Regenerative Burner Flame Straightness and NOx Reduction
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Solution Overview
Problem
Conventional regenerative burners experience issues with non-uniform temperature distribution and flame spread, leading to defects in fired articles due to lower in-furnace stirring effect and oxidation of fuel nozzles, resulting in discolored spots and reduced product yield.
Innovation Solution
The regenerative burner design injects the total amount of fuel into the combustion chamber, burns it inside, and ejects a high-speed flame from a nozzle, with a heat exchange chamber utilizing exhaust gas as combustion air to enhance flame straightness and reduce thermal NOx, incorporating a heat accumulator and combustion air fan system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If fuel is burned outside the burner tile with preheated combustion air, then thermal NOx is reduced, but flame spreads in multiple directions causing non-uniform temperature distribution
Solution Approach 1:
The invention extracts the combustion process from the conventional external mixing zone and relocates it inside the burner tile combustion chamber. By injecting fuel directly into the combustion chamber where it mixes with preheated combustion air and burns internally, the flame is confined and ejected straight ahead, preventing multi-directional spread and achieving uniform temperature distribution while maintaining thermal NOx reduction benefits
2Ease of manufacture
If fuel nozzle tip and air hole tip are provided at burner tip, then combustion occurs outside burner tile, but flame spreads widely reducing in-furnace stirring effect
Solution Approach 1:
The invention inverts the conventional combustion location by placing the fuel nozzle inside the burner tile rather than at the tip. The fuel is injected into the combustion chamber, mixed with preheated air, and combusted internally before ejection, which confines the flame and enhances stirring effect without complicating the overall burner structure
3Ease of operation
If metallic fuel nozzle is installed penetrating heat accumulator space, then fuel can be supplied, but nozzle oxidizes and rusts causing discolored spots on fired articles
Solution Approach 1:
The invention extracts the fuel nozzle from the conventional position penetrating the heat accumulator space and relocates it inside the combustion chamber. This eliminates exposure to high-temperature oxidizing environments that cause rust, preventing discolored spots on fired articles while maintaining fuel supply functionality through the combustion air stream
4Use of energy by moving object
If total amount of fuel is mixed with combustion air outside burner, then combustion is slow and efficient, but flame spreads in all directions causing melting defects
Solution Approach 1:
The invention segments the combustion process into two stages: first, fuel mixes with preheated combustion air inside the combustion chamber for efficient combustion; second, the resulting flame is ejected as a focused high-velocity jet. This segmentation maintains combustion efficiency while directing flame in a straight line, preventing multi-directional spread and melting defects on workpieces
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 design achieves a higher straightness of flame, improving in-furnace stirring and temperature uniformity, reducing defects, and simultaneously lowering thermal NOx emissions, thereby enhancing product quality and yield while reducing environmental impact.
Implementation Method 1
a function of burning fuel, as well as a function of recovering heat of a combustion exhaust gas by heat accumulator installed therein
Implementation Method 2
pass through a space filled with the heat accumulator
Implementation Method 3
combustion air introduced from the air port into the heat exchange chamber can pass through a space filled with the heat accumulator
Implementation Method 4
fuel introduced from the fuel nozzle into the combustion chamber can be burned in the combustion chamber using combustion air introduced into the combustion chamber
Implementation Method 5
eject high speed flame from a nozzle
Data Source
AI summary
A regenerative burner including: a combustion chamber; a heat exchange chamber; and a communication passage therebetween, the combustion chamber includes a tip of a fuel nozzle and a flame ejection port, and is configured such that fuel introduced from the fuel nozzle into the combustion chamber can be burned in the combustion chamber using combustion air introduced into the combustion chamber through the communication passage to eject flame from the flame ejection port; the fuel nozzle is configured such that fuel burned in the regenerative burner is introduced into the combustion chamber; and the heat exchange chamber comprises a heat accumulator interposed between the communication passage and an air port, and is configured such that combustion air can pass through the heat accumulator and then be introduced into the combustion chamber such that an exhaust gas passes through the heat accumulator and is discharged from the air port.