Passive Mixing Matrix for Compact Staged Combustion Boilers
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Solution Overview
Problem
Conventional steam generating boilers are large and heavy due to their design accommodating the size of the combustion envelope, leading to inefficiencies such as incomplete combustion, higher emissions, and increased risk of flame impingement, which results in costly repairs and downtime.
Innovation Solution
A steam generating boiler design featuring a matrix within the combustion furnace that radially disperses and axially shortens the combustion envelope by passively mixing gaseous fuel and oxidant streams, utilizing a matrix with varying cross-sectional open areas to enhance mixing and maintain constant ignition, thereby reducing boiler size and weight while minimizing emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional burners are used with standard combustion envelope design, then sufficient thermal energy is produced for steam production, but the boiler size and weight become large and heavy
Solution Approach 1:
The combustion envelope is transformed from a conventional elongated shape to a spherical geometry. This dimensional change allows the same thermal energy output to be achieved in a more compact volume, reducing boiler size and weight while maintaining power production capabilities.
Solution Approach 2:
The combustion envelope parameters are optimized by changing the shape from elongated to spherical and controlling the length-to-diameter ratio within 0.5:1 to 1.5:1. This parameter optimization enables compact boiler design while preserving sufficient thermal energy for steam generation.
2Reliability
If the combustion envelope is made larger to avoid flame impingement, then complete combustion is achieved, but the boiler size and weight increase
Solution Approach 1:
By changing the combustion envelope geometry to spherical shape with optimized dimensions, the design achieves complete combustion without requiring excessive boiler volume. The spherical shape provides uniform heat distribution and prevents flame impingement while maintaining compact size.
Solution Approach 2:
The length-to-diameter ratio of the combustion envelope is controlled within 0.5:1 to 1.5:1, and the envelope dimensions are optimized to prevent flame impingement. These parameter changes ensure complete combustion while minimizing boiler size and weight.
3Length of moving object
If flow control mechanisms are used to restrict radial expansion of combustion envelope, then flame length is reduced, but shearing forces increase and mixing is affected
Solution Approach 1:
The flow control mechanisms are removed from the burner design. Instead of using complex flow control devices to manage flame length, the invention relies on the natural spherical expansion of the combustion envelope and optimized fuel/oxidant injection patterns to achieve appropriate flame characteristics.
Solution Approach 2:
The combustion envelope naturally regulates its own expansion and shape through the physics of combustion. The spherical geometry self-adjusts to optimize mixing and flame propagation without requiring external flow control mechanisms, simplifying the overall burner design.
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 achieves a compact, low NOx and low CO steam generating boiler with improved mixing and reduced emissions, allowing for smaller, lighter designs without sacrificing heat output and maintaining constant ignition, thus reducing boiler size and weight while minimizing emissions.
Implementation Method 1
a matrix within the combustion furnace that radially disperses and axially shortens the combustion envelope by passively mixing gaseous fuel and oxidant streams
Implementation Method 2
radially disperses and axially shortens the combustion envelope
Implementation Method 3
Fossil fuel burners convert chemical energy stored in fossil fuels to thermal heating by combusting the fossil fuel in the presence of an oxidant
Implementation Method 4
utilizing a matrix with varying cross-sectional open areas to enhance mixing and maintain constant ignition
Data Source
AI summary
A steam generating boiler having a matrix means for reducing combustion volume. Matrix means is placed in the combustion furnace of a steam generating boiler, preferably downstream of fuel and oxidant stream. Matrix means produces a shorter combustion envelope than that of a conventional boiler, allowing for reduced volume steam generating boilers.