Prefabricated Integrated Combustion Assembly for Heat Transfer and Emissions

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Solution Overview

Problem

Existing combustion systems operate below theoretical maximum efficiency for converting chemical energy of fuel into heat and produce pollutants like NOx, which negatively impact the environment.

Innovation Solution

A prefabricated integrated combustion assembly is installed into a combustion chamber, featuring a mounting flange, a fuel nozzle assembly, supports, and a perforated flame holder, which improves heat transfer efficiency and reduces pollutant production by optimizing fuel and oxidant mixing and combustion conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If conventional combustion systems are used, then they can operate and provide heat, but they operate below theoretical maximum efficiency for converting chemical energy of fuel into heat

Engineering Contradiction:

Improveenergy conversion efficiencyVSAvoidenergy loss

Core Design Contradiction:

Use of energy by moving objectVSLoss of energy

Solution Approach 1:

The combustion system is divided into distinct functional components: a perforated flame holder with multiple apertures, a fuel nozzle assembly with separate fuel and oxidant outlets, and a mounting flange. This segmentation allows each component to be optimized independently for its specific function, improving overall energy conversion efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flame holder, fuel nozzle assembly, and mounting flange are combined into a single integrated combustion assembly that is pre-assembled and designed to work together as a unified system, ensuring optimal coordination between fuel injection, oxidant delivery, and flame stabilization

Inventive Principle:

Principle #5Merging (Combining)

2Power

If conventional combustion systems are used, then they can produce heat, but they produce pollutants like NOx that negatively impact the environment

Engineering Contradiction:

Improveheat productionVSAvoidpollutant production

Core Design Contradiction:

PowerVSObject-generated harmful factors

Solution Approach 1:

The flame holder features a perforated design with multiple apertures that create localized combustion zones, allowing for more uniform temperature distribution and reducing hot spots that generate NOx pollutants while maintaining effective heat production

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system changes combustion parameters by separately controlling fuel and oxidant delivery through the fuel nozzle assembly, enabling optimization of the air-fuel ratio to reduce pollutant formation while maintaining efficient heat generation

Inventive Principle:

Principle #35Parameter changes

3Use of energy by moving object

If a prefabricated integrated combustion assembly is installed, then heat transfer efficiency is enhanced and pollutant production is reduced, but the device complexity increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidassembly complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The combustion assembly is pre-assembled and pre-configured with all components (flame holder, fuel nozzle assembly, mounting flange) integrated into a ready-to-install unit, eliminating the need for complex on-site assembly and reducing installation complexity despite the sophisticated design

Inventive Principle:

Principle #10Preliminary action

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 enhances heat transfer efficiency, converting more chemical energy into usable heat, and reduces pollutant production, such as NOx, by optimizing combustion conditions, leading to a more environmentally friendly and efficient combustion process.

Implementation Method 1

The fuel mixes with an oxidant, such as air

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

after mixing, the fuel and oxidant mixture is ignited and combusted in the combustion chamber to generate heat

Methodology Applied

Scientific EffectCombustion: Combustion

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

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS20250164104A1Prefabricated integrated combustion assemblies and methods of installing the same into a combustion system

Publication Date: 2025.05.22 CLEARSIGN TECHNOLOGIES CORPORATION

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.