Outer Burner Positioning for Furnace Heat Transfer Homogeneity
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Solution Overview
Problem
Vertically-fired furnaces used in endothermic processes like steam methane reforming face issues with inhomogeneous heat transfer due to outer burner flames bending towards inner flames, leading to temperature inconsistencies and reduced efficiency, which existing solutions have not adequately addressed.
Innovation Solution
Positioning outer burners closer to the furnace walls, with a distance between the outer burner and the wall along the X-axis being equal to or less than the equivalent burner nozzle diameter, prevents flame bending and ensures uniform heat distribution among tube rows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If outer burners are positioned at conventional distances from the furnace walls, then installation and maintenance are easier, but flame bending occurs causing inhomogeneous heat transfer and temperature inconsistencies
Solution Approach 1:
The patent applies parameter changes by modifying the distance parameter between outer burners and furnace walls. Specifically, it positions outer burners at a distance of 0.15 to 0.30 meters from the furnace walls, which is a specific parameter change from conventional positioning. This parameter adjustment prevents flame bending towards inner flames, thereby achieving homogeneous heat transfer across all tube rows while maintaining practical installation and maintenance accessibility.
2Manufacturing precision
If outer burners are positioned closer to the furnace walls to prevent flame bending, then heat transfer homogeneity improves, but the distance constraint becomes more restrictive
Solution Approach 1:
The patent defines a specific parameter range for the burner-to-wall distance (0.15 to 0.30 meters) that optimizes both heat transfer homogeneity and spatial constraints. This parameter change ensures that outer burner flames do not bend towards inner flames while maintaining adequate clearance for installation and maintenance operations.
Solution Approach 2:
The patent applies partial action by positioning outer burners at a moderate distance (not extremely close to the wall) that is sufficient to prevent flame bending but not so close as to create installation difficulties. The distance of 0.15 to 0.30 meters represents a partial solution that achieves the necessary flame control without excessive constraint.
3Power
If outer burners operate at lower power to heat only one row of tubes, then inner burners can provide sufficient heat to two rows, but overall heat transfer efficiency decreases
Solution Approach 1:
The patent changes the operational parameter of outer burners by enabling them to operate at higher power levels (equivalent to inner burners) due to the prevented flame bending. This parameter change allows outer burners to effectively heat their adjacent tube row without losing energy to deflecting flames, thereby improving overall heat transfer efficiency while maintaining balanced power distribution across all burners.
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 approach enhances the homogeneity of heat transfer, maintains consistent tube temperatures, and improves the overall efficiency and durability of the furnace by reducing temperature differences between tube rows, thereby optimizing the endothermic process.
Implementation Method 1
combusting fuel with air in burners that are mounted either to the furnace floor or to the furnace ceiling
Implementation Method 2
The necessary heat for the endothermic process is provided by roof burners placed in rows between the tubes
Implementation Method 3
The SMR process is mainly based on the reforming reaction of methane that yields to a mixture of hydrogen (H2) and carbon monoxide (CO) in the presence of water vapor. The reaction is endothermic and slow and requires additional heat input
Data Source
AI summary
A furnace for performing an endothermic process, comprising tubes containing catalyst for converting gaseous feed, wherein tubes are positioned inside the furnace in rows parallel to refractory walls along X axis, wherein burners are mounted either to the furnace floor or to the furnace ceiling, inner burners being mounted in rows between the rows of tubes and outer burners being mounted in rows between tubes rows and the wall along X axis, and close to said wall along X axis, wherein the outer burners are positioned such that the distance b2w between the outer burner and the wall along X axis is smaller than or equal to equivalent burner nozzle diameter øb of said outer burner (b2w/øb≤1).