Perforated Metal Radiant Burner for Flashback-Free High Fuel Input
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Solution Overview
Problem
Existing gas-fired infrared burners face limitations such as fragile ceramic emitter surfaces, limited fuel input capacity, frequent failures due to thermal stress, and inefficient energy distribution, leading to incomplete combustion and the need for secondary air, which complicates control and reduces efficiency.
Innovation Solution
A gas-fired burner unit with a perforated metal plate and venturi system that allows for increased fuel input per unit area, uses multiple layers of perforated metal members to quench flames and control oxygen supply, and distributes energy uniformly over a larger surface area, eliminating the need for secondary air and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ceramic plate is used as emitter surface, then infrared radiation is produced, but the burner is fragile and subject to failure
Solution Approach 1:
The patent changes the material parameter from ceramic to metal, fundamentally altering the physical and mechanical properties of the emitter surface. This allows the burner to maintain infrared radiation emission capability while gaining superior mechanical strength, durability, and resistance to thermal shock and moisture damage.
Solution Approach 2:
The patent employs a composite structure combining metal emitter surface with specific hole patterns and thickness specifications. This composite design integrates the high thermal conductivity and strength of metal with optimized geometric features to achieve both durability and effective infrared radiation emission.
2Productivity
If fuel input is increased beyond 350 BTUH/in2, then energy output increases, but flashback occurs and combustion becomes incomplete
Solution Approach 1:
The patent changes the geometric parameters of the emitter surface, specifically the hole size (0.025-0.062 inches) and thickness (0.0156-0.0625 inches), which fundamentally alters the combustion dynamics. These parameter changes enable the system to handle higher fuel input rates by improving flame quenching capability and oxygen distribution, preventing flashback while maintaining complete combustion.
Solution Approach 2:
The emitter surface is segmented into multiple small holes distributed across the metal plate. This segmentation creates numerous small combustion zones that improve flame stability and prevent flashback by limiting the size of individual flame fronts while collectively handling high fuel input rates.
3Strength
If woven metal screen is used, then durability improves, but screen fails due to thermal stress and weaving stress
Solution Approach 1:
The patent transitions from a woven screen structure to a perforated plate structure, fundamentally changing the geometric and structural parameters. This eliminates the weaving stresses inherent in screen construction and provides a more uniform stress distribution that resists thermal fatigue, significantly improving reliability for continuous operation.
Solution Approach 2:
The patent uses a perforated metal plate with specifically sized holes (0.025-0.062 inches) that creates a porous-like structure for combustion. This approach provides the necessary porosity for flame quenching and oxygen supply while maintaining the structural integrity and thermal fatigue resistance of solid metal, avoiding the weaknesses of woven screens.
4Reliability
If aperture size is reduced for flame quenching, then flashback is prevented, but wire diameter is limited and strength decreases
Solution Approach 1:
The patent optimizes the hole size parameter to a specific range (0.025-0.062 inches) that provides effective flame quenching for flashback prevention. Simultaneously, the hole thickness parameter (0.0156-0.0625 inches) is optimized to maintain structural strength. This coordinated parameter optimization achieves both safety and structural integrity without the limitations of wire-based screens.
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 enables operation at higher fuel input rates without flashback, provides uniform infrared radiation distribution, and maintains high combustion efficiency by using 100% primary air, thus increasing the burner's reliability and energy output while reducing maintenance needs.
Implementation Method 1
at least one venturi mounted for providing the gas and air to the plenum
Implementation Method 2
The metal screens are woven from metal strands. Experience with using these types of burners indicates that they have limited life due to failure of the screen. Failure of the screen allows the flame to retrogress into the burner plenum resulting in flashback.
Implementation Method 3
A gas-fired burner unit with a perforated metal plate and venturi system that allows for increased fuel input per unit area, uses multiple layers of perforated metal members to quench flames and control oxygen supply, and distributes energy uniformly over a larger surface area
Implementation Method 4
The other method by which gas-fired radiant burners operate is for the flame and hot combustion gases from a conventional port type burner to be impinged on a surface (usually ceramic) capable of emitting infrared radiant energy
Data Source
AI summary
A gas-fired burner unit for providing combustion and infrared radiation includes at least one plenum for receiving at least the gas, and at least one perforated metal plate mounted for receiving at least the gas from the plenum and supplying at least the gas to the combustion so that the combustion is proximate the perforated metal plate.