Gas premix burner
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Solution Overview
Problem
Gas premix burners experience thermo-acoustic instabilities, leading to irritating noise due to complex interactions between air, gas, and flame fluctuations, which are difficult to manage across varying operational conditions, and existing solutions like mufflers are expensive.
Innovation Solution
A gas premix burner with a woven, knitted, or braided burner deck comprising metal fibers, featuring zones of high and low density, supported by a perforated plate or woven wire mesh, which reduces thermo-acoustic instabilities through synergistic benefits of different density zones and easy production of complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a uniform density burner deck is used, then the structure is simple to manufacture, but thermo-acoustic instabilities occur leading to noise
Solution Approach 1:
The burner deck employs varying fiber density across different zones - higher density in central combustion zones and lower density at peripheral zones. This local variation in material properties optimizes flame stabilization and reduces thermo-acoustic instabilities without compromising overall manufacturability, as the varying density is achieved through controlled fiber distribution during the mat formation process.
2Object-generated harmful factors
If the burner deck density is increased to reduce noise, then thermo-acoustic instabilities are reduced, but the burner deck becomes less permeable to gas flow
Solution Approach 1:
The burner deck employs varying fiber density across different zones - higher density in central combustion zones and lower density at peripheral zones. This local variation in material properties optimizes flame stabilization and reduces thermo-acoustic instabilities without compromising overall manufacturability, as the varying density is achieved through controlled fiber distribution during the mat formation process.
Solution Approach 2:
The invention changes the density parameter of the burner deck material across different zones. By controlling the fiber distribution to create high density zones (at least 1250 g/dm³) covering at least 25% of the surface area, the system optimizes both noise reduction and gas flow characteristics through parameter variation rather than uniform properties.
3Object-generated harmful factors
If the burner deck is made from high density zones only, then thermo-acoustic noise is reduced, but the manufacturing complexity increases
Solution Approach 1:
The burner deck employs varying fiber density across different zones - higher density in central combustion zones and lower density at peripheral zones. This local variation in material properties optimizes flame stabilization and reduces thermo-acoustic instabilities without compromising overall manufacturability, as the varying density is achieved through controlled fiber distribution during the mat formation process.
Solution Approach 2:
The invention changes the density parameter of the burner deck material across different zones. By controlling the fiber distribution to create high density zones (at least 1250 g/dm³) covering at least 25% of the surface area, the system optimizes both noise reduction and gas flow characteristics through parameter variation rather than uniform properties.
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 deck design significantly reduces thermo-acoustic instabilities, allowing for quieter operation across a range of conditions without the need for expensive mufflers, while maintaining the ability of the burner deck to freely expand and keep the supporting structure cool.
Implementation Method 1
The burner deck design significantly reduces thermo-acoustic instabilities, allowing for quieter operation across a range of conditions
Implementation Method 2
The zone with a high density has a density of at least 1250 g/dm3... significantly reduces thermo-acoustic instabilities
Implementation Method 3
the burner deck (e.g. a knitted or woven fabric) can freely expand when hot, while the perforated plate or the woven wire mesh is remaining sufficiently cool
Implementation Method 4
The hot flue gas transfers its thermal energy to a fluid in a heat exchanger
Implementation Method 5
The hot flue gas transfers its thermal energy to a fluid in a heat exchanger after which the flue gas is evacuated through a chimney
Data Source
Figure 1
Figure 2~4
Figure 5
AI summary
The invention describes a gas premix burner comprising a perforated plate, a woven wire mesh or an expanded metal sheet; and a woven, knitted or braided burner deck comprising metal fibers supported by the perforated plate, woven wire mesh or expanded metal sheet. The woven, knitted or braided burner deck comprises at least a zone with a high density of at least 1250 g/dm3. The zone with a high density includes at least 25% of the surface of the burner deck