High Shape Factor Nozzle for Rapid Heat Release
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Solution Overview
Problem
Conventional oxy-fuel burners suffer from inefficient heat transfer and high flue gas temperatures due to slow heat release, particularly in applications where scrap is close to the burner or in furnaces with large aspect ratios, leading to energy loss and reduced efficiency.
Innovation Solution
A rapid energy release burner design featuring a high shape factor nozzle with a tapered shape and an annular nozzle configuration, where the high shape factor nozzle is axially offset and surrounded by the annular nozzle, optimizing the velocity ratio and shape factor to enhance mixing and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional oxy-fuel burners are used, then the flame can form a cavity through the scrap, but heat transfer efficiency is poor and flue gas temperatures are high
Solution Approach 1:
The patent changes the geometric parameters of the nozzle by introducing a high shape factor design with specific aspect ratios and opening configurations. This modifies the flow characteristics to achieve rapid energy release and improve heat transfer efficiency while reducing flue gas temperatures
Solution Approach 2:
The burner system is segmented into multiple nozzle openings arranged in specific patterns (e.g., cross-shaped, grid patterns). This segmentation allows the flame to distribute heat more uniformly across the scrap charge rather than forming a single cavity, improving overall heat transfer efficiency
2Productivity
If conventional burners are used in single-pass furnaces, then the structure is simple, but heat transfer is insufficient and heat is lost out the flue
Solution Approach 1:
The high shape factor nozzle design changes the flow parameters to achieve rapid energy release within the single-pass furnace. The optimized geometry ensures that sufficient heat is transferred to the charge during the brief residence time, preventing heat loss through the flue
3Productivity
If conventional burners are used in furnaces with large aspect ratios, then the burner configuration is simple, but heat transfer efficiency is low
Solution Approach 1:
The nozzle is segmented into multiple openings arranged in patterns suitable for large aspect ratio furnaces. This segmentation allows the flame to cover a wider area and improve heat transfer efficiency across the extended furnace geometry
Solution Approach 2:
The nozzle geometric parameters are optimized to produce a flame pattern that distributes heat effectively in furnaces with large length-to-width ratios, achieving improved heat transfer efficiency without excessive complexity
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 design achieves a more uniform and rapid heat release, reducing flue gas temperatures and improving furnace efficiency by creating a voluminous flame that heats the furnace charge more effectively, with enhanced mixing of fuel and oxidizer streams.
Implementation Method 1
enhanced mixing of fuel and oxidizer streams
Implementation Method 2
rapid energy release combustion
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A burner having a high shape factor nozzle including a nozzle opening having a shape factor from about 10 to about 75, the shape factor being defined as the square of the nozzle perimeter divided by twice the nozzle cross-sectional area, and an annular nozzle surrounding the high shape factor nozzle, wherein the high shape factor nozzle is configured to be supplied with one of a fuel gas and an oxidizer gas, and the annular nozzle is configured to be supplied with the other of a fuel gas and an oxidizer gas. A method of rapid energy release combustion, including supplying a fuel gas and an oxidizer gas to a burner having a high shape factor nozzle and an annular nozzle surrounding the high shape factor nozzle.