Flare Stack Diffuser Tip With Open-Core Flame Bridging
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Solution Overview
Problem
Existing flare stack tips face challenges in maintaining ignition and complete combustion of waste gases at low flow rates, especially in harsh conditions, leading to incomplete combustion, soot formation, and unburnt greenhouse gas emissions.
Innovation Solution
A flare stack diffuser tip with continuous diffuser rings and radial transfer spokes that ensure all waste gas release points are ignited, using flame bridges for cross-lighting and an open core for balanced air flow, eliminating the need for additional fuel gas and complex components like ring burners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If radial slot air assisted flare stack tips are used, then complete combustion is supported through high velocity air mixing, but individual slots can be snuffed out by crosswind at low flow rates causing ignition failure
Solution Approach 1:
The diffuser is segmented into multiple radial slots arranged circumferentially, allowing the gas stream to be divided into multiple smaller streams. This segmentation reduces the impact of crosswinds on individual slots and ensures more reliable ignition across all slots even in windy conditions
Solution Approach 2:
The invention transitions from a traditional vertical diffuser orientation to a radial configuration where slots are arranged in a circumferential pattern. This dimensional change allows the gas to be discharged horizontally in multiple directions simultaneously, reducing vulnerability to crosswind effects that would affect a single vertical stream
2Reliability
If radial slot style tips release air in a wedge shape, then air supply to the core is reduced, but gas concentration increases towards the center causing incomplete combustion and soot formation
Solution Approach 1:
The diffuser design creates different flow characteristics at different radial positions. The radial slots are positioned and sized to create an optimized velocity and concentration distribution across the cross-section, ensuring adequate oxygen supply to the core region while maintaining proper fuel-air mixing ratios throughout the flame zone to prevent soot formation
Solution Approach 2:
The diffuser geometry is designed to dynamically adapt the flow pattern, creating a more uniform radial expansion of gas streams that prevents excessive concentration in the core. The configuration allows the flow to self-adjust based on operating conditions to maintain complete combustion
3Reliability
If a capped core is used in radial slot style tips, then the fuel/air mixture is pulled down into the center concentrating excess gas, but this causes incomplete combustion and greenhouse gas emissions
Solution Approach 1:
The invention removes the capped core configuration entirely, extracting the problematic feature that caused gas concentration and incomplete combustion. Instead, an open core design is implemented that allows free flow and mixing, preventing the accumulation of excess fuel in the center and ensuring complete combustion of all gas streams
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
Ensures reliable ignition and complete combustion across varying flow rates, reducing carbon footprint, construction costs, and emissions by enhancing combustion efficiency and flame stability.
Implementation Method 1
The one or more radial transfer spokes are in fluid connection with the concentric diffuser rings... Using an uninterrupted ring ensures all released waste gas will be ignited and burnt
Implementation Method 2
The flare stack diffuser tip uses continuous diffuser rings to introduce the waste gas into the air stream
Implementation Method 3
The radial transfer spokes define an open core permitting air flow through a central opening defined by a concentric diffuser ring
Data Source
AI summary
There is a flare stack diffuser tip for use with a flare stack having a waste gas conduit. The flare stack diffuser tip has one or more concentric diffuser rings. One or more radial transfer spokes connect to the waste gas conduit of the flare stack to receive waste gas. The one or more radial transfer spokes is in fluid connection with the one or more concentric diffuser rings.