Pilot Gas Preheating for Flare Burner Frost Prevention

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Solution Overview

Problem

Conventional pilot burners in gas flares malfunction in cold environments due to frost or ice buildup at the inspirator, which inhibits the flow of pilot gas and air, leading to improper mixing and ignition issues.

Innovation Solution

A pilot burner design that includes a gas preheat conduit section in the pilot gas supply line, which is heated by the pilot flame to preheat the pilot gas before it reaches the inspirator, preventing frost or ice buildup and ensuring proper flow and mixing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the pilot burner operates in cold environments, then the gas flare can ignite waste gas, but frost or ice forms at the inspirator from moisture in the pilot gas, air, or snow/rain, which inhibits flow and causes malfunction

Engineering Contradiction:
Improvepilot burner operationVSAvoidfrost and ice formation
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by heating the pilot gas in the supply line before it reaches the inspirator. The gas preheat conduit section is positioned to receive heat from the pilot flame, preheating the pilot gas upstream before mixing occurs. This prevents frost and ice formation at the inspirator by ensuring the gas temperature is already elevated before encountering ambient moisture in cold environments.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent converts the harmful cold environment and moisture into a beneficial heating mechanism. The pilot flame, which is necessary for ignition, also serves to heat the gas supply line and prevent frost formation. The heat from the flame that would otherwise be wasted is utilized to maintain gas temperature and prevent harmful ice buildup at the inspirator.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

If the gas preheat conduit section is positioned adjacent to the pilot output, then the pilot gas is preheated by the flame, but the system requires additional structural components

Engineering Contradiction:
Improvepilot gas flowVSAvoidpilot gas supply line structure
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the gas supply function with the heating function by positioning the gas preheat conduit section adjacent to the pilot output where the flame is generated. The conduit section is integrated into the existing gas supply infrastructure, combining the transport of pilot gas with the heating process in a single integrated system rather than adding separate heating equipment.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The system applies self-service by using the pilot flame itself to heat the gas supply line. The flame, which is already present and necessary for ignition, automatically provides the heat needed to prevent frost formation. No external heating source or complex control system is required - the system uses its own operational element (the flame) to solve the freezing problem.

Inventive Principle:
Principle #25Self-service

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 preheating of pilot gas effectively prevents frost and ice formation at the inspirator, ensuring consistent operation of the pilot burner even in cold conditions, thereby maintaining proper ignition of the gas flare.

Implementation Method 1

a gas preheat conduit section that is positioned adjacent to the pilot output and is configured to be heated by the flame

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20250052422A1Pilot gas preheating for a gas flare pilot burner
Publication Date: 2025.02.13 STEFFES LLC
  • US20250052422A1 patent drawing
  • US20250052422A1 patent drawing
  • US20250052422A1 patent drawing

AI summary

A pilot burner for igniting a gas flare includes a pilot gas supply line, an inspirator, a gas feed line, a pilot output and an igniter. The pilot gas supply line is configured to receive a flow of pilot gas from a pilot gas source. The inspirator receives the flow of pilot gas from the pilot gas supply line and mixes the flow of pilot gas with air to form a mixed flow of air and gas. The gas feed line receives the mixed flow from the inspirator. The pilot output is connected to the gas feed line and discharges the mixed flow. The igniter is configured to ignite the mixed flow discharged through the pilot output to form a flame. The pilot gas supply line includes a gas preheat conduit section that is positioned adjacent to the pilot output and is configured to be heated by the flame.