One-Piece Coal Burner Stabilizing Ring for Low NOx
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Solution Overview
Problem
Burners used for burning dusty carbon face challenges in reducing NOx emissions and require complex designs with multiple welds, which increase design effort, susceptibility to faults, and reduced service life due to high temperatures and aggressive media exposure.
Innovation Solution
A burner design featuring a one-piece component that includes the air deflector throat, stabilizing ring, and part of the primary air pipe, allowing for a single weld seam and improved durability, with adjustable components for optimal air flow and NOx reduction, utilizing centrifugal casting for production and adjustable swirler configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate components (stabilizing ring, air deflector throat, primary air pipe) are connected through welding, then the burner can be assembled from individual parts, but the design effort increases, susceptibility to faults increases, and service life decreases due to high temperatures and aggressive media exposure
Solution Approach 1:
The patent merges the stabilizing ring, air deflector throat, and primary air pipe into a single integrated component manufactured as one piece using centrifugal casting. This eliminates the need for multiple weld connections, thereby reducing design complexity while simultaneously improving reliability by removing weak points caused by welding in high-temperature and chemically aggressive environments.
2Adaptability or versatility
If multiple weld seams are used to connect burner components, then the burner can be constructed from separate parts, but the manufacturing time increases and the structural complexity increases
Solution Approach 1:
By combining multiple components into a single piece manufactured via centrifugal casting, the patent eliminates multiple welding operations. This significantly reduces manufacturing time and simplifies the production process, thereby improving productivity while maintaining the functional adaptability of the burner through design flexibility in the integrated component.
3Ease of operation
If separate components are welded together in the mouth area of the primary air pipe, then the burner can be assembled modularly, but the service life is impaired due to high temperatures and aggressive media flow through the weld joints
Solution Approach 1:
The patent creates a single integrated component for the mouth area of the primary air pipe, eliminating weld joints that would be exposed to high temperatures and aggressive media flow. This unified structure, manufactured through centrifugal casting, ensures uniform material properties and eliminates potential failure points, thereby extending the service life while maintaining ease of operation through modular replacement of the entire assembly if needed.
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 design enhances durability, reduces malfunctions, and achieves more effective NOx emission reduction by creating a low-oxygen recirculation area near the burner, shifting reduction reactions closer to the burner zone, and optimizing the recirculation area for enhanced NOx breakdown.
Implementation Method 1
The air deflector throat, the stabilizing ring and a part of the primary air tube are designed in one piece
Implementation Method 2
the stabilizing ring projecting radially inwards in the form of internal teeth into the primary air tube
Data Source
Figure 1~2
Figure 3~4
AI summary
A coal-dust burner with low NOx emissions has a concentric general arrangement with primary a primary air pipe (1) within a secondary (2) air pipe. The primary air pipe inlet has an external array of deflection grooves (3) and an inner stabilization ring (4) formed as a one-piece component.