Double-Staged Oxy-Fuel Boosting for Stable Regenerative Glass Melting
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Solution Overview
Problem
Oxy-fuel boost burners in regenerative glass melting furnaces face instability due to turbulent air-fuel flame interactions, leading to overheating, incomplete combustion, and increased emissions, which are exacerbated by regenerator reversal cycles.
Innovation Solution
A synchronized oxy-fuel boosting system using double-staged burners with adjustable oxygen staging and control valves to optimize flame properties (length, luminosity, and momentum) in response to regenerator reversals, ensuring consistent flame quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If oxy-fuel boost burners are used in regenerative glass melting furnaces, then furnace efficiency and productivity are improved, but flame stability deteriorates due to turbulent air-fuel flame interactions
Solution Approach 1:
The system dynamically adjusts the oxy-fuel boost burner operation to synchronize with the regenerator reversal cycle. The controller receives signals about which regenerator is firing and actively modulates the boost burner fuel and oxygen flow rates accordingly, transforming the static burner system into a dynamic one that adapts to changing flow conditions throughout the cycle.
Solution Approach 2:
The system changes operational parameters (fuel flow rate, oxygen flow rate, staging ratio) of the oxy-fuel boost burner based on the regenerator firing state. By adjusting these parameters in response to the periodic reversal cycle, the system optimizes flame stability and combustion efficiency under varying turbulent conditions.
2Duration of action of stationary object
If regenerator reversal cycles are implemented, then furnace operation continuity is maintained, but flame characteristics and heat release patterns become unstable
Solution Approach 1:
The system implements periodic adjustment of boost burner parameters that synchronizes with the regenerator reversal cycle. The controller receives periodic signals about the firing state and applies corresponding periodic adjustments to fuel and oxygen flow, creating a coordinated periodic action that maintains flame stability throughout the cycle repetitions.
Solution Approach 2:
The system uses feedback from the furnace control system about regenerator firing state to continuously adjust boost burner operation. This feedback loop ensures that the burner parameters are constantly optimized in response to the changing flow conditions created by the reversal cycle, maintaining consistent flame characteristics.
3Use of energy by moving object
If staged oxy-fuel burners are used to create longer luminous flames, then heat transfer to glass is improved, but combustion completeness deteriorates due to delayed mixing
Solution Approach 1:
The system dynamically adjusts the staging ratio (proportion of primary vs. secondary oxygen) based on the regenerator firing state. During different phases of the reversal cycle, the controller modifies the staging configuration to optimize the balance between flame length for heat transfer and mixing efficiency for complete combustion, preventing excessive CO emissions.
Solution Approach 2:
The system changes the oxygen staging parameters (flow rates, distribution ratios) of the burners in response to regenerator reversal signals. By adjusting these parameters, the system maintains optimal conditions for both heat transfer to the glass and complete combustion, minimizing harmful emissions while maximizing energy utilization.
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 system stabilizes flames, reduces overheating, improves heat transfer, decreases emissions, and enhances glass quality while lowering energy consumption by customizing flame settings for each regenerator cycle.
Implementation Method 1
oxy-fuel boost burners fire continually... both the strength and direction of these oxy-flames and their air-fuel flame interactions
Implementation Method 2
high levels of turbulence created inside air-fired regenerative glass furnaces... changing air currents and turbulence patterns
Implementation Method 3
concentrated heat release close to the breast wall... flame lofting toward the crown... heat transfer rate between the flame and glass surface
Implementation Method 4
combustion space turbulence can also interrupt mixing between fuel and oxygen... periodic nature of the firing direction within regenerative furnace creates changing air currents
Data Source
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AI summary
A system and method for synchronized oxy-fuel boosting of a regenerative glass melting furnace including first and second sets of regenerative air-fuel burners, a first double-staged oxy-fuel burner mounted in a first wall, and a second double-staged oxy-fuel burner mounted in a second wall, each oxy-fuel burner having a primary oxygen valve to apportion a flow of oxygen between primary oxygen and staged oxygen and a staging mode valve to apportion the flow of staged oxygen between an upper staging port and a lower staging port in the respective burner, and a controller programmed to control the primary oxygen valve and the staging mode valve of each of the first and second oxy-fuel burners to adjust flame characteristics of the first and second oxy-fuel burners depending on the state of operation of the furnace.