Interchangeable Nozzle Barrels for Combustion Air Velocity Control
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Solution Overview
Problem
Existing combustion air delivery systems in furnaces, particularly in waste-to-energy facilities and power plants, face issues with complex and costly designs that require high maintenance due to moving parts prone to plugging and seizing in high-temperature, corrosive environments, and struggle with optimizing air flow velocity independently of flow rate.
Innovation Solution
The Optimized Overfire Air Nozzles and System feature interchangeable nozzle barrels with smooth flow paths and no moving parts, allowing for adjustable nozzle sizes and shapes, enabling independent control of flow velocity and rate through upstream pressure regulation, with nozzles designed for easy replacement and maintenance in high-temperature environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If velocity dampers or moveable obstructions are used to control air flow, then air flow quantity and velocity can be adjusted, but the flow path becomes poor requiring more pressure and the moving parts are prone to plugging and seizing in high-temperature environments
Solution Approach 1:
The patent removes all moving parts (velocity dampers, moveable obstructions) from the high-temperature furnace environment. Instead, it uses fixed geometric nozzles with optimized flow paths that achieve flow control through pressure regulation upstream, eliminating the reliability issues of moving parts in corrosive, high-temperature conditions
Solution Approach 2:
The patent replaces the mechanical velocity damper system with a streamlined nozzle design controlled by upstream pressure regulation. The mechanical adjustment of velocity via moving parts is substituted with aerodynamic optimization of the nozzle geometry combined with pressure control, eliminating mechanical wear and plugging issues
2Ease of operation
If divided nozzles with upstream dampers are used, then flow control is improved, but the design becomes more costly, complex and requires larger footprint
Solution Approach 1:
The patent uses multiple separate nozzles positioned at different locations around the furnace rather than one complex divided nozzle. Each nozzle is simple in design with optimized geometry, but collectively they provide comprehensive flow control. This segmentation avoids the complexity of internal divisions while achieving similar or better control effectiveness
Solution Approach 2:
The patent designs universal nozzle components that can be used in multiple positions and configurations. The same basic nozzle design with optimized geometry serves multiple functions: flow delivery, flow direction, and velocity control, eliminating the need for specialized divided nozzle designs with multiple dampers and complex internal structures
3Speed
If complex nozzles with moving parts are used to accelerate air flow, then air flow velocity is improved, but maintenance requirements increase due to plugging and seizing in corrosive environments
Solution Approach 1:
Instead of trying to protect moving parts from the harsh furnace environment, the patent inverts the approach by placing all moving parts (pressure regulation components) upstream in the cooler, cleaner air supply system. The nozzles themselves have no moving parts and are designed for easy replacement as disposable or wear components, dramatically reducing maintenance complexity
Solution Approach 2:
The patent designs nozzles as simple, inexpensive components with no moving parts that can be easily replaced when worn or damaged. By eliminating complex mechanical systems, the nozzles become replaceable rather than repairable items, reducing maintenance costs and downtime despite the harsh operating environment
4Device complexity
If fixed nozzle sizes are used, then the design is simpler, but the ability to tune combustion air flow independently of flow rate is limited
Solution Approach 1:
The patent makes the nozzle system dynamically adjustable through interchangeable nozzle barrels with different geometries and sizes. While each individual nozzle is fixed and simple, the system as a whole can be tuned by swapping nozzle components, allowing optimization for different operating conditions without requiring complex adjustable mechanisms in each nozzle
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
This solution enhances combustion air delivery efficiency, reduces maintenance costs, and allows for precise tuning of combustion air flow in boilers, improving overall system performance while minimizing the need for complex and costly designs.
Implementation Method 1
The nozzle body (2) includes a streamlined flow path (3) leading to an exit opening (4)
Implementation Method 2
upstream pressure regulation
Implementation Method 3
a converging section (12) having an upstream end connected to the nozzle body (2) and a downstream end connected to the nozzle barrel (5), the converging section (12) accelerating the flow
Implementation Method 4
converging sections
Data Source
AI summary
Nozzles for delivering air into a combustion system of a boiler including an interchangeable nozzle barrel. Nozzle barrels can be easily replaced for maintenance or to change the size and flow velocity of the nozzles to optimize combustion performance. Nozzles may include converging sections with an arc, double arc's, bell shaped, or hyperbolic curves around the entire perimeter of the nozzle and optimized for delivery of air into the combustion system from ducting or from within a plenum.