Description:FIELD OF THE INVENTION
The present invention relates to a liquid absorption carbon particulate filter (CPF) with a wet electrostatic precipitator and a separate liquid filtration method. More particularly, the invention relates to the self-cleaning tubular collection electrode which collects PM2.5, PM10, dust particles, and smoke particles by dissolving with a 30% w/v KOH solution or with 30% w/v NaCl solution.

BACKGROUND OF THE INVENTION
Particulate matter contains microscopic solids or liquid droplets that are so small which when inhaled cause serious health problems. Some particles less than 10 micrometers in diameter can get deep into your lungs and some may even get into your bloodstream. These particles which are less than 2.5 micrometers in diameter, also known as fine particles or PM2.5, pose great risk to health.
Particulate Matter 2.5 and Particulate Matter 10:
PM2.5 is associated with great proportion of adverse health effects related to air pollution, both in India and worldwide based on the World Health Organization’s Global Burden of Disease Project.
Particles in the PM 2.5 size range are able to travel deeply into the respiratory tract, reaching the lungs. Exposure to fine particles can cause short-term health effects such as eye, nose, throat, and lung irritation, coughing, sneezing, running nose, and shortness of breath. Exposure to fine particles can also affect lung function and worsen medical conditions such as asthma and heart disease. Scientific studies have linked increases in daily PM2.5exposure with increased respiratory and cardiovascular hospital admissions, emergency department visits, and deaths.
PM10 (particles with a diameter of 10 micrometers or less): these particles are small enough to pass through the throat and nose and enter the lungs. Once inhaled, these particles can affect the heart and lungs and cause serious health effects.
Electrostatic precipitators for the absorption of PM 2.5 and 10:
Electrostatic precipitators, or collectors, are known to the art. In the simplest form, an electrostatic precipitator has a collection electrode that is electrostatically charged. Adjacent to or surrounding the collection electrode is another surface that can be electrostatically charged. The collection electrode and the adjacent or surrounding surface are oppositely charged by a power source, thereby creating an electrostatic field.
There are two main types of electrostatic precipitators. Dry precipitators are essential as described above. Constituents collected on the electrode must be periodically wiped off or otherwise removed from the electrode, or the electrode must be replaced. Wiping mechanisms may be used, or the precipitator must be periodically shut down for cleaning.
Wet or liquid electrostatic precipitators also make use of collection electrodes. In this type of precipitator, however, the collection electrode is periodically or continually washed with a liquid. In these types of precipitators, the collection electrodes are generally planar sheets or plates and are arranged vertically. A liquid such as water is conveyed along the upper edges of the sheets or plate such that it flows down the electrodes. The liquid serves to clean the collection electrode(s) on a continuous or periodic basis, avoiding the need to stop the operation of the precipitator to clean or replace electrodes. The liquid is typically conveyed to a disposal system where it can be filtered and otherwise cleaned.
Limitations of current electrostatic precipitators:
For these major reasons, electrostatic precipitators known to the current technology are limited to be used for a prolonged time due to electrode dust composition and the physical cleaning process. They are also limited due to the huge size to be used at locations such as diesel vehicles, smoke emitters, hotels, and diesel generators. And another major limitation is that these electrostatic precipitators work for only removing dust particles, particulate matter, and smoke particles while limited to the absorption of unburned hydrocarbons, carbon monoxide, carbon dioxide, sulfur dioxide, nitrogen oxides, etc.

This limitation coined us the way for the development of a carbon particulate filter with a 30% w/v KOH solution atomizer spraying system on collection electrodes for self-cleaning of electrodes and the partial dissolving of unburned hydrocarbons, carbon monoxide, carbon dioxide, sulfur dioxide, PM2.5, PM10 and nitrogen oxides from the incoming flue gas and the dissolved solution is transported to the filtration system for purification. After the purification, the KOH liquid is recirculated to the carbon particulate filter and the cycle is carried on throughout the smoke absorption process.

OBJECT OF THE INVENTION
An object of the present invention is to provide a portable carbon particulate filter which has a liquid absorption filter chamber with self-cleaning of carbon particulate filter membrane.
An object of the present invention to provide separate portable filtration unit for dissolved solid particles in the absorption liquid which has been absorbed from vehicle exhaust or industrial exhaust.
Another object of the present invention relates to provide a KOH solution reaction chamber that is capable of dissolving a partial amount of unburned hydrocarbons, carbon monoxide, carbon dioxide, sulfur dioxide, and nitrogen oxides from the incoming flue gas.
This invention relates to an aqueous potassium hydroxide pre-wet electrostatic precipitator method that provides a reduction or dissolving of acid gases, hydrogen chloride, and hydrogen fluoride from the combusted flue gases.
This invention is directed towards the production of useful slurry residue, which can be used for the production of potassium compounds like potassium carbonate, potassium sulfate, and potassium nitrate, carbon powder that can be neutralized and separated by using electro dialysis or solar evaporation and that concentrated potassium compound residue can be used as potassium supplement fertilizer for plants, an alternative to potassium chloride fertilizer.
The present invention relates to a portable retrofitting setup that is mainly designed for Non-BS6 diesel vehicles and industrial chimneys, the device can be fitted directly to the exhaust port and the separate filtration unit can be fitted inside the car chassis or car bonnet.

SUMMARY OF THE INVENTION
The present invention relates to carbon particulate filter which has a liquid absorption chamber integrated with an electrostatic precipitator and self-filtration unit.
In one embodiment, The current invention is directed to a tubular collection carbon particulate filter with an electrostatic precipitator capable of collecting PM2.5, PM10, dust particles, and smoke particles by dissolving with 30% w/v KOH solution, and the dissolved solution is pumped to the filtration drum, where the PM2.5, PM10, carbon dust particles are trapped in the 1 micron HEPA pre-filter membrane and the remaining KOH solution gets purified through the membrane and reaches to the storage tank, this purified liquid is recirculated to the carbon particulate filter and the cycle is carried on throughout the smoke absorption process.
In another embodiment, present invention relates to a device with the partial dissolving of flue gas pollutants like unburned hydrocarbons, carbon monoxide, carbon dioxide, sulfur dioxide, and nitrogen oxides which dissolve in the KOH solution and this dissolved solution is filtered in the filtration unit and the purified solution is recirculated to the carbon particulate filter and the cycle is carried on. The solid particles will be trapped in the filtration unit which can be used as fertilizer to garden plants or disposed of, after neutralizing the obtained material.
Other aspects of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learnt by the practice of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 depicts diagrammatic illustration of a first design, a preferred embodiment of the linear designed structure of a carbon particulate filter with a vertical filtration method.
Figure 2 shows 2D illustration of the invention part names and part classifications.
Figure 3 represents 2D illustration of the second design with the direct insertion of a carbon particulate filter on the vehicle exhaust port or industrial exhaust port and a separate filtration unit.
Figure 4 is an illustration of the third design of the linear designed structure of a carbon particulate filter with a horizontal filtration method.
Figure 5 is an illustration of the fourth design of the carbon particulate filter without the electrostatic field method.
Figure 6 show 3D illustration of a linear carbon particulate filter with a horizontal filter.
Figure 7 depicts 3D illustration, a front-side view of a carbon particulate filter hub of the invention.
Figure 8 shows a device fixed to the exhaust port of the diesel car.
Figure 9 shows liquid storage tank and reservoir tank.
Figure 10 shows the car exhaust port connected to the carbon particulate filter inlet port.
Figure 11 shows an image of a beaker with collected solution.

Referring to the drawings, the embodiments of the present invention are further described. The figures are not necessarily drawn to scale, and in some instances the drawings have been exaggerated or simplified for illustrative purposes only. One of ordinary skill in the art may appreciate the many possible applications and variations of the present invention based on the following examples of possible embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
The following description is presented to enable any person skilled in the art to make and use the embodiments, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the scope of the present invention. Thus, the present invention is not limited to the embodiments shown, but is to be accorded the widest scope.
The present invention relates to a tubular-liquid absorption carbon particulate filter that uses self-filtration and electrostatic field method for the better absorption of PM 2.5, PM 10, carbon dust particles, and smoke particles. The specially designed filter is made of fine SS 120 mesh with a porous filter membrane which can be reused by dissolving fine solid particles with 30% w/v KOH Solution or with 30% w/v NaCl solution. The device is mainly designed to effectively absorb particulate matter and carbon dust particles from all type of diesel vehicles and industrial exhausts etc. The device consists of a high-pressure liquid transportation channel, SS fine mesh with porous filter, atomizer nozzles, electrostatic precipitator electrodes, HEPA filter, high pressure liquid transportation pump, and a compact Sealed SS enclosure. The exhaust gas flows through the carbon particulate filter inlet port where the primary atomizer sprays the KOH or NaCl solution which is mixed with the gases thoroughly, then the gas enters into the liquid absorption chamber where the soot, PM2.5, PM10, carbon particles, and dust in the exhaust gases are trapped by electrode surfaces, these particles which is dissolved by the spraying the KOH or NaCl solution and collected in the reservoir tank, this dissolved liquid is transported to filtration unit and releases the dust particles and gets purified, after the purification process KOH solution is recirculated to the carbon particulate filter and the cycle is carried out throughout the engine running process.
The invention is directed to a tubular collection carbon particulate filter with a pre-wet electrostatic precipitator capable of collecting PM2.5, PM10, dust particles, and smoke particles by dissolving with 30% w/v KOH solution or NaCl solution in which both of the electrodes and the porous filter is regenerated again and again by spraying KOH or NaCl solution continuously, and the dissolved solution is pumped to the filtration unit, where the PM2.5, PM10, carbon dust particles which will be trapped in the 1 micron HEPA filter membrane and the remaining solution gets purified through the membrane and reaches to the storage tank, this purified liquid is recirculated to the carbon particulate filter for liquid absorption process and the cycle is carried on throughout smoke absorption process.
Trace amount of gases like CO2, H2O, NO2, and SO2are partially reacted with KOH solution and the remaining gases are released through the exhaust port. In this way, both the electrostatic precipitator method and liquid absorption method are employed for the effective capture of PM2.5 - PM10, and carbon dust from non-BS6engines and industrial exhaust.

Partial Flue Gas Absorption Process:
Potassium Hydroxide with Carbon monoxide:
〖CO〗_((g))+〖KOH〗_((aq))→〖KHCO〗_(2(aq))
Potassium Hydroxide with Carbon dioxide:
〖KOH〗_((aq) )+〖CO〗_(2(g))→〖KHCO〗_(3(aq))

Potassium Hydroxide with Sulfur dioxide:
〖2KOH〗_((aq) )+〖SO〗_(2(g))→K_2 〖SO〗_(3(aq))+H_2 O_((1))
Potassium Hydroxide with Nitrogen oxides:
〖6NO〗_(x(g))+〖4KOH〗_((aq))→〖4KNO〗_(2(aq))+N_(2(g))+〖2H〗_2 O_((1))
Particulate matter 2.5μm - 10μm + KOH(catalyst) + H2O(liquid medium) → Blackslurry
The following description shows different designs for the carbon particulate filter;-
DESIGN 1:
The design is developed as a linear designed structure of a carbon particulate filter with a vertical filtration method.
DESIGN 2:
The design is developed as a direct insertion of a carbon particulate filter on the vehicle exhaust port or industrial exhaust port and a separate filtration unit as a portable model.
DESIGN 3:
The design is developed as the linear designed structure of a carbon particulate filter with a horizontal filtration method.
DESIGN 4:
The design is developed without the electrostatic field, which runs only with a liquid atomizer nozzle for the effective liquid absorption of carbon particles and particulate matter.
FIG. 1 shows, a 2D diagrammatic form design 1, some of the primary components of the apparatus according to the invention. The design is related to a linear carbon particulate filter with an inbuilt vertical filtration unit.
FIG. 2 is a 2D diagrammatic form, in which the vehicle exhaust port (1) is connected to the carbon particulate filter through tube connector port (2), and the inlet CPF tube is fitted with a primary atomizer nozzle (3) the tube (10) is projected to ¾ of the carbon particulate filter, which is 4mm holed SS tube, the CPF hub contains negative electrode (8) surrounded by porous filter membrane (7)and the membrane is surrounded by the positive electrode (6),the electrodes are connected to the respective positive terminal (30) and the negative terminal (4) which is highly insulated by a ceramic insulator (13). The CPF is mounted on a Teflon membrane (5) for better insulation and grip.
The filter membrane is surrounded by a 4mm holed SS hub (11) and it is enclosed by the SS sealed enclosure (9), at the back side of the CPF there is a secondary atomizer nozzle (14) which is used for effective solid particle absorption, at the back side of the CPF the gases flow out after filtration through the 4mm porous SS plate (15) and the gases enters into the exhaust port (24) and gets exited through the CPF exhaust port (17).
The solid dust particle dissolved KOH solution gets collected in the absorption liquid reservoir tank (28) and the 12 volt DC diaphragm pump (29) pumps the solution through pipe channels (27) to the filtration unit and the solution is distributed through the distributor nozzle (18) and the solution is filtered by the 1 micron filtration membrane(19).
The filtration system contains a 1 micron HEPA filter (19) mounted inside the filtration chamber, the incoming dissolved KOH liquid gets purified by the filter membrane and the filtered solution gets collected in the reservoir tank (22), this filtered KOH liquid is transported to the carbon particulate filter through the high pressure pump (23) through the distribution channels (12) and the liquid is feed to primary atomizer nozzle (3) and secondary atomizer nozzle (14).
The filtration system can be opened with opened for cleaning purposes periodically. The carbon particulate filter can also be opened regularly which is waterproof and sealed by a hand lock clamp (25) on both sides of CPF. The entire CPF and filtration unit is mounted on the MS rod frame (26) which can be used for surface mounting on the required place in diesel vehicles.
FIG. 3 is a 2D diagrammatic form of design 2, where the carbon particulate filter is inserted into the vehicle exhaust port or industrial exhaust port and the filtration unit is fixed separately as a portable unit. The filtration unit is mounted on the MS frame (31) and can be fixed to the vehicle chassis or as required. This filtration unit contains both the liquid transportation pumps, mainly the suction pump (32), and the filtered solution transportation high pressure pump (33) is placed inside the filtration unit.
FIG. 4 is a 2D diagrammatic form of design 3, which demonstrate the linear carbon particulate filter with a horizontal filtration method, in this design the liquid filtration unit is mounted horizontally with double-side rubber housing (35)(37) and mounted on the SS wall (34). The dissolved solution is pumped into the center of the filter membrane through the discharge tube (36).
The below table shows part name and specifications as per Fig.2, Fig.3, Fig. 4.
Numerals Part name Material / Spec
01 Vehicle exhaust port SS tube
02 CPF - exhaust port connectors SS connectors
03 CPF inlet port atomizer nozzle Brass atomizer nozzle
04 High voltage negative terminal High voltage ( - ) connection port
05 High-temperature rubber gasket Teflon gasket
06 High voltage positive electrode SS (+) electrode
07 Porous SS membrane filter Porous 120 mesh SS filter
08 High voltage negative electrode SS ( - ) electrode
09 Outer SS Hub SS fabrication
10 CPF inlet 4mm holed tube SS tube
11 SS mesh 4mm holed Mesh
12 Filtered solution transportation
tube Pneumatic tube
13 High voltage insulator Ceramic insulator
14 CPF Backward nozzle Brass nozzle
15 SS back filter mesh SS 4mm Mesh
16 Open - close clamp MS clamp
17 Gas exhaust port SS tube
18 Filter distributor nozzle Brass nozzle
19 Filter drum. HEPA filter
20 Filter membrane 1 micron HEPA filter membrane
21 Hand open-close clamp, lock type Hand lock clamp
22 Reservoir Tank Storage tank HDPE
23 High pressure diaphragm pump 12 DC volt pump
24 Exhaust port SS tube
25 Lock clamps Hand lock clamp
26 CPF frame - chassis connector rod MS frame
27 Absorption solution transportation tube Pneumatic tube
28 Absorption liquid reservoir tank SS enclosed tank
29 Liquid transportation pump DC 12 volt pump
30 High voltage positive terminal. High voltage ( + ) connection port.
31 Filter connector rod MS rod fabrication
32 Dissolved solution suction pump Diaphragm 12-volt DC pump
33 Filtered solution transportation high pressure pump High pressure 12-volt DC pump
34 Filter mounting wall SS plate
35 Filter mounting port. Rubber housing
36 Absorption solution discharge port Nozzle
37 Filter backside mounting port Rubber Housing

Experimental Results:
The device is fixed to the exhaust port of the diesel car which is fixed with the additional frame attached to the vehicle chassis as shown in FIG .8. The separate carbon particulate filter is equipped with a 120-mesh porous SS filter drum, and an atomizer sprayer nozzle is attached at the back side of the drum, and the porous SS filter is enclosed with an SS container that acts as a liquid storage tank and reservoir tank as shown in the image FIG. 9.
In the phase of testing, the car exhaust port is connected to the carbon particulate filter inlet port, where the gases enter into the SS filter chamber as shown in the image FIG. 10, the atomizer nozzle sprays the KOH solution into fine droplets directly to the incoming gases, where the PM2.5, PM10, and carbon dust particles get dissolved, and the dissolved solution gets collected in the reservoir tank.
The collected solution in the reservoir tank is transported to the filtration unit by using a diaphragm DC 12 Volt pump for filtration process. The collected solution appears as a Black liquid that contains PM 2.5 - PM10 sized particles and carbon dust particles as shown in FIG 11.
The filtration unit contains a 1-micron filter membrane. The incoming particulate matter dissolved solution from the carbon particulate filter is fed inside the filter at high pressure using a pump and the solution gets filtered leaving out the large particles up to PM 10 and carbon dust particles, and these particles are deposited in the filter membrane and the filter is cleaned periodically for removing the particle slurry and after cleaning the filter is reused again and again or changed periodically.
After the solution is filtered, the solution gets collected in the filtration unit reservoir tank and the filtered solution is pumped to the carbon particulate filter atomizer nozzle by using a 12-volt high pressure diaphragm DC pump.
In this manner, the KOH solution is used for dissolving the particulate matter and carbon particles of the diesel vehicle exhaust and after dissolving the solution is filtered by the filtration unit and re-circulated to the carbon particulate filter and this cycle is continued throughout the engine running process.
The KOH solution acts as a catalyst for the effective absorption of Particulate matter and carbon dust particles and also partially reacts with carbon monoxide, sulfur oxides, and nitrogen oxides.
As of FIG 2, the vehicle exhaust gas enters into the carbon particulate filter inlet port (1) where the primary atomizer nozzle (3) sprays KOH solution from the filtration unit reservoir chamber (22). The exhaust gas which contains PM2.5, PM10, and solid particles will get dissolved into the KOH solution and the gas enters into the carbon particulate filter hub, where the secondary atomizer nozzle (14) sprays the KOH solution for the secondary effective absorption of the solid particles.
After the liquid absorption process, the gas is passed through the 4 mm SS mesh (15) and passed into the exhaust port (24) and gets existed through the carbon particulate filter exhaustion (17). The dissolved solution flows down the reservoir tank where the pump (29), pumps the residue liquid through the transportation channel (27) into the filtration unit (19) for filtration process.
After the filtration process the solution gets collected in the filter reservoir tank (22) which is pumped by using a high pressure pump (23) and transports to the carbon particulate filter and the cycle is continued until the engine running process. This is a continuous flow reactor where the carbon particulate filter and self-filtration unit are integrated for the effective absorption process.
It may be appreciated by those skilled in the art that the foregoing drawings, examples and experimental evidences are merely illustrative and are not to be taken as limitations upon the scope of the invention. Various changes and modifications to the disclosed embodiments will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the scope of the invention. , Claims:We Claim:
1. A portable tubular-liquid absorption carbon particulate filter for absorption of PM2.5, PM10, carbon dust particles, and smoke particles from the exhaust flue gas of a diesel engine vehicle and industrial exhausts, comprises
a carbon particulate filter integrated with an electrostatic precipitator and self- filtration unit;
wherein the exhaust flue gas enters into the carbon particulate filter inlet port (1) where the primary atomizer nozzle (3) sprays KOH solution from the filtration reservoir chamber (22);
wherein the exhaust flue gas which contains PM2.5, PM10, and solid particles get dissolved into the KOH solution, where the secondary atomizer nozzle (14) sprays the KOH solution for the secondary effective absorption of the solid particles;
wherein the flue gases are filtered through the porous SS membrane (7) and through the electrostatic field (6)(8) in which the fine-sized particles get trapped on the electrode surface, the trapped particles are dissolved by the KOH solution, and after the electrostatic absorption, the gas is passed through the 4mm SS mesh (15) and passed into the exhaust port (24) and gets existed through the carbon particulate filter exhaustion (17);
wherein the dissolved solution flows down the reservoir tank where the pump (29), pumps the residue liquid through the transportation channel (27) into the filtration unit (19) for filtration process;
wherein the solution gets collected after the filtration process in the reservoir tank (22) which is pumped by using a high pressure pump (29) and transports to the carbon particulate filter;
characterized in that, the carbon particulate filter with 30%w/v KOH atomizer spraying system partially dissolves particulate matters and solid particles from the incoming flue gas and the dissolved solution is transported to the filtration unit for purification and the purified solution is recirculated to the carbon particulate filter and the cycle is continued until the engine running process.
2. The portable tubular-liquid absorption carbon particulate filter as claimed in claim 1, wherein the filter is fitted directly to the exhaust port of the vehicle or industrial exhaust and the separate liquid filtration unit is fitted inside the vehicle chassis or bonnet.
3. The portable tubular-liquid absorption carbon particulate filter as claimed in claim 1, wherein the ionization of the chamber is increased by introducing fine KOH droplets.
4. The portable tubular-liquid absorption carbon particulate filter as claimed in claim 1, wherein the unburned Hydrocarbons, carbon monoxide, carbon dioxide, sulfur dioxide, and nitrogen oxides from the incoming flue gas are partially dissolved into the aqueous30% w/v KOH solution.
5. The portable tubular-liquid absorption carbon particulate filter as claimed in claim 1, wherein the high-voltage generator capable of producing an ionizing voltage of DC 10 - 50 kv for the production of high electrostatic fields, and the static fields is increased by introducing fine droplets of KOH solution.
6. The portable tubular-liquid absorption carbon particulate filter as claimed in claim 1, wherein the 1 micron HEPA filter absorbs PM 2.5, PM 10, and carbon dust particles from the absorbing solution.
7. The portable tubular-liquid absorption carbon particulate filter as claimed in claim 1, wherein the HEPA filter is removed periodically for cleaning and the filter membrane is reused again and again or replaced periodically.
8. The portable tubular-liquid absorption carbon particulate filter as claimed in claim 1, wherein the filter membrane contains useful slurry residue contains dissolved particles of potassium carbonate, potassium sulfate, potassium nitrate, potassium hydroxide, carbon particles, PM2.5, and PM10 which are reused by neutralizing by means of chemical electro dialysis or solar evaporation method.
9. The portable tubular-liquid absorption carbon particulate filter as claimed in claim 1, wherein the filter is made of fine SS 120 mesh with a porous filter membrane which is reusable by dissolving trapped solid particles with 30% w/v KOH Solution.
10. The portable tubular-liquid absorption carbon particulate filter as claimed in claim 1, wherein the filter is designed with a vertical or horizontal filtration unit for portable design.
11. The portable tubular-liquid absorption carbon particulate filter as claimed in claim 1, wherein the carbon particulate filter is self-cleaned by the KOH solution without manual intervention.
12. The portable tubular-liquid absorption carbon particulate filter as claimed in claim 1, wherein the electrostatic precipitator electrode is cleaned by KOH solution periodically for the regeneration of electrodes without shutting down the operation or manual cleaning process.