Braided Burner Flame Stabilization Flashback Resistance
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Solution Overview
Problem
Existing surface burners for premixed combustion face challenges in achieving effective flame stabilization, resistance to flashback, oxidation resistance, long-term reliability, and maintaining low emissions while operating under high thermal and mechanical stresses, especially at elevated temperatures and pressures.
Innovation Solution
A burner with a braided surface formed by intertwining or interweaving an elongated flexible element made of multiple strands of yarn across a structural frame, creating curved and inclined flow channels of variable cross section, which enhances flame stabilization and resistance to flashback without the need for pre-fabricated cloths or cooling elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional surface burners (ceramic/metal felt, perforated decks, knitted burners) are used for premixed combustion, then flame stabilization is achieved, but resistance to flashback, oxidation resistance, and long-term reliability deteriorate under high thermal and mechanical stresses
Solution Approach 1:
The patent employs an elongated flexible element (such as a cord or ribbon) made of oxidation-resistant material that is braided or woven into a three-dimensional structure. This flexible element forms a surface burner that maintains structural integrity under thermal stress while providing effective flashback resistance through its intricate braided configuration, which creates tortuous flow paths that prevent flame propagation back into the fuel supply.
Solution Approach 2:
The burner utilizes a composite structure combining an oxidation-resistant flexible material (such as ceramic-coated metal or high-temperature alloy) braided into a three-dimensional configuration. This composite approach provides both the necessary thermal/oxidation resistance and the structural stability required for long-term reliable operation under high thermal and mechanical stresses.
2Temperature
If cooling elements are added to burner heat exchangers to manage thermal load, then hardware temperature is reduced, but combustion characteristics are negatively affected (burning temperature, velocity, stability, flashback, blow-off, dynamics, noise)
Solution Approach 1:
The patent deliberately excludes cooling elements from the burner design, extracting the heat management function from the combustion system. By using oxidation-resistant materials that can withstand high temperatures without active cooling, the invention maintains pure premixed combustion characteristics and avoids the negative impacts of cooling on burning temperature, velocity, stability, and combustion dynamics.
3Ease of manufacture
If pre-fabricated metal cloth or textile articles are used for knitted burners, then manufacturing is simplified, but flame stabilization effectiveness and flashback resistance are reduced
Solution Approach 1:
The patent employs a flexible element that is braided or woven into a three-dimensional structure, creating a dynamic, tortuous flow path configuration that enhances flame stabilization and flashback resistance. The flexible nature of the braided structure allows it to adapt to thermal expansion and mechanical stresses while maintaining effective flame anchoring, overcoming the limitations of rigid pre-fabricated metal cloth.
4Strength
If the burner surface is made from rigid materials to maintain structural integrity, then oxidation resistance improves, but flexibility to accommodate thermal expansion and mechanical stress deteriorates
Solution Approach 1:
The patent uses a flexible element made of oxidation-resistant material that is braided into a three-dimensional structure. This configuration provides both the necessary oxidation resistance for high-temperature operation and the structural flexibility to accommodate thermal expansion and mechanical stresses, resolving the contradiction between rigidity and flexibility.
Data Source
AI summary
A surface burner for gas combustion has a burner surface which is fabricated by intertwining or interweaving an elongated flexible element across a distinct burner frame. This fabrication method can be best referred to as braiding, but also plaiting, lacing or another comparable method.