Oxy-burner Cooling Unit for Glass Fibre Forehearth
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Solution Overview
Problem
Oxy-burners in glass fibre manufacturing forehearths are prone to thermal degradation due to higher flame temperatures and lower oxygen and fuel flow rates, leading to irreversible damage and reduced service life, especially when oxygen and fuel flow cease, causing the burner tip to overheat.
Innovation Solution
A cooling unit with a thermally conductive cooling plate and annular cavity surrounding the oxy-burner's downstream end, connected to both inlet and outlet for fluid communication, maintains the oxy-burner's temperature below safety thresholds by circulating a refrigerating fluid, preventing overheating and carbon deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If oxy-burners are used to heat the forehearth, then energy efficiency is improved, but the burner tip temperature exceeds safety thresholds causing thermal degradation
Solution Approach 1:
The burner system is segmented into a heating function (oxy-burner flame) and a cooling function (separate cooling channels). The cooling channels are integrated into the burner block structure, allowing independent control of heating and cooling processes. This segmentation enables the burner to efficiently heat the forehearth while simultaneously protecting the burner tip from overheating through dedicated cooling passages.
Solution Approach 2:
Cooling channels are strategically positioned at critical locations within the burner block, particularly near the burner tip and in areas experiencing highest thermal loads. The cooling fluid flow rate and temperature are optimized for each local region to maintain burner components below safety threshold temperatures while allowing the flame zone to reach high temperatures for efficient heating.
2Use of energy by moving object
If oxygen and fuel flow rates are reduced in oxy-burners, then energy efficiency is improved, but carbon deposition increases due to lower combustion completeness
Solution Approach 1:
The combustion parameters (oxygen and fuel flow rates, mixture ratio, pressure) are precisely controlled and optimized to maintain complete combustion at lower flow rates. The cooling system allows operation at reduced flow rates without thermal degradation, enabling parameter optimization to prevent carbon deposition while maintaining energy efficiency. The cooling channels provide a safety margin that allows operating point adjustment without compromising burner integrity.
3Productivity
If conventional air-burners are replaced by oxy-burners, then productivity is improved, but burner reliability decreases due to thermal degradation
Solution Approach 1:
Cooling channels are pre-integrated into the burner block structure before the burner is installed in the forehearth. The cooling system is designed and positioned in advance to protect critical components from the high temperatures generated during oxy-burner operation. This preliminary integration ensures that the burner can operate at high productivity levels from the start without risk of thermal degradation, extending service life and reliability.
4Manufacturing precision
If the number of oxy-burners is increased to improve temperature uniformity, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Each oxy-burner is designed as a universal module with integrated cooling channels that can be installed in standardized positions along the forehearth. The modular design with multi-functional components (heating flame plus integrated cooling protection) reduces the variety of different burner types needed, simplifying the overall system despite having multiple burners for temperature uniformity control.
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 cooling unit significantly reduces the frequency of oxy-burner cleaning operations, extends their service life, and allows for a broader range of flow rates, ensuring the oxy-burner operates within safe temperature limits, thereby enhancing operational efficiency and longevity.
Implementation Method 1
a cooling channel (3C) defined by walls and comprising an inlet (3U) and an outlet (3D) for circulating a refrigerating fluid
Implementation Method 2
The downstream end (1D) of the burner is in thermal contact with the aperture wall of the cooling plate
Implementation Method 3
the oxygen and fuel flowing through an oxy-burner and mixed at a tip of the oxy-burner act as cooling medium
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
The present invention concerns a glass fibre manufacturing plant comprising a forehearth (31) comprising a longitudinal wall provided with at least one burner assembly comprising: (A) a burner block (20) made of a refractory material and comprising a through-passage and comprising a hot surface (20H) forming a portion of the longitudinal wall (31 L); and (B) a burner sub-assembly comprising: (a) an oxy-burner (1) comprising a downstream end ending at a free end of the downstream end, wherein a cross-sectional area of said downstream end of the oxy-burner body decreases towards the free end of the downstream end; characterized in that, the burner sub-assembly further comprises: (b) a cooling unit (3) comprising: · a cooling plate (5) comprising an aperture which geometry matches the geometry of the downstream end of the oxy-burner which is inserted in said aperture to form a thermal contact therewith; • a cooling channel (3C) defined by walls and comprising an inlet (3U) and an outlet (3D) for circulating a refrigerating fluid, wherein a cooling wall (5W) of said cooling channel is formed by a portion of the cooling plate, and in that, the cooling plate is encased in the through-passage.