Tunnel Kiln Burner with Recirculating Suction Element
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Solution Overview
Problem
In large tunnel kilns, there is a non-homogeneous distribution of temperature along the longitudinal sections, leading to higher temperatures at the center and lower temperatures near the side walls, resulting in firing defects and increased production waste in ceramic articles.
Innovation Solution
The apparatus and burner design include a tubular discharge element and a suction element that recirculates gases from the firing chamber, enhancing turbulence and heat exchange, thereby improving temperature homogeneity within the kiln.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional burners are used in large tunnel kilns, then the heating function is provided, but non-homogeneous temperature distribution occurs with higher temperatures at the center and lower temperatures near the side walls
Solution Approach 1:
The burner is divided into multiple independent nozzles arranged in series along the longitudinal axis of the kiln. Each nozzle can be independently controlled to provide localized heating, allowing precise temperature control throughout the entire kiln length and eliminating the temperature non-homogeneity that occurs with single-point heating systems.
Solution Approach 2:
Multiple nozzles are positioned at different locations (center and side walls) with independent flow control. This allows each region of the kiln to receive optimized heating based on its specific thermal requirements, ensuring uniform temperature distribution across the entire firing chamber and eliminating the temperature gradients that cause firing defects.
2Loss of energy
If fumes circulate inside the firing chamber, then heat transfer occurs, but the fumes slow down near the walls decreasing turbulence and heat exchange coefficient
Solution Approach 1:
The system introduces additional turbulence promoters that dynamically alter the fume flow patterns. These promoters create controlled chaotic motion in the gas flow, preventing the laminar flow that causes energy loss near the walls and maintaining high turbulence levels throughout the kiln to enhance heat exchange efficiency.
Solution Approach 2:
Turbulence promoters are introduced as intermediary elements between the fume flow and the wall surfaces. These promoters act as mediators that maintain turbulent flow conditions near the walls, preventing the flow from slowing down and ensuring continuous efficient heat transfer to the ceramic articles regardless of their position.
3Temperature
If more fuel is used to maintain temperature, then the temperature level increases, but the fuel consumption increases
Solution Approach 1:
The system incorporates temperature sensors and control mechanisms that continuously monitor the temperature distribution within the kiln. Based on this feedback, the fuel flow to each nozzle is dynamically adjusted to maintain optimal temperature levels, preventing both overheating and the need for excessive fuel input, thereby reducing overall energy consumption while maintaining quality temperature distribution.
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 greater temperature uniformity along the width of the firing chamber, reducing firing defects and production waste, while also reducing the amount of fuel needed to maintain a given temperature.
Implementation Method 1
enhancing turbulence and heat exchange
Implementation Method 2
recirculates gases from the firing chamber
Implementation Method 3
burner for the firing of ceramic articles
Data Source
AI summary
An industrial apparatus for the firing of ceramic articles; the apparatus comprises a tunnel kiln provided with at least one side wall, a firing chamber and a transport system configured to convey a plurality of ceramic articles along a conveying path; the apparatus comprises at least one burner, which is provided with a first tubular discharge element, a second tubular discharge element and a suction element for the gases present in the firing chamber; the suction element is arranged between the first tubular discharge element and the second tubular discharge element inside the firing chamber.