Hot Surface Pilot Burner Ignition for Rotary Kiln Reliability
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Solution Overview
Problem
Existing ignition systems for rotary kilns, such as those used in petcoke calcining, are prone to failure due to shorting, require precise air/fuel mixtures, and necessitate frequent maintenance, leading to significant downtime and inefficiencies.
Innovation Solution
A pilot burner igniter apparatus utilizing a hot surface igniter positioned at an angle within a tubing system to ignite and maintain a flame, with a support brace and fuel pipe to optimize fuel/air mixture interaction, and a threaded region for access, minimizing exposure to extreme temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spark igniter transformer is used to ignite the fuel, then ignition can be achieved, but the device is prone to shorting to ground and premature failure
Solution Approach 1:
The patent replaces the spark igniter transformer (electrical/mechanical system) with a hot surface igniter that uses a heating element to ignite the fuel/air mixture. This substitution eliminates the transformer component that is prone to shorting to ground, thereby improving reliability and removing the harmful effect of electrical shorting while maintaining the ignition function.
2Reliability
If a spark igniter with energized electrode and grounding rod is used, then ignition can be achieved, but the system requires a tight tolerance gap that is sensitive to alterations
Solution Approach 1:
The patent replaces the spark igniter system with a hot surface igniter that does not rely on electrical gaps between electrodes. The heating element is positioned to directly heat the fuel/air mixture without requiring precise gap tolerances, thereby eliminating the manufacturing precision requirement while maintaining reliable ignition.
3Reliability
If a spark system is used for ignition, then ignition can be achieved, but a smaller heat/ignition source is provided requiring more precise air/fuel mixture
Solution Approach 1:
The patent replaces the spark system with a hot surface igniter that provides a larger, more robust heat source through the heating element. This larger heat source is less sensitive to air/fuel mixture precision requirements, thereby improving ease of operation while maintaining reliable ignition capability.
4Reliability
If current ignition systems are used in the kiln, then ignition can be achieved, but frequent maintenance and replacement are required due to extreme temperatures
Solution Approach 1:
The patent replaces the spark igniter system with a hot surface igniter that has no exposed electrical components susceptible to thermal damage. The heating element and its mounting structure are designed to withstand the extreme kiln temperatures, thereby reducing maintenance and replacement frequency while maintaining reliable ignition function.
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 effectively eliminates kiln operation downtime and maintains consistent ignition, reducing maintenance needs and enhancing productivity.
Implementation Method 1
the hot surface igniter comprising a first end and a second end, where the first end is operably connected to a power source and the second end comprises a heating element
Implementation Method 2
a first tubing having a proximal end and a distal end, the proximal end of the first tubing functional to receive a fuel/air mixture and the distal end of the first tubing functional to allow emission of a flame
Data Source
AI summary
The present disclosure provides, inter alia, an apparatus, system, and method for applying heat to a rotary kiln using a pilot burner hot surface igniter.