Methanol pilot burner

Abstract

The present application relates to a kind of methanol ignition combustor, belong to methanol combustion technical field.It includes methanol supply module, combustion module, combustion air supply module, multistage atomization mixing module and intelligent control module;Fuel supply module is used to store and deliver methanol fuel to combustion module;Combustion air supply module is used to provide combustion air;Multistage atomization mixing module is used to provide compressed air, assist methanol fuel atomization;Combustion module includes methanol inlet section, air inlet cavity, mixed cyclone section, nozzle outlet section and flame stabilization assembly connected in turn;Intelligent control module is electrically connected with fuel supply module, combustion air supply module and multistage atomization mixing module respectively.The present application provides a kind of methanol ignition combustor, by using methanol fuel, clean combustion without sulfur without black smoke;By multistage atomization and internal mixing type cyclone structure, effectively prevent carbon deposition, reduce maintenance frequency, by PLC intelligent closed-loop control, realize accurate regulation of air-fuel ratio.

Description

Technical Field

[0001] This invention relates to a methanol ignition burner, belonging to the field of methanol combustion technology. Background Technology

[0002] The safe start-up, shutdown, and stable operation of industrial boilers, kilns, and various combustion devices highly depend on reliable ignition and combustion stabilization devices. Currently, the industry generally uses diesel ignition burners as the mainstream ignition device for the start-up ignition and low-load combustion stabilization of such equipment. These burners use diesel fuel and achieve ignition and combustion stabilization functions through fuel atomization and air-assisted combustion, making them the most widely used ignition device in traditional combustion systems.

[0003] Although diesel ignition burners are a mature and widely used technology, they have several inherent technical defects in actual operation, failing to meet the requirements of modern industrial combustion equipment for low cost, low emissions, high stability, long lifespan, and easy maintenance. These defects are as follows:

[0004] The high cost of diesel fuel procurement means that long-term continuous use will significantly increase the overall operating costs of the equipment and raise the company's operating costs.

[0005] High-temperature combustion of diesel fuel easily produces carbon deposits, which can clog burner nozzles, leading to unstable flames and requiring frequent shutdowns for cleaning and maintenance, thus affecting the continuous operating efficiency of the equipment.

[0006] Diesel combustion produces pollutants such as black smoke, particulate matter, and sulfur oxides, and emission standards are difficult to meet increasingly stringent environmental control requirements.

[0007] It requires complex auxiliary facilities such as oil storage, filtration, and pressurization. During operation, it is prone to problems such as pipeline leakage, oil pump failure, and filter blockage, resulting in low equipment reliability.

[0008] The combustion flame is highly rigid and directly impacts the furnace walls and refractory materials, easily causing refractory material burn-out, localized overheating of the furnace, and shortening the furnace's service life.

[0009] In winter, diesel fuel has high viscosity and poor fluidity at low temperatures. It has poor atomization during cold starts, which can easily lead to ignition failure and black smoke. It also has poor adaptability to low-temperature operating conditions.

[0010] Insufficient precision in controlling the fuel and combustion air ratio can lead to flame instability and flameout under low load conditions, making it impossible to guarantee reliable stable combustion under low load. Summary of the Invention

[0011] This invention provides a methanol ignition burner to solve the problems of high operating costs, easy carbon buildup and blockage, frequent maintenance, complex fuel supply system, high failure rate, low control accuracy, and weak stable combustion at low loads in the prior art.

[0012] This invention provides a methanol ignition burner, comprising:

[0013] A fuel supply module is used to store and supply methanol fuel to the combustion module;

[0014] Combustion-supporting air supply module, used to provide combustion-supporting air;

[0015] A multi-stage atomization mixing module is used to provide compressed air to assist in the atomization of methanol fuel;

[0016] The combustion module includes a methanol inlet section, an air inlet chamber, a mixing swirl section, a nozzle outlet section, and a flame stabilization component connected in sequence. The methanol inlet section is connected to the fuel supply module, and the air inlet chamber is connected to the combustion-supporting air supply module and the multi-stage atomization mixing module. The methanol fuel, combustion-supporting air, and compressed air are mixed and atomized in the mixing swirl section and then sprayed out through the nozzle outlet section, and the flame is stabilized by the flame stabilization component.

[0017] The intelligent control module is electrically connected to the fuel supply module, the combustion air supply module, and the multi-stage atomization mixing module, respectively, and is used to adjust the operating status of each module according to a preset program or sensor feedback signal to realize closed-loop regulation of methanol fuel supply and combustion air volume.

[0018] Preferably, the fuel supply module includes a methanol storage tank, a high-precision filter, a high-pressure methanol pump, a methanol electric regulating valve, a methanol mass flow meter, and a second pressure transmitter connected in sequence; the methanol storage tank is equipped with a first pressure transmitter; the high-pressure methanol pump adopts frequency conversion control and works in conjunction with the methanol electric regulating valve to regulate the fuel supply.

[0019] Preferably, the combustion-supporting air supply module includes a combustion-supporting fan, a filter, a first electric regulating valve, and a turbine flow meter connected in sequence; the combustion-supporting fan is a variable frequency type and adjusts the air supply volume according to the instructions of the intelligent control module.

[0020] Preferably, the multi-stage atomizing mixing module includes an air compressor, a refrigerated dryer, an air tank, a second electric regulating valve, an electromagnetic flow meter, and a fourth pressure transmitter connected in sequence; the air tank is equipped with a third pressure transmitter.

[0021] Preferably, the mixing swirl section adopts an internal mixing structure, which is provided with an adjusting column, a fixed seat and a nozzle base inside; the fixed seat is provided with multiple annular diversion holes, and the nozzle base is provided with multiple annularly arranged nozzles. The nozzles are set at an angle to the axis, so that the gas-liquid mixture forms a swirl when it is ejected.

[0022] Preferably, the adjusting column is disposed inside the fixed base, and its insertion depth is adjusted by a threaded connection to change the flow cross-sectional area of ​​methanol fuel.

[0023] Preferably, the nozzle exit section is made of high-temperature resistant hard alloy material, with a diameter of 2-4 mm and an atomization cone angle of 45°; the flame stabilizing component is installed at the end of the nozzle exit section.

[0024] Preferably, the flame stabilizing component has a disc structure, with multiple radially swirling blades evenly arranged on the disc. The inclination angle of the swirling blades is 15-30°, and a circular opening is provided in the central area of ​​the disc.

[0025] Preferably, the high-pressure methanol pump pressurizes the methanol for primary mechanical atomization; the multi-stage atomization mixing module provides compressed air into the air intake chamber, where it undergoes secondary air-assisted atomization with the methanol in the mixing swirl section.

[0026] Preferably, the outlet of the combustion module is connected to the furnace, and the furnace is equipped with a first thermocouple, a second thermocouple, and a third thermocouple; the intelligent control module includes a PLC control cabinet, which contains a PLC controller, a touch screen, and an actuator drive module; the PLC controller is electrically connected to the methanol mass flow meter, the turbine flow meter, the electromagnetic flow meter, the first pressure transmitter, the second pressure transmitter, the third pressure transmitter, the fourth pressure transmitter, the first thermocouple, the second thermocouple, and the third thermocouple, respectively.

[0027] The beneficial effects of this invention are:

[0028] This invention provides a methanol ignition burner that uses methanol as fuel, which has a low cost and effectively reduces fuel procurement costs, thereby reducing the company's operating costs.

[0029] By optimizing the combustion process and adopting a multi-stage atomization method with primary mechanical atomization and secondary air-assisted atomization, combined with an internal mixing swirl section, methanol and air are fully mixed, atomized evenly, and combusted completely, significantly extending continuous operating time and reducing maintenance frequency.

[0030] Methanol atomization produces a gentle flame, which, combined with the flame stabilization components, creates a low-speed recirculation zone, stabilizing the flame and preventing it from directly scouring the furnace, thus extending the furnace's lifespan.

[0031] By acquiring real-time sensor signals such as methanol flow rate, air flow rate, pressure, and furnace temperature through a PLC controller, precise air-fuel ratio control can be achieved, maintaining stable combustion even under low-load conditions. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the overall structure of a methanol ignition burner according to the present invention.

[0033] Figure 2 This is a schematic diagram of the structure of a methanol ignition burner according to the present invention.

[0034] Figure 3 This is a schematic diagram of the mixing swirl section structure of a methanol ignition burner according to the present invention.

[0035] Figure 4 This is another schematic diagram of the mixing swirl section of a methanol ignition burner according to the present invention.

[0036] Figure 5 This is a schematic diagram of the flame stabilization component structure of a methanol ignition burner according to the present invention.

[0037] In the diagram: 1. Methanol storage tank; 2. Safety valve; 3. First pressure transmitter; 4. High-precision filter; 5. High-pressure methanol pump; 6. Methanol electric regulating valve; 7. Methanol mass flow meter; 8. Second pressure transmitter; 9. Methanol ignition burner; 10. Furnace; 11. First thermocouple; 12. Second thermocouple; 13. Third thermocouple; 14. Combustion fan; 15. Filter; 16. First electric regulating valve; 17. Turbine flow meter; 18. Air compressor; 19. Refrigerated dryer; 20. Gas storage tank; 21. Third pressure transmitter; 22. Second electric regulating valve; 23. Electromagnetic flow meter; 24. Fourth pressure transmitter; 25. PLC control cabinet; 26. Methanol inlet section; 27. Air inlet chamber; 28. Mixing swirl section; 29. ​​Nozzle outlet section; 30. Flame stabilization assembly; 31. Regulating column; 32. Fixing base; 33. Nozzle base. Detailed Implementation

[0038] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] This embodiment provides a methanol ignition burner, including a methanol supply module, a combustion module, a combustion-supporting air supply module, a multi-stage atomization mixing module, and an intelligent control module;

[0040] The combustion module includes a methanol ignition burner 9, which includes a methanol inlet section 26, an air inlet chamber 27, a mixing swirl section 28, a nozzle outlet section 29, and a flame stabilization component 30, wherein the methanol inlet section 26, the air inlet chamber 27, the mixing swirl section 28, the nozzle outlet section 29, and the flame stabilization component 30 are connected in sequence.

[0041] The methanol supply module is used to store, filter and stably transport methanol fuel. It mainly includes a methanol storage tank 1, a high-precision filter 4 and a high-pressure methanol pump 5. The methanol storage tank 1 is equipped with a safety valve 2 and a first pressure transmitter 3. The outlet of the methanol storage tank 1 is connected to the inlet of the high-precision filter 4 through a methanol-resistant pipeline to filter impurities in the fuel and prevent downstream components from being blocked. The outlet of the high-precision filter 4 is connected to the inlet of the high-pressure methanol pump 5. The outlet of the high-pressure methanol pump 5 is connected in sequence to a methanol electric regulating valve 6, a methanol mass flow meter 7 and a second pressure transmitter 8. The outlet of the second pressure transmitter 8 is connected to the methanol inlet section 26 of the combustion module through a methanol-resistant heat-insulated pipeline.

[0042] The methanol storage tank 1 preferably adopts a double-layer stainless steel structure with insulation material in between to reduce methanol volatilization. The high-pressure methanol pump 5 is made of stainless steel that is resistant to methanol corrosion. Its motor adopts frequency conversion control and works in conjunction with the methanol electric regulating valve 6 to achieve closed-loop precise regulation of fuel supply.

[0043] The combustion air supply module is used to provide stable combustion air for the combustion process and to regulate the mixing ratio of air and methanol. It includes a combustion air blower 14, a filter 15, a first electric regulating valve 16, and a turbine flow meter 17. The outlet of the combustion air blower 14 is connected to the inlet of the filter 15. The combustion air blower 14 adopts a frequency conversion structure and can adjust the air supply volume in real time according to the instructions of the intelligent control module. The filter 15 is used to filter dust and impurities in the air. The outlet of the filter 15 is connected in sequence to the first electric regulating valve 16 and the turbine flow meter 17. The outlet of the turbine flow meter 17 is connected to the air intake chamber 27 of the combustion module through an air duct. The outlet of the combustion module is connected to the furnace 10. The furnace 10 is equipped with a first thermocouple 11, a second thermocouple 12, and a third thermocouple 13.

[0044] The multi-stage atomization mixing module includes an air compressor 18, a refrigerated dryer 19, and an air tank 20. The outlet of the air compressor 18 is connected to the inlet of the refrigerated dryer 19, and the outlet of the refrigerated dryer 19 is connected to the inlet of the air tank 20. The air tank 20 is equipped with a third pressure transmitter 21. The outlet of the air tank 20 is sequentially connected to a second electric regulating valve 22, an electromagnetic flow meter 23, and a fourth pressure transmitter 24. The outlet of the fourth pressure transmitter 24 is connected to the compressed air inlet of the combustion module via an air pipe.

[0045] The intelligent control module includes a PLC control cabinet 25, which contains a PLC controller, a touch screen, and various actuator drive modules. The PLC controller is electrically connected to the first pressure transmitter 3, the second pressure transmitter 8, the third pressure transmitter 21, the fourth pressure transmitter 24, the methanol mass flow meter 7, the turbine flow meter 17, the electromagnetic flow meter 23, the first thermocouple 11, the second thermocouple 12, and the third thermocouple 13. The PLC controller receives the detection signals from the above sensors and adjusts the operating status of the high-pressure methanol pump 5, the combustion fan 14, the air compressor 18, the refrigerated dryer 19, and the methanol electric regulating valve 6, the first electric regulating valve 16, and the second electric regulating valve 22 in real time according to the preset program.

[0046] The methanol inlet section 26 is made of corrosion-resistant 316L stainless steel, and its inlet is connected to the outlet of the high-pressure methanol pump 5. The air inlet chamber 27 is equipped with a methanol inlet and a compressed air inlet, which are connected to the methanol supply pipeline and the compressed air pipeline, respectively.

[0047] The mixing swirl section 28 adopts an internal mixing structure. It contains an adjusting column 31, a fixed base 32, and a nozzle base 33. The fixed base 32 has six annular diversion holes that converge at the center of the nozzle base. The nozzle base 33 has twelve annularly arranged nozzles, evenly distributed and angled at 30° with the axis, causing the gas-liquid mixture to form a high-speed swirl upon ejection, greatly improving mixing uniformity and atomization effect. The adjusting column 31 is located inside the fixed base 32 and its insertion depth can be adjusted via a threaded connection, thereby changing the flow cross-sectional area of ​​the methanol fuel in the middle to adapt to different combustion conditions.

[0048] The nozzle exit section 29 is made of high-temperature resistant hard alloy material. The diameter of the nozzle exit section 29 is 2-4mm, and the atomization cone angle is about 45°. The flame stabilization component 30 is installed at the end of the nozzle exit section 29, about 10mm away from the nozzle. The main body of the flame stabilization component 30 is a disc structure. Multiple radial swirl blades with inclination angles are evenly arranged on the disc. The inclination angle of the swirl blades is 15-30°. The central area has a circular opening with a diameter of about 50mm, which can guide the combustion air to form a controllable swirl field and generate a low-speed backflow zone at the burner outlet to ensure flame stability and prevent flameout.

[0049] When the system is powered on, the PLC controller performs a self-test and receives initial signals from all sensors. The PLC controller then starts the high-pressure methanol pump 5, air compressor 18, and combustion fan 14. Methanol is pressurized to 0.5-1.5 MPa by the high-pressure methanol pump 5 for primary mechanical atomization. Simultaneously, compressed air at 0.3-0.6 MPa enters the air intake chamber 27. Methanol and compressed air are vigorously mixed in the mixing swirl section 28, achieving secondary air-assisted atomization.

[0050] When the silicon nitride ceramic igniter is powered on, it generates a high-temperature electric spark. The atomized methanol-air mixture is ejected at high speed from the nozzle outlet section 29 and ignited by the electric spark. The swirling field generated by the flame stabilization component 30 stabilizes the flame combustion. The flame detector monitors the flame status in real time. If ignition fails, the PLC controller immediately cuts off the fuel supply and sounds an alarm.

[0051] During combustion, the PLC controller reads data from the methanol mass flow meter 7, turbine flow meter 17, and the first thermocouple 11, second thermocouple 12, and third thermocouple 13 in real time. Based on the preset air-fuel ratio and temperature target, the PLC controller dynamically adjusts the opening of the methanol electric regulating valve 6 and the speed of the combustion fan 14 through a PID algorithm.

[0052] Compared to existing designs, methanol storage tank 1 adopts a double-layer stainless steel structure filled with insulation material, effectively reducing methanol volatilization. Compared to traditional storage tanks, it can store methanol fuel more stably, reducing fuel loss and safety hazards caused by volatilization. Methanol storage tank 1 is equipped with a safety valve 2 and a first pressure transmitter 3, which can monitor the tank pressure in real time to ensure storage safety. The high-pressure methanol pump 5 uses a frequency converter motor and works in conjunction with the methanol electric regulating valve 6 to achieve closed-loop precise regulation of fuel supply. This allows for precise control of fuel supply according to actual needs, avoiding excessive or insufficient fuel supply, and improving combustion efficiency and stability.

[0053] A high-precision filter 4 is installed to filter methanol fuel and prevent clogging of downstream components. The outlet of methanol storage tank 1 is connected to the inlet of high-precision filter 4 via an alcohol-resistant pipeline. The outlet of high-precision filter 4 is connected to the inlet of high-pressure methanol pump 5, which extends the service life of the equipment.

[0054] The combustion air blower 14 adopts a variable frequency structure, which can adjust the air volume in real time according to the instructions of the intelligent control module. The outlet of the combustion air blower 14 is connected to the inlet of the filter 15. The outlet of the filter 15 is connected in sequence to the first electric regulating valve 16 and the turbine flow meter 17. The outlet of the turbine flow meter 17 is connected to the air intake chamber 27 of the combustion module through the air duct. It can flexibly adjust the supply of combustion air according to different combustion conditions and methanol supply, ensuring that the air-methanol mixing ratio is always in the optimal state and improving combustion efficiency.

[0055] Filter 15 is used to filter dust and impurities in the air, ensuring the quality of the air entering the combustion module. Clean air helps improve combustion efficiency and reduces the damage of impurities to the combustion process and equipment.

[0056] The mixing swirl section 28 adopts an internal mixing structure, internally equipped with an adjusting column 31, a fixed seat 32, and a nozzle base 33. The fixed seat 32 has six annular diverting holes that converge at the center of the nozzle base. The nozzle base 33 has twelve annularly arranged nozzles, evenly distributed and at a 30° angle to the axis, causing the gas-liquid mixture to form a high-speed swirl upon ejection, greatly improving mixing uniformity and atomization effect. The adjusting column 31 is located inside the fixed seat 32 and its insertion depth can be adjusted via a threaded connection, thereby changing the flow cross-sectional area of ​​the methanol fuel in the middle to adapt to different combustion conditions.

[0057] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the invention, such designs should fall within the protection scope of the present invention.

Claims

1. A methanol ignition burner, characterized in that, include: A fuel supply module is used to store and supply methanol fuel to the combustion module; Combustion-supporting air supply module, used to provide combustion-supporting air; A multi-stage atomization mixing module is used to provide compressed air to assist in the atomization of methanol fuel; The combustion module includes a methanol inlet section (26), an air inlet chamber (27), a mixing swirl section (28), a nozzle outlet section (29), and a flame stabilization component (30) connected in sequence. The methanol inlet section (26) is connected to the fuel supply module. The air inlet chamber (27) is connected to the combustion-supporting air supply module and the multi-stage atomization mixing module. The methanol fuel, combustion-supporting air, and compressed air are mixed and atomized in the mixing swirl section (28) and then sprayed out through the nozzle outlet section (29), and the flame is stabilized by the flame stabilization component (30). The intelligent control module is electrically connected to the fuel supply module, the combustion air supply module, and the multi-stage atomization mixing module, respectively, and is used to adjust the operating status of each module according to a preset program or sensor feedback signal to realize closed-loop regulation of methanol fuel supply and combustion air volume.

2. The methanol ignition burner according to claim 1, characterized in that: The fuel supply module includes a methanol storage tank (1), a high-precision filter (4), a high-pressure methanol pump (5), a methanol electric regulating valve (6), a methanol mass flow meter (7), and a second pressure transmitter (8) connected in sequence; the methanol storage tank (1) is equipped with a first pressure transmitter (3); the high-pressure methanol pump (5) adopts frequency conversion control and works in conjunction with the methanol electric regulating valve (6) to regulate the fuel supply.

3. A methanol ignition burner according to claim 2, characterized in that: The combustion-supporting air supply module includes a combustion-supporting fan (14), a filter (15), a first electric regulating valve (16), and a turbine flow meter (17) connected in sequence; the combustion-supporting fan (14) is a variable frequency structure, and the air supply volume is adjusted according to the instructions of the intelligent control module.

4. A methanol ignition burner according to claim 3, characterized in that: The multi-stage atomizing mixing module includes an air compressor (18), a refrigerated dryer (19), an air tank (20), a second electric regulating valve (22), an electromagnetic flow meter (23), and a fourth pressure transmitter (24) connected in sequence; the air tank (20) is equipped with a third pressure transmitter (21).

5. A methanol ignition burner according to claim 1, characterized in that: The mixing swirl section (28) adopts an internal mixing structure, which is provided with an adjusting column (31), a fixed seat (32) and a nozzle base (33) inside. The fixed seat (32) is provided with multiple annular diversion holes, and the nozzle base (33) is provided with multiple annularly arranged nozzles. The nozzles are set at an angle to the axis, so that the gas-liquid mixture forms a swirl when it is ejected.

6. A methanol ignition burner according to claim 5, characterized in that: The adjusting column (31) is located inside the fixed base (32) and its insertion depth is adjusted by a threaded connection to change the flow cross-sectional area of ​​methanol fuel.

7. A methanol ignition burner according to claim 5, characterized in that: The nozzle outlet section (29) is made of high-temperature resistant hard alloy material, with a diameter of 2-4 mm and an atomization cone angle of 45°; the flame stabilizing component (30) is installed at the end of the nozzle outlet section (29).

8. A methanol ignition burner according to claim 7, characterized in that: The flame stabilizing component (30) is a disc structure with multiple radial swirling blades with tilt angles evenly arranged on the disc. The tilt angle of the swirling blades is 15-30°, and a circular opening is provided in the central area of ​​the disc.

9. A methanol ignition burner according to claim 2, characterized in that: The high-pressure methanol pump (5) pressurizes methanol for primary mechanical atomization; the multi-stage atomization mixing module provides compressed air into the air intake chamber (27), where it undergoes secondary air-assisted atomization with methanol in the mixing swirl section (28).

10. A methanol ignition burner according to claim 4, characterized in that: The outlet of the combustion module is connected to the furnace (10), and the furnace (10) is provided with a first thermocouple (11), a second thermocouple (12), and a third thermocouple (13); the intelligent control module includes a PLC control cabinet (25), which is provided with a PLC controller, a touch screen and an actuator drive module; the PLC controller is electrically connected to the methanol mass flow meter (7), the turbine flow meter (17), the electromagnetic flow meter (23), the first pressure transmitter (3), the second pressure transmitter (8), the third pressure transmitter (21), the fourth pressure transmitter (24), the first thermocouple (11), the second thermocouple (12) and the third thermocouple (13).

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