Radiant Tube Ceramic Insert for Heat Transfer

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Solution Overview

Problem

Radiant tube furnaces experience uneven heat transfer and energy wastage due to the configuration of radiant tubes, leading to inefficient heating of materials and high operational costs.

Innovation Solution

A ceramic insert with a tubular member and wing sections is designed to absorb heat from combustion gases and direct it radiantly towards the material being heated, enhancing heat transfer by creating a gap between the insert and the radiant tube and utilizing a metal coating to react with exhaust gases, thereby improving fuel efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If radiant tubes are used in conventional configuration, then heat transfer occurs through convection and radiation, but uneven heat distribution and energy wastage occur in the exhaust section

Engineering Contradiction:

Improveenergy wastage in exhaust sectionVSAvoidevenness of heat transfer to material

Core Design Contradiction:

Loss of energyVSManufacturing precision

Solution Approach 1:

The patent converts the harmful waste heat in the exhaust section into beneficial heating by installing a ceramic insert that absorbs thermal energy from the outgoing flue gases and re-radiates it toward the material being processed. This transforms the previously wasted thermal energy into useful heat, simultaneously reducing energy loss and improving heat distribution uniformity

Inventive Principle:

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

Solution Approach 2:

The ceramic insert is strategically positioned in the exhaust section where heat distribution is most uneven. The insert's curved surface geometry is specifically designed to redirect thermal radiation toward areas requiring more heat, creating localized quality improvement in the heat transfer distribution without affecting the entire tube system

Inventive Principle:

Principle #3Local quality

2Productivity

If thermal energy is transmitted primarily from the burner section, then heating occurs but a large amount of thermal energy is wasted in the exhaust section without directing it to the material

Engineering Contradiction:

Improveheating efficiencyVSAvoidthermal energy exiting furnace without heating material

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The ceramic insert acts as an intermediary device between the flue gases and the material being heated. It absorbs thermal energy from the gases and re-radiates it in a controlled manner toward the material, mediating the heat transfer process to ensure thermal energy is effectively utilized rather than wasted

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The ceramic insert is pre-positioned in the exhaust section to capture and redirect thermal energy before it exits the furnace. This preliminary action ensures that heat which would otherwise be lost is recovered and applied to the material, improving overall heating efficiency

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 insert increases heat transfer to the material being heated, reduces energy wastage, and enhances fuel efficiency by 5-20%, leading to cost savings in furnace operation.

Implementation Method 1

a first section adapted to absorb heat from the combustion gases passing through the radiant tube

Methodology Applied

Scientific EffectHeat absorption: Absorption (EM radiation)

Implementation Method 2

radiantly transfer the heat to a wall of the radiant tube

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 3

a second section for directing heat and gases in the radiant tube toward the first section of the insert

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS10823396B2Radiant heat insert

Publication Date: 2020.11.03 PSNERGY LLC

AI summary

An insert for a radiant tube of a furnace including a first section adapted to absorb heat from combustion gases passing through the radiant tube and radiantly transfer the heat to a wall of the radiant tube and a second section for directing heat and gases in the radiant tube toward the first section of the insert and a system including a radiant tube and one or more such inserts. Also, a method of improving heat transfer from a radiant tube of a furnace to the material being heated including supplying an insert as described above and placing the insert into the radiant tube such that the first section corresponds to a portion of the radiant tube that is closest to the material being heated. Also, an insert for a radiant tube of a furnace including a ceramic body and a metal deposited on the surface of the ceramic body.