Compact Premix Burner with Twisted Gas Injector
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Solution Overview
Problem
Industrial gas burners face challenges in achieving stable, low-emission flames with minimal nitrogen oxides (NOx) and carbon monoxide (CO) while being compact, flexible, and easily integratable into small-sized installations with single gas inlets, which often result in significant pressure losses and instability due to conventional gas injection and mixing methods.
Innovation Solution
A compact gas burner design utilizing premix technology with a single gas inlet, featuring an upstream gas injector that combines gas injection and mixing functions, a downstream gas injection, and a stabilizing element, along with a concentric secondary air tube and peripheral gas injections, to ensure efficient mixing, turbulence, and flame stability, minimizing pressure losses and allowing for increased air factor beyond conventional limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional gas injection and mixing methods are used, then gas injection function is achieved, but significant pressure losses occur
Solution Approach 1:
The patent combines the gas injection function and mixing function into a single integrated component called an 'upstream gas injector'. This injector features gas injection holes arranged in a twisted configuration that simultaneously performs gas delivery and creates turbulence for mixing, eliminating the need for separate mixers that caused pressure losses. The twisted geometry of the injection holes generates vortices that enhance mixing efficiency while minimizing pressure drop.
Solution Approach 2:
The patent implements preliminary mixing of gas and air before the combustion zone. The upstream gas injector performs mixing in advance by creating turbulent flow patterns, ensuring that the gas-air mixture is well-prepared for combustion. This preliminary action reduces the need for subsequent mixing stages and minimizes pressure losses in the combustion chamber.
2Volume of moving object
If compact burner design is implemented, then small size is achieved, but mixing efficiency deteriorates
Solution Approach 1:
The patent employs curved and twisted geometries in the gas injector design. The gas injection holes are arranged in a twisted configuration rather than straight lines, creating vortex flows that enhance mixing efficiency. The curved path of the injection holes generates rotational motion that improves gas-air mixing within the compact burner volume, achieving both small size and high mixing efficiency.
Solution Approach 2:
The patent transitions from two-dimensional planar mixing to three-dimensional turbulent mixing by using twisted injection holes and conical diffusers. The gas injection holes are arranged in a twisted configuration that creates vortices extending in multiple dimensions, enhancing mixing efficiency within the compact burner volume. The conical diffuser further promotes three-dimensional flow patterns that improve mixing without increasing burner size.
3Ease of operation
If single gas inlet is used, then ease of integration is improved, but flexibility in power management deteriorates
Solution Approach 1:
The patent segments the gas injection system into multiple functional zones within a single inlet structure. The burner includes an upstream gas injector, a conical diffuser, and a downstream gas injection zone, all fed through a single gas inlet tube. This segmentation allows different regions to perform specific functions (injection, mixing, stabilization) while maintaining overall system compactness and ease of integration. The modular design enables flexible power management by controlling gas flow distribution to different zones.
4Object-generated harmful factors
If premix technology is used, then NOx emissions are reduced, but pressure losses increase
Solution Approach 1:
The patent employs a self-stabilizing flame design where the premixed gas-air mixture automatically maintains stable combustion without requiring external stabilization systems. The conical diffuser and downstream gas injection zones work together to create a self-regulating combustion process that maintains optimal mixing and flame stability. This self-service approach reduces the need for additional pressure-driven stabilization components, minimizing pressure losses while maintaining low NOx emissions through effective premixing.
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 ultra-low NOx and CO emissions, maintains flame stability, and provides flexible power management by optimizing gas and air mixing, reducing pressure losses, and limiting CO formation, while being compact and cost-effective.
Implementation Method 1
The upstream gas injector comprises at least two mixing elements of axes y and y′ that are inclined with respect to the radius of the air inlet tube and connect the air inlet tube and the gas injection duct, and each mixing element has gas injection holes disposed along its axis y or y′. This makes it possible to simultaneously ensure turbulence that is able to promote the mixing of the gas and the air
Implementation Method 2
The upstream gas injection makes it possible to minimize pressure losses through an aerodynamic form and to create turbulence through a twisted form inclined with respect to the radius of the air inlet tube
Implementation Method 3
a stabilizing element, and is characterized in that the gas injection constitutes a one-piece mechanical assembly that ensures a self-stable elementary flame
Implementation Method 4
The premix burner according to the disclosure is made up of an air inlet tube of length L and a specific gas injection... In order to obtain ultra-low NOx performance by using the premix technology, it is necessary not only to supply the gas and the air in specific proportions but also to ensure intimate mixing between the gas and the air
Implementation Method 5
The upstream gas injection makes it possible to minimize pressure losses through an aerodynamic form
Data Source
AI summary
A premix burner made up of an air inlet tube of length L and a single specific gas injection, the gas injection includes an upstream gas injector, a mixer, a downstream gas injection situated at a distance L3 from an upstream end of the air inlet tube and a stabilizing element, where the gas injection constitutes a one-piece mechanical assembly that ensures a self-stable elementary flame.