Continuous Regenerative Burner Firing via Counter-Cycle Flow Control
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Solution Overview
Problem
Existing methods for firing combustion chambers with regenerative burners suffer from pressure fluctuations during changeover processes, leading to inefficient energy use, false air intake, incomplete combustion of carbonization gases, and potential pollutant emissions due to the need for frequent ignition and large regenerator designs.
Innovation Solution
A method utilizing at least three regenerative burners with proportional valves on the cold gas side for continuous regulation of supply and exhaust air flows, maintaining constant combustion chamber pressure by adjusting the volume flows of one regenerative burner in counter-cycle mode with a third burner, eliminating the need for changeover processes and reducing thermal stress on actuators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If two regenerative burners are used with alternating combustion and exhaust modes, then the thermal mass of regenerators can be reduced, but pressure fluctuations occur during changeover causing false air intake and incomplete combustion
Solution Approach 1:
The system divides the regenerative burner function into three separate units instead of two, allowing one burner to remain in combustion mode while the other two alternate between combustion and exhaust modes. This segmentation eliminates the need for complete combustion interruption during changeover, maintaining continuous combustion stability while enabling regenerator switching.
Solution Approach 2:
The invention changes the operational parameters by introducing a third regenerative burner and modifying the cycling pattern. Instead of direct alternation between two burners causing pressure swings, the system uses proportional valve control to gradually transition flow parameters, maintaining near-constant total supply and exhaust air flows throughout the changeover process.
2Ease of operation
If proportional valves are placed on the hot gas side for flow control, then flow regulation is achieved, but the valves are exposed to high temperatures causing high wear
Solution Approach 1:
The invention introduces cold gas side proportional valves as intermediaries to control the flow of preheated air before it enters the hot combustion zone. These valves operate in the cooler preheated air environment rather than directly in the high-temperature combustion gases, significantly reducing thermal stress and wear while maintaining effective flow control capability.
3Device complexity
If discrete shut-off valves are used on the cold gas side, then simple valve operation is achieved, but flow control of volume flows is not suitable
Solution Approach 1:
The invention replaces static discrete shut-off valves with dynamic proportional valves on the cold gas side. These proportional valves can continuously modulate their opening degree to precisely control the volume flow of preheated air to each regenerator, enabling smooth transitions during changeover processes while maintaining simple valve actuation through proportional control signals.
4Productivity
If changeover processes are implemented between regenerative burners, then regenerator switching is achieved, but combustion interruption occurs requiring re-ignition
Solution Approach 1:
The invention maintains continuous combustion action by keeping one regenerative burner in constant combustion mode while the other two alternate. This ensures that combustion never completely stops during regenerator changeover, eliminating re-ignition requirements and associated time losses, while still achieving effective regenerator utilization through the cycling of two burners.
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 approach prevents false air intake and toxic gas emissions, enables efficient energy use, and allows for shorter operating cycles with more compact regenerator designs, reducing wear and maintenance needs while maintaining consistent combustion chamber pressure.
Implementation Method 1
a first of the regenerative burners is cyclically first in the combustion mode carrying supply air and a second of the regenerative burners is in the exhaust mode carrying exhaust air
Implementation Method 2
reducing the volume flow of the supply or exhaust air through the first or second regenerative burner continuously and in countercurrent to the volume flow of the supply or exhaust air through the third regenerative burner
Implementation Method 3
the hot process exhaust gas produced in the combustion chamber during the combustion process
Data Source
AI summary
A method for continuous firing of combustion chambers with at least three regenerative burners, wherein a first regenerative burner cyclically in the combustion mode conveys supply air and a second regenerative burner in the exhaust mode conveys exhaust air. To avoid escape of hazardous process gases from the combustion chamber into the environment and high carbon monoxide emissions, and to provide energy-efficient firing operation despite use of compact regenerators, the volume flow of the supply or exhaust air through the first or second regenerative burner is reduced continuously and in counter-cycle mode to the volume flow of supply or exhaust air through a third regenerative burner at constant combustion chamber pressure until the first or second regenerative burner is flow-free.