Flat Coolable Diffuser for Stable Industrial Furnace Flame
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Solution Overview
Problem
Existing fuel gas injectors for regeneratively or recuperatively heated industrial furnaces face challenges in maintaining a stable, flat, fan-like flame configuration over a large surface area while avoiding damage to ceramic wall materials and ensuring efficient energy transfer and NOx reduction, particularly due to limitations in adapting to throughput fluctuations and turbulence issues.
Innovation Solution
A fuel gas injector with a long diffuser having a flat, coolable diffuser tube that forms a contact-free termination at the ceramic injector insert opening, featuring a diffuser outlet and inlet with specific transverse and vertical extensions to maintain a stable flame configuration and adjustable range, and a cooling jacket for improved heat management and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a conventional fuel gas injector is used, then the flame configuration becomes unstable and turbulent, but the device structure remains simple
Solution Approach 1:
The diffuser is segmented into multiple functional zones: a first diffuser section with a first opening angle for initial flow expansion, and a second diffuser section with a second opening angle for fine-tuning the flame configuration. This segmentation allows each section to optimize specific aspects of flame stability without requiring complete redesign of the entire diffuser structure.
Solution Approach 2:
The diffuser incorporates adjustable elements that allow the opening angles of the diffuser sections to be modified during operation. This dynamic adjustment capability enables the flame configuration to be optimized for different operating conditions while maintaining structural simplicity through a single adjustable mechanism.
2Area of stationary object
If the flame range is extended to cover larger surface area, then the energy transfer improves, but the flame stability decreases
Solution Approach 1:
The invention transitions from a single-cone diffuser geometry to a multi-section diffuser with different opening angles in axial sections. This dimensional complexity in the diffuser structure creates a more controlled flow expansion pattern that maintains flame stability while extending the flame's reach and surface coverage area.
Solution Approach 2:
Different sections of the diffuser have locally optimized opening angles: the first section uses a larger opening angle for rapid expansion and coverage, while the second section uses a smaller opening angle for stability control. This local quality differentiation allows the flame to achieve both extended range and maintained stability simultaneously.
3Productivity
If turbulence is increased to enhance mixing, then the combustion efficiency improves, but the NOx production increases
Solution Approach 1:
The adjustable diffuser sections allow dynamic control of the flow expansion rate and mixing intensity. By optimizing the opening angles of the diffuser sections, the system achieves sufficient mixing for high combustion efficiency while controlling turbulence levels to minimize thermal NOx formation through lower peak temperatures and shorter residence times.
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 solution achieves high surface coverage, improved burnout, reduced NOx/CO production, and optimized energy flow into the glass melt, with the ability to adjust flame range and stability, enhancing the operational flexibility and efficiency of the industrial furnace.
Implementation Method 1
a long diffuser (4) having a metallic, coolable diffuser tube (5, 6) forming the orifice (2)
Implementation Method 2
a cooling jacket (21, 22) for improved heat management and protection
Implementation Method 3
a long diffuser with a free jet opening angle
Implementation Method 4
fuel gas injector... to fire a regeneratively or recuperatively heated industrial furnace
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
The invention relates to a combustion gas injector (100) for firing a regeneratively or recuperatively heated industrial furnace (1000) with a gas supply pipe (1) and a mouth (2), wherein the connection (V) thereof to a longitudinal diffuser is designed with a free-jet opening angle, wherein the longitudinal diffuser has a metallic, coolable diffuser pipe forming the mouth (2) which is intended to form an end to the mouth (2) of the combustion gas injector, relative to the ceramic injector insert opening (7). It is proposed, according to the invention, that – the longitudinal diffuser is designed as a flat longitudinal diffuser (4), wherein the diffuser pipe is formed with a diffuser output flat pipe (5) and a diffusor input flat pipe (6), wherein – the diffuser output flat pipe (5) and/or the diffusor input flat pipe (6) has a transverse extent (Q) and a height extent (H), wherein – the free-jet opening angle (w1, w2) opens in the height extent (H) and/or the transverse extent (Q) of the flat longitudinal diffuser (4), in particular of the diffuser output flat pipe (5).