Prefabricated Combustion Assembly with Perforated Flame Holder
Solution Overview
Problem
Conventional combustion systems operate below theoretical maximum efficiency and produce pollutants like NOx, which negatively impact the environment and reduce fuel energy conversion to heat effectively.
Innovation Solution
A prefabricated integrated combustion assembly is installed into a combustion system, featuring a mounting plate, fuel nozzle assembly, and a perforated flame holder with apertures, which supports the flame at a predetermined distance from the fuel nozzle, optimizing fuel and oxidant mixing and reducing combustion temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional combustion systems are used, then they can operate and provide heat, but they operate below theoretical maximum efficiency and produce pollutants like NOx
Solution Approach 1:
The flame holder is divided into multiple segments with apertures that allow oxidant to penetrate through different zones of the flame, creating segmented combustion regions that improve mixing efficiency and reduce pollutant formation while maintaining energy conversion efficiency
Solution Approach 2:
The combustion system implements local quality variations by positioning the flame holder at a specific distance from the fuel nozzle and creating zones of different oxidant concentration through the aperture structure, enabling leaner combustion in critical regions while maintaining overall system performance
2Loss of energy
If a prefabricated integrated combustion assembly is installed, then heat transfer efficiency is enhanced and NOx production is reduced, but the device complexity increases
Solution Approach 1:
The mounting plate, fuel nozzle assembly, supports, and flame holder are merged into a single prefabricated integrated combustion assembly that is pre-positioned at the base of the combustion chamber, simplifying installation while maintaining the complex internal geometry needed for efficient heat transfer and low NOx emission
Solution Approach 2:
The combustion assembly is pre-fabricated with the flame holder positioned at a predetermined distance from the fuel nozzle and the mounting plate prepared with attachment features before installation, allowing the complex configuration to be prepared in advance and installed as a unit, reducing on-site complexity
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 configuration enhances heat transfer efficiency, reduces NOx production, and allows for leaner combustion, improving the overall operation of the combustion system by converting more chemical energy into heat while minimizing pollutant emission.
Implementation Method 1
The fuel mixes with an oxidant, such as air, and after mixing, the fuel and oxidant mixture is ignited and combusted in the combustion chamber to generate heat
Implementation Method 2
The fuel mixes with an oxidant, such as air, and after mixing, the fuel and oxidant mixture is ignited and combusted
Implementation Method 3
heat generated by the combustion system may be transferred and may raise the temperature of one or more objects and/or materials
Data Source
AI summary
Embodiments disclosed herein are directed to devices and methods for improving operation of a combustion system. According to various embodiments disclosed herein, a prefabricated integrated combustion assembly is disclosed that may be installed into a combustion chamber of a combustion system. The combustion system may be a new combustion system that is being manufactured or a conventional combustion system that is being retrofitted.