Double-Staged Oxy-Fuel Burner for Uniform Furnace Heating
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Solution Overview
Problem
Conventional oxy-fuel burners face challenges in uniformly distributing heat in furnaces, particularly in melting processes, and are not flexible enough to handle decarbonized fuels like hydrogen, leading to issues such as soot formation, reduced heat transfer, and high NOx emissions.
Innovation Solution
A double-staged burner design that includes fuel and oxidizer staging, allowing for flexible fuel use (natural gas, hydrogen, or mixtures) and oxidant control, positioned to minimize soot formation and NOx emissions, with configurations for both roof and sidewall mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional oxy-fuel burners are used to provide heat to furnaces, then heating capability is achieved, but heat distribution uniformity deteriorates
Solution Approach 1:
The burner system is divided into multiple burner elements (first burner element, second burner element, third burner element) that can be independently controlled. Each burner element directs flame to different portions of the furnace, enabling selective heating of specific zones to achieve uniform heat distribution across the entire furnace volume.
Solution Approach 2:
Different burner elements are configured with different nozzle arrangements and firing characteristics to provide locally optimized heating. The system directs larger flames to certain portions and smaller flames to other portions based on local heating requirements, creating non-uniform local heating that results in uniform overall heat distribution.
2Temperature
If single-flame burners are used, then simple burner structure is maintained, but heat distribution uniformity deteriorates
Solution Approach 1:
The burner comprises multiple burner elements (at least three) arranged in a specific configuration, where each element is a relatively simple component with inner and outer nozzles. The segmentation of the heating function across multiple simple elements achieves uniform heat distribution without requiring each individual element to be complex.
Solution Approach 2:
Multiple burner elements are combined into a single integrated burner assembly that operates as a coordinated system. The elements share common support structures and control systems while maintaining independent firing capabilities, merging simplicity of individual elements with the heat distribution benefits of multiple sources.
3Object-generated harmful factors
If decarbonized fuels like hydrogen are used, then greenhouse gas emissions are reduced, but combustion stability deteriorates
Solution Approach 1:
The burner elements are specifically configured with nozzle geometries and arrangements optimized for decarbonized fuels like hydrogen. The inner and outer nozzles of each element create controlled fuel-oxidizer mixing patterns that stabilize combustion of these challenging fuels while maintaining low emissions.
Solution Approach 2:
The burner system allows dynamic adjustment of fuel and oxidizer flows to each burner element to maintain stable combustion under varying operating conditions. The multi-element configuration provides redundancy and flexibility to adapt to the unique combustion characteristics of decarbonized fuels.
4Temperature
If flameless combustion is used to improve heat uniformity, then heat distribution uniformity is improved, but radiative heat transfer deteriorates
Solution Approach 1:
The burner uses segmented flame structures across multiple elements rather than a single large flameless combustion zone. This segmentation maintains sufficient flame presence for radiative heat transfer while distributing the heating function to achieve uniform heat distribution throughout the furnace.
Solution Approach 2:
The system adjusts combustion parameters (equivalence ratio, flame temperature, residence time) of each burner element to optimize the balance between radiative heat transfer and heat distribution uniformity. By controlling these parameters, the burner maintains flame structures that provide both radiation and uniform heating.
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
Improves heat distribution uniformity, reduces NOx emissions by up to 50%, enhances energy efficiency by 9%, increases production by 26%, and achieves fuel savings of 26% while supporting decarbonized fuels.
Implementation Method 1
Conventional oxy-fuel burners are known for providing primary or supplemental heat to furnaces
Implementation Method 2
Flameless combustion doesn't have soot formation, which can reduce the overall heat transfer to the bath surface due to absence of radiative heat transfer from soot to the bath
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A burner including a first burner element having a first annular oxidant nozzle surrounding a first inner fuel nozzle; a second burner element having a second annular oxidant nozzle surrounding a second inner fuel nozzle, the second burner element being positioned adjacent to and spaced apart from the first burner element; a staging nozzle configured to flow secondary oxidant and being positioned adjacent to and spaced apart from the second burner element and separated from the first burner element by the second burner element; wherein the first inner nozzle and the second inner nozzle each have a major axis defined by a length L and a minor axis defined by a height hf; wherein 5 <= L/hf <= 15; wherein the staging nozzle has a major axis; and wherein the major axes of the first and second inner nozzles and the staging nozzle are substantially parallel with each other.