Regenerator Burner Bypass Flow for Lower Pressure Loss
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Regenerator burners used for flameless oxidation in closed or enclosed spaces face high blower power requirements due to high flow resistance and pressure losses, leading to increased operating costs and reduced heating efficiency.
Innovation Solution
Incorporating a bypass channel for a portion of the exhaust gas stream to reduce pressure losses, allowing the exhaust gas to flow around the regenerator cartridges or through a heat exchanger, thereby reducing the power consumption of the exhaust gas blower and enhancing heat recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a regenerator burner is used for flameless oxidation in closed spaces, then heating efficiency is improved, but blower power requirements increase due to high flow resistance and pressure losses
Solution Approach 1:
The exhaust gas flow path is segmented into two separate channels: a bypass channel that allows partial exhaust gas to flow directly from the combustion chamber to the blower inlet, and a regenerator channel that directs exhaust gas through the regenerator cartridges for heat recovery. This segmentation reduces the overall flow resistance by providing a low-resistance bypass path while maintaining heat recovery functionality through the regenerator channel.
Solution Approach 2:
An orifice plate is introduced as an intermediary component in the bypass channel to control and regulate the partial exhaust gas flow. The orifice plate creates a controlled pressure drop that balances the flow distribution between the bypass channel and the regenerator channel, optimizing the overall system performance by reducing blower power requirements while maintaining heating efficiency.
2Loss of energy
If exhaust gas is conducted through regenerator cartridges for heat recovery, then heat recovery efficiency is improved, but pressure losses increase due to flow resistance
Solution Approach 1:
The exhaust gas flow is divided into two streams: one stream passes through the regenerator cartridges for heat recovery, while the other stream bypasses the cartridges through a dedicated bypass channel. This segmentation allows the system to recover heat from a portion of the exhaust gas without subjecting the entire exhaust flow to the high pressure losses associated with passing through the regenerator cartridges.
Solution Approach 2:
Instead of directing 100% of the exhaust gas through the regenerator cartridges, the system uses partial action by directing only a portion of the exhaust gas through the cartridges while allowing the remainder to bypass. This partial flow through the regenerator reduces pressure losses while still achieving effective heat recovery from the portion that does pass through.
3Productivity
If the pulse rate of air at output nozzles is increased to maintain flameless oxidation, then recirculation is improved, but pressure losses increase due to high flow rate in air nozzles
Solution Approach 1:
The bypass channel extracts a portion of the exhaust gas directly from the combustion chamber before it passes through the regenerator cartridges. This extracted bypass flow contributes to the recirculation needed for flameless oxidation without adding to the pressure losses that would result from increasing the pulse rate of air through the high-resistance regenerator cartridges.
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 solution decreases the energy consumption of the exhaust gas blower by approximately 35% and increases heating efficiency, while maintaining low NOx emissions and high combustion efficiency, with virtually no additional expense or effort.
Implementation Method 1
regenerators are heat storage devices through which alternately exhaust gas and combustion air is conducted whereby the storage device heat up in one phase and, as a result, the exhaust gas is cooled. In order to transfer the absorbed heat to the combustion air, the combustion is subsequently conducted through hot storage device in another phase.
Implementation Method 2
heat of the hot exhaust gas is transferred through a dividing wall to the combustion air
Implementation Method 3
a partial stream of the exhaust gas is conducted under the control of an orifice plate through a bypass space in which the regenerator cartridges are disposed
Implementation Method 4
A control structure is disposed in a burner head for controlling the exhaust gas bypass flow volume and also to control the main exhaust gas flow as well as the combustion air flow through the regenerator cartridges
Implementation Method 5
nozzles discharging the preheated air at a high speed. As a result of this, a strong exhaust gas recirculation is produced in the furnace. The thusly effected flameless oxidation (FLOX® principle) is particularly suitable
Data Source
AI summary
In a high efficiency regenerator burner for heating spaces, the exhaust gas generated by the burner is provided which is conducted alternately through different regenerator cartridges and a partial stream of the exhaust gas is conducted under the control of an orifice plate through a bypass space in which the regenerator cartridges are disposed. A control structure is disposed in a burner head for controlling the exhaust gas bypass flow volume and also to control the main exhaust gas flow as well as the combustion air flow through the regenerator cartridges.