Low Porosity Burner Deck Flame Stabilization
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Solution Overview
Problem
Conventional premix burners require complex devices in the mixing chamber for flame stabilization, leading to noise and emission issues, and are not stable across varying CO2 levels and gas qualities, while also producing high NOx levels.
Innovation Solution
A premix burner with a burner deck having an overall porosity of 11% or lower, featuring a perforated metal plate with specific perforation patterns that vary in pitch and distribution, eliminating the need for diffusers and anti-noise devices, and stabilizing flames across different operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional premix burners use devices in the mixing chamber for flame stabilization, then flame stability is improved, but device complexity increases and noise problems worsen
Solution Approach 1:
The invention extracts and removes the diffuser and anti-noise devices from the mixing chamber, achieving flame stabilization through the burner deck porosity alone. This eliminates the need for additional stabilization devices while reducing complexity and noise.
Solution Approach 2:
The invention uses a burner deck with specifically controlled porosity (14-18%) as the primary flame stabilization mechanism. The porous structure of the burner deck itself provides the necessary flame holding and stabilization function that previously required separate devices.
2Reliability
If conventional premix burners use devices in the mixing chamber for flame stabilization, then flame stability is improved, but noise emissions worsen
Solution Approach 1:
The invention removes the anti-noise devices from the mixing chamber, achieving noise reduction by relying on the burner deck porosity for flame stabilization instead. This extraction eliminates the noise generated by these additional devices while maintaining flame stability.
Solution Approach 2:
The porous burner deck structure serves as both the flame stabilization mechanism and the noise control element, replacing the need for separate anti-noise devices and thereby reducing noise emissions.
3Reliability
If burner deck porosity is increased to improve flame stability, then flame stability improves, but NOx emissions increase
Solution Approach 1:
The invention optimizes the burner deck porosity to a specific range (14-18%) that balances flame stability with NOx emission control. This parameter optimization ensures stable combustion while maintaining low NOx levels, resolving the trade-off between stability and emissions.
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 stable flame patterns and reduced noise and NOx emissions, eliminating humming and whistling sounds, and maintaining stability over a wide range of CO2 levels and gas qualities without the need for additional devices in the mixing chamber.
Implementation Method 1
The burner deck has an overall porosity which is equal to or lower than 11%, preferably lower than 10%, even more preferably lower than 9%
Implementation Method 2
lowering the porosity of the burner deck decreased acoustic time-lag of the flames formed on the burner deck
Implementation Method 3
This burner also had a more stable response on the first Helmholtz resonance of the heat exchanger and its peripheral parts
Implementation Method 4
a burner deck, the burner deck consists of a blind piece at the bottom, a perforated piece, with a regular (circular) pattern
Data Source
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Figure 8~11
AI summary
A gas burner (10) comprises a support (12) having a central gas inlet port (14) for supply of gas into a gas supply chamber (16). The gas supply chamber (16) is enclosed by a perforated metal plate (22), connected at the bottom to the support (12) through a base section. The perforation (24) in the perforated metal plate (22) provides a burner deck (20). The burner deck (20) has an overall porosity being equal to or lower than 11%. The burner deck has different patterns of perforations. The burner deck has a gradually changing porosity.