Gastight Metallic Fuel Container for Ceramic Burner Leakage
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Solution Overview
Problem
Ceramic burners in regenerative heat generators face issues due to high temperature expansion and contraction of refractory bricks, leading to damage, and leakage of combustible fuel into the exhaust gas chamber, causing high CO concentrations and premature mixing, which reduces efficiency and shortens the burner's lifespan.
Innovation Solution
A gastight metallic fuel container is integrated into the burner feed chamber, with an undulated partition wall to prevent fuel and air from mixing prematurely and to isolate the fuel chamber from the air and exhaust gas chambers, while allowing for expansion and contraction without applying forces to the burner feed chamber, thus preventing fuel leakage and maintaining a low CO concentration in exhaust fumes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If refractory bricks are used to separate fuel chamber and air chamber, then the ceramic burner can withstand high temperatures, but the bricks contract and expand causing damage to brick walls and reduced lifetime
Solution Approach 1:
The patent extracts the fuel chamber from the refractory brick structure and places it inside a metallic fuel container. This removes the refractory bricks from the critical separation function between fuel and air chambers, eliminating their thermal expansion/contraction damage while maintaining high temperature resistance through the metallic container designed to accommodate thermal changes.
Solution Approach 2:
The metallic fuel container acts as an intermediary element between the fuel supply system and the combustion chamber. It provides a stable, gastight separation structure that mediates the interaction between fuel and air while being designed to handle thermal expansion and contraction without damaging surrounding refractory structures.
2Strength
If refractory bricks are used to separate fuel chamber from exhaust gas chamber, then structural integrity is maintained, but fuel leaks through porosity causing high CO concentration in exhaust gases
Solution Approach 1:
The patent extracts the fuel chamber from the porous refractory brick structure and relocates it to a gastight metallic fuel container. This extraction eliminates the porosity problem that caused fuel leakage into the exhaust gas chamber, while the metallic container maintains structural integrity through its solid, non-porous construction.
Solution Approach 2:
The metallic fuel container serves as a replaceable component that can be easily replaced if damaged, rather than requiring replacement of the entire burner structure. This approach uses a simpler, more reliable gastight structure that addresses the fuel leakage issue without compromising structural integrity.
3Stability of the object's composition
If refractory brick partition wall is used, then fuel and air chambers are separated, but premature mixing occurs due to ageing and porosity
Solution Approach 1:
The patent extracts the separation function from the porous refractory brick partition wall and relocates it to a gastight metallic fuel container. This ensures stable separation of fuel and air chambers without the ageing and porosity problems that caused premature mixing, thereby maintaining optimal combustion efficiency.
Solution Approach 2:
The metallic fuel container serves as a reliable intermediary structure that maintains gastight separation between fuel and air chambers throughout the burner's operational life. It mediates the interaction between fuel supply and combustion air while preventing premature mixing, ensuring consistent combustion efficiency.
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 effectively prevents fuel leakage, reduces CO concentrations in exhaust gases, and prolongs the lifespan of the ceramic burner by maintaining a gastight separation and ensuring efficient combustion through controlled mixing of fuel and air, enhancing the overall efficiency of the regenerative heat generator.
Implementation Method 1
the ceramic burners are exposed to high temperatures and high temperature differences, the refractory bricks contract and expand
Implementation Method 2
the ceramic burners are exposed to high temperatures and high temperature differences, the refractory bricks contract and expand
Implementation Method 3
a gastight metallic fuel container is integrated into the burner feed chamber, with an undulated partition wall to prevent fuel and air from mixing prematurely and to isolate the fuel chamber from the air and exhaust gas chambers
Implementation Method 4
Combustion air and combustible fuel, generally combustible gases, are supplied to the ceramic burner and a mixture of the combustion air and fuel is burned in the combustion chamber
Implementation Method 5
The flue gases emanating from the combustion rise upwards in the combustion chamber, are diverted via a cupola and then pass through the heat-retention shaft filled with checker bricks. Heat from the flue gases is absorbed by the checker bricks
Implementation Method 6
Heat from the flue gases is absorbed by the checker bricks
Implementation Method 7
The flue gasses which have now cooled down escape the stove via an exhaust gas chamber and at least one discharge port. Once the checker bricks have been heated to a sufficient temperature, the supply of combustion air and fuel is discontinued and air is blown through the stove in the opposite direction. The air is heated as it passes through the heat-retention shaft containing the hot checker bricks
Data Source
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AI summary
The present invention proposes a ceramic burner (20) for use in a combustion chamber (12) of a regenerative heat generator, such as a hot blast stove (10) of a blast furnace. The ceramic burner (20) comprises a burner feed chamber (21 ) with a partition wall (30) for dividing the burner feed chamber (21 ) into a fuel chamber (24) and an air chamber (28). The fuel chamber (24) has a fuel inlet (22) for receiving combustible fuel and a fuel outlet (32) for feeding the combustible fuel to a mixing zone (34). The air chamber (28) has an air inlet (26) for receiving combustion air and an air outlet (36) for feeding the combustion air to the mixing zone (34). According to an important aspect of the invention, the ceramic burner (20) further comprises a gastight metallic fuel container (48) arranged in the burner feed chamber (21 ), the fuel container (48) comprising the fuel chamber (24) therein, a wall portion of the fuel container (48) forming the partition wall (30) between the fuel chamber (24) and the air chamber (28).