Burner Diffuser with Inclined Holes for Ceramic Flame Stability
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Solution Overview
Problem
Existing burners for thermal treatment of ceramic articles suffer from suboptimal air and gas mixing, leading to inefficient combustion and unstable flames, especially at minimal gas flows, and require frequent maintenance due to air contamination and obstruction issues.
Innovation Solution
A burner design with a diffuser featuring elongated slots and inclined holes for improved fluid flow orientation, combined axial and centrifugal mixing, and the ability to use recovered hot air, ensuring stable flames and reduced maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional diffusers with circular through holes are used, then the structure is simple, but the mixing of air and combustible gas is suboptimal leading to inefficient combustion
Solution Approach 1:
The diffuser is divided into two functional zones: a central region with inclined through holes for axial flow and a peripheral region with notches for centrifugal flow. This segmentation allows each zone to contribute differently to the mixing process, improving overall combustion efficiency while maintaining manufacturing simplicity.
Solution Approach 2:
Different regions of the diffuser are given different geometries suited to their specific functions: the central area has inclined holes for linear flow patterns, while the peripheral area has notches for rotational flow patterns. This local differentiation optimizes mixing efficiency in each zone.
2Loss of energy
If conventional burners operate with minimal gas flows, then energy consumption is reduced, but flame stability is compromised
Solution Approach 1:
The diffuser design creates dynamic flow patterns where air is drawn axially through inclined holes and centrifugally through notches, creating a self-regulating mixing process that maintains flame stability across varying gas flow rates including minimal operations.
Solution Approach 2:
The diffuser utilizes pneumatic principles to create pressure differentials that draw air through the inclined holes and notches, ensuring consistent air-gas mixing even at minimal gas flows, thereby maintaining flame stability without requiring high energy input.
3Adaptability or versatility
If conventional burners use recovered air, then operational flexibility is improved, but the air supply becomes contaminated and obstructed over time
Solution Approach 1:
The design extracts and separates the air flow paths from the combustion products, allowing recovered air to be used without direct contact with contaminants. The inclined holes and notches create dedicated air intake channels that remain clear even when using recovered air streams.
Solution Approach 2:
The diffuser structure acts as an intermediary element that conditions the recovered air flow, creating controlled flow patterns that prevent direct contamination while still allowing the use of recovered air for operation.
4Loss of energy
If conventional burners operate with reduced gas flows, then fuel consumption is lowered, but unburned substances form due to suboptimal mixing
Solution Approach 1:
The diffuser performs preliminary mixing of air and gas before combustion occurs, creating optimal mixture conditions even at reduced gas flows. The inclined holes and notches pre-arrange the flow patterns to ensure complete mixing, preventing unburned substances from forming during combustion.
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 burner achieves stable and efficient combustion across varying gas flow ratios, including minimal levels, and maintains performance with recovered air without frequent cleaning or replacement, enhancing operational efficiency and longevity.
Implementation Method 1
The above-mentioned openings penetrate the entire thickness of the diffuser, running from the first to the second faces... permit a linear flow of the air in the combustion chamber
Implementation Method 2
The diffuser also has a plurality of notches formed on its peripheral region according to planes that are inclined with respect to the longitudinal axis, to give the amount of air that passes through them a helicoidal motion along the combustion chamber
Implementation Method 3
a combustion head (7) which is provided with a plurality of nozzles for the outflow of the combustible gas... obtain the mixing with the combustible gas flowing out of the nozzles of the combustion head
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A burner (1) with high flame stability, particularly for the thermal treatment of ceramic articles, comprising a supporting body (2) provided with at least one first port (4) for the inflow of an oxidizing fluid and with at least one second port (5) for the inflow of a combustible fluid, and a combustion head (7) which is associated with the supporting body (2) and is provided, in its central region, with nozzle means (8) which are associated with the second port, for the outflow of the combustible fluid in a combustion region (9) and, in its peripheral region, with an annular diffuser (14) provided with a plurality of through openings (15) for orienting the flow of the oxidizing fluid toward the combustion region. At least one of the openings (15) comprises a slot (15a), which is provided inside the diffuser (14) and has an extension along a first transverse dimension that is substantially larger than the extension along a second direction that is transverse to the first direction.