Submerged Combustion Burner Change-Out System
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Solution Overview
Problem
In submerged combustion melting (SCM) processes, the frequent replacement of submerged combustion burners requires shutting down the entire melting system, leading to significant downtime due to the need to cool and drain the molten matrix, which is inefficient and disrupts continuous operation.
Innovation Solution
A method and system for replacing burners without shutting down the melter system, involving the formation of a skull of material around the burner using a cooling liquid to isolate it from the molten matrix, allowing the burner to be moved to a cooler position outside the melt vessel for replacement, and using a cooling vessel to accelerate the cooling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the burner is replaced using prior approaches, then the burner can be removed for service and replacement, but the entire melting system must be shut down, requiring removal of molten matrix and cooling of components, resulting in considerable system downtime
Solution Approach 1:
The system is divided into separate functional components: the burner assembly, the melt vessel, and the cooling system. The burner can be independently removed and replaced without affecting the overall system operation, allowing maintenance of one component while others continue functioning.
Solution Approach 2:
The burner is extracted from the melt vessel through a designated opening while the vessel remains in operation. The cooling system is separately controllable, allowing the burner to be removed and replaced without requiring extraction or cooling of the entire melt vessel contents.
Solution Approach 3:
A cooling system is installed around the burner prior to replacement operations. This preliminary cooling capability allows the burner to be cooled and removed independently while the melt vessel maintains operational temperature, enabling burner replacement without shutting down the entire system.
2Ease of operation
If the burner is replaced by cooling and draining the molten matrix, then the burner can be accessed for replacement, but significant time is lost due to system shutdown and cooling requirements
Solution Approach 1:
A cooling system acts as an intermediary between the burner and the melt vessel. This intermediate cooling mechanism allows the burner to be cooled and removed independently without requiring cooling of the entire melt vessel, thus providing access to the burner without time-consuming system-wide cooling.
Solution Approach 2:
Cooling is applied locally to the burner assembly rather than globally to the entire melt vessel. The cooling system is positioned around the burner only, allowing selective cooling and removal of the burner while the bulk melt remains hot and operational.
3Reliability
If the entire melting system is shut down for burner replacement, then the burner can be safely removed and replaced, but continuous operation is disrupted and production losses occur
Solution Approach 1:
The system is segmented into independently controllable units. The burner assembly can be safely removed and replaced in isolation while the melt vessel and other system components continue operating, maintaining production continuity while ensuring safe burner replacement procedures.
Solution Approach 2:
The melt vessel maintains continuous operation during burner replacement. The cooling system enables the burner to be replaced without interrupting the melting process, ensuring continuous useful action of the overall system while the burner maintenance is performed.
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
Enables burner replacement during ongoing operations, reducing downtime and extending component life by allowing continuous melting without the need for system shutdown, thus improving operational efficiency and reducing production losses.
Implementation Method 1
delivering a liquid into a void between a burner and a melt vessel so as to form a skull of a material
Implementation Method 2
delivering a liquid into a void between a burner and a melt vessel
Implementation Method 3
a cooling vessel having a housing defining an interior cooling volume
Implementation Method 4
delivering a liquid into a void between a burner and a melt vessel
Data Source
AI summary
Liquid is delivered into a void between a burner and a melt vessel, which causes a skull of a material to form within an interior of the melt vessel. The void is in fluidic communication with the interior of the melt vessel. The burner is moved from a first position internal to the void to a second position external from the void. Thereafter, the burner is isolated from the void.