Oxygen-Enriched Burner for Inorganic Fiber Production
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Solution Overview
Problem
Current mineral fiber manufacturing processes face challenges in reducing energy consumption and producing high-quality fibers due to the dilution of high-velocity gas streams, which hampers the ability to achieve optimal fiber diameter reduction and filtration properties, and there is a lack of oxy-fuel burners adapted for glass re-melt fiberization applications.
Innovation Solution
The development of a burner apparatus and method that utilizes oxygen-enriched oxidants and heat recovery to elevate combustion gas temperatures, producing a flat flame that enhances fiberization, with options for preheating air and fuel using auxiliary heat sources when oxygen is not available, and includes a refractory block design with oxygen manifolds to disperse fuel and oxygen uniformly for efficient combustion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high gas flow rates are used to stretch filaments and reduce diameter, then fiber attenuation is improved, but energy consumption increases
Solution Approach 1:
The patent changes the physical parameters of the combustion process by using oxygen-enriched oxidants (increasing oxygen concentration from 21% to 30-50%) and preheating combustion gases (raising temperature from ambient to 200-500°C). These parameter changes enable the combustion stream to maintain higher temperatures and velocities with lower gas flow rates, achieving the same fiber attenuation effect while reducing energy consumption.
Solution Approach 2:
The patent applies strong oxidants by introducing oxygen-enriched air or pure oxygen into the combustion process. This accelerates the oxidation of fuel, releasing more energy per unit time and volume, which maintains the high-velocity combustion stream needed for fiber attenuation without requiring proportionally higher energy input.
2Manufacturing precision
If oxygen-enriched oxidants are used to elevate combustion gas temperatures, then fiberization quality is improved, but equipment complexity increases
Solution Approach 1:
The patent designs the burner system to perform multiple functions: the same oxygen enrichment system that elevates combustion temperature also extends flame length and maintains combustion stream velocity. The refractory block with integrated oxygen manifolds serves both as a structural component and as a fluid distribution system, reducing the need for separate specialized components.
Solution Approach 2:
The patent segments the oxygen delivery system into multiple manifolds with distributed outlets within the refractory block. This segmentation allows uniform oxygen distribution throughout the combustion chamber, enabling controlled elevation of combustion temperature across the entire flame zone rather than at a single point, which simplifies thermal management.
3Strength
If conventional air-fuel combustion is used, then equipment simplicity is maintained, but fiber strength and length are reduced
Solution Approach 1:
The patent applies preliminary action by preheating the combustion gases (air and/or fuel) before they enter the combustion chamber. This preheating, achieved through heat exchangers using waste heat from the process, elevates the initial temperature of the combustion stream, resulting in higher flame temperatures that produce stronger, longer fibers without requiring additional energy input during the fiberization process.
Solution Approach 2:
The patent implements feedback by using waste heat from the combustion process to preheat the incoming air and/or fuel through heat exchangers. This feedback loop recovers energy that would otherwise be lost and uses it to elevate combustion temperatures, improving fiber quality while reducing overall energy consumption and minimizing shot.
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 reduces energy usage while producing fibers with greater average strength and length, minimizing shot and achieving better quality fibers suitable for filtration, insulation, and paper products, making the process more energy-efficient and attractive for industrial implementation.
Implementation Method 1
combusting the fuel in the combustion chamber to form a flame
Implementation Method 2
elevate the combustion gas temperature, or flame temperature, leaving the burner
Implementation Method 3
an oxygen manifold fluidly connected to the combustion chamber and adapted to route oxygen to the combustion chamber through a plurality of passages through the refractory block
Implementation Method 4
The high velocity attenuation blast entrains cooler air from its surroundings. This low energy, low velocity air is mixed with the attenuation stream thereby diluting it and reducing both its temperature and velocity.
Data Source
AI summary
Inorganic fiber production burner apparatus and methods of use are disclosed. One burner includes a refractory block adapted to be in fluid connection with sources of primary oxidant and fuel, the refractory block having a fuel and primary oxidant entrance end and a flame exit end, the flame exit end having a substantially rectangular flame exit having a width greater than its height, the refractory block defining a combustion chamber and a second chamber fluidly connecting the combustion chamber and the flame exit end; and an oxygen manifold fluidly connected to the combustion chamber and adapted to route oxygen to the combustion chamber through a plurality of passages through the refractory block. This abstract allows a searcher or other reader to quickly ascertain the subject matter of the disclosure. It will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b).