Perforated Flame Holder Combustion Assembly for NOx Reduction
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Solution Overview
Problem
Conventional combustion systems operate below theoretical maximum efficiency and produce pollutants, such as NOx, due to suboptimal fuel combustion and heat transfer processes.
Innovation Solution
Integrated combustion assemblies featuring a perforated flame holder and fuel distribution hub, which preassemble components for easy installation and retrofitting, improving fuel mixing and combustion efficiency by positioning the flame holder downstream from the fuel nozzles to enhance fuel and oxidant mixing and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional combustion systems are used, then fuel combustion and heat transfer processes occur, but the systems operate below theoretical maximum efficiency and produce pollutants such as NOx
Solution Approach 1:
The combustion system is segmented into multiple fuel nozzles arranged in a circular pattern, each injecting fuel into a separate sector of the combustion chamber. This segmentation allows for better control of fuel distribution and combustion zones, improving combustion efficiency while reducing pollutant formation through more uniform mixing and combustion.
Solution Approach 2:
The system implements local quality optimization by positioning fuel nozzles to create specific combustion zones at different locations within the combustion chamber. Each nozzle sector creates a localized combustion environment that optimizes mixing and burning conditions, thereby improving overall combustion efficiency and reducing NOx production through controlled local combustion characteristics.
2Use of energy by moving object
If fuel nozzles are positioned closer to the flame holder, then fuel and oxidant mixing is enhanced, but combustion stability may be compromised
Solution Approach 1:
The fuel nozzles are arranged in a circular pattern around the flame holder, utilizing radial positioning in addition to axial distance. This dimensional arrangement allows fuel to be injected from multiple directions simultaneously, enhancing mixing efficiency while maintaining optimal distance from the flame holder to ensure combustion stability. The circular configuration creates a balanced three-dimensional combustion pattern.
3Productivity
If a single large burner is used, then fuel combustion occurs, but retrofitting and installation require complex assembly and modifications
Solution Approach 1:
The combustion system is divided into multiple modular fuel nozzle assemblies arranged in a circular pattern, each capable of being installed independently. This segmentation allows for simplified retrofitting where individual nozzle sectors can be installed or replaced without requiring complete disassembly of the combustion system, reducing installation complexity while maintaining high combustion output through the combined effect of multiple nozzles.
Solution Approach 2:
The fuel nozzle assemblies are pre-configured in a circular arrangement with predetermined spacing and orientation relative to the flame holder. This preliminary configuration allows the entire nozzle assembly to be pre-assembled and tested before installation, significantly reducing on-site assembly complexity and modification requirements during retrofitting while ensuring optimal combustion performance.
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 increases heat transfer efficiency, reduces pollutant production, particularly NOx, and allows for leaner combustion ratios, improving the overall performance and environmental impact of combustion systems.
Implementation Method 1
The fuel mixes with an oxidant (e.g., air) and, after mixing, the fuel and air mixture is ignited and combusted
Implementation Method 2
the fuel and air mixture is ignited and combusted in the combustion chamber to generate heat
Implementation Method 3
heat generated by the combustion system may be transferred and may raise a temperature of one or more objects and/or materials
Data Source
AI summary
Embodiments disclosed herein are directed to integrated combustion assemblies including a perforated flame holder, combustion systems that include one or more integrated combustion assemblies, and related methods. For example, an integrated combustion assembly may be placed into service (e.g., integrated into a combustion system) as a complete and/or replaceable unit, such that elements and/or components of the combustion assembly are preassembled and no further assembly is required at the installation site.