Air heater for a drying tower and drying tower for drying a product to be dried
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Solution Overview
Problem
Existing air heaters for dry towers experience temperature fluctuations in heated air, which can degrade product quality and increase fire and explosion hazards in temperature-sensitive processes.
Innovation Solution
Incorporating a sacrificial combustion chamber with multiple openings distributed over its lateral surface, surrounding the flame, to enhance uniform heat distribution and complete combustion, thereby stabilizing the temperature of the process air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a conventional air heater with direct fuel injection is used, then the heating efficiency is high, but the temperature of the heated air fluctuates significantly
Solution Approach 1:
The combustion chamber is segmented into an inner combustion chamber and an outer combustion chamber. The inner chamber handles the primary combustion process while the outer chamber provides a controlled environment for heat distribution. This segmentation allows the system to maintain high heating efficiency in the inner chamber while achieving temperature stability through the moderating effect of the outer chamber walls and distributed heat release ports.
Solution Approach 2:
The outer combustion chamber acts as an intermediary between the intense combustion in the inner chamber and the process air. It distributes the heat more evenly through its walls and heat release ports, preventing direct exposure of process air to temperature extremes and fluctuations, thereby stabilizing the output temperature while maintaining heating efficiency.
2Power
If the combustion chamber walls are directly exposed to the flame, then the heating effect is strong, but the walls require frequent monitoring and replacement
Solution Approach 1:
The combustion chamber is divided into inner and outer chambers, separating the high-temperature combustion zone from the structural walls. The inner chamber can be designed with materials optimized for withstanding intense heat, while the outer chamber provides structural support and easier access for maintenance, reducing overall maintenance complexity while maintaining heating power.
Solution Approach 2:
The inner combustion chamber is designed as a replaceable component that can be easily swapped out when worn or damaged. This allows the use of less durable but more effective heating materials in the inner chamber, while the outer chamber and other structural components remain intact, reducing overall maintenance costs and complexity.
3Use of energy by moving object
If fuel is burned directly in contact with process air, then the heating efficiency is high, but emissions and incomplete combustion increase
Solution Approach 1:
The two-chamber design separates the combustion process from direct contact with process air. The inner chamber completes the combustion process with controlled air supply, while the outer chamber allows for more complete combustion of any remaining fuel before heat is transferred to the process air, reducing emissions while maintaining heating efficiency.
Solution Approach 2:
The outer combustion chamber extends the combustion process, allowing continuous and more complete combustion of fuel. This ensures that fuel is fully burned before heat transfer to process air, eliminating incomplete combustion products and reducing harmful emissions while maintaining continuous heating efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves a consistent temperature delivery of heated air with reduced emissions and extended equipment lifespan, ensuring high-quality drying processes and safety by maintaining temperature fluctuations within ±5°C.
Implementation Method 1
Fuel burned by means of the burner, a heat generated thereby released in the combustion chamber
Implementation Method 2
a uniform heat distribution within the combustion chamber is achieved and thus a more uniform delivery of the heat generated by the combustion to the process air
Implementation Method 3
the sacrifice chamber within the Brennkammer is arranged... the sacrifice combustion chamber has a plurality of openings, which are distributed over a lateral surface
Data Source
Figure 1
AI summary
The invention relates to an air heater for a drying tower, wherein the air heater has a combustion chamber, a burner, an air heating chamber, a process air inlet, a process air outlet, and/or a flue gas outlet, wherein, in the case of an operation of the air heater, process air is supplied to the air heating chamber via the process air inlet, a fuel is burned by means of the burner, heat thereby generated in the combustion chamber is discharged to the process air in the air heating chamber, and the heated process air is discharged out of the air heater via the process air outlet, and the air heater has a sacrificial combustion chamber, wherein the sacrificial combustion chamber is arranged within the combustion chamber. The invention further relates to a drying tower for drying a product to be dried by means of an air heater.