,

In particular, the following three work conditions may arise, corresponding to three conditions of the control unit 15:

• a4) if T3<(TA_CC - I_ACC) and (T_ACC - I_ACC)<T3<T_ACC, the boiler 11 functions at its maximum power and the pump 13 modulates the flow rate to keep T1 equal to Tw.
• b4) if T2> T_ACC, the boiler 11 is switched off and the pump 13 modulates the flow rate to keep T1 equal to Tw.
• c4) if T2>T_ACC and T1<T2+1, both the boiler 11 and the pump 13 are switched off.

It is clear that modifications and/or additions of parts may be made to the apparatus 10 and the methods to optimize the functioning of a boiler as described heretofore, without departing from the field and scope of the present invention.

It is also clear that, although the present invention has been described with reference to some specific examples, a person of skill in the art shall certainly be able to achieve many other equivalent forms of apparatus and/or methods to optimize the functioning of a boiler , having the characteristics as set forth in the claims and hence all coming within the field of protection defined thereby.