Single Burner Regenerative Combustion System for Low NOx Emissions
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Solution Overview
Problem
Regenerative combustion systems for heating furnaces and heat treatment furnaces face challenges including large dimensions, complex piping and control systems, and increased NOx emissions due to the need for pairs of burners and complex heat recovery systems, which complicate plant design and efficiency.
Innovation Solution
A self-regenerative combustion system with a single burner and a four-way, three-position valve that allows simultaneous combustion and waste gas aspiration, using a regeneration body to preheat the oxidizing agent efficiently and reduce NOx emissions through optimized heat recovery and combustion techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If regenerative burners are used to preheat the oxydizing agent to high temperatures, then fuel efficiency is improved, but NOx emissions increase
Solution Approach 1:
The burners are divided into multiple zones with different functions: primary burners for combustion and secondary burners for preheating the oxydizing agent. This segmentation allows the preheating function to be separated from the main combustion zone, enabling temperature control that reduces NOx formation while maintaining fuel efficiency.
Solution Approach 2:
Different regions of the combustion system are assigned different thermal characteristics. The secondary burners create localized preheating zones with controlled temperatures, while the main combustion zone operates at optimal temperatures. This local quality differentiation enables efficient energy use without excessive temperatures that would generate NOx.
2Use of energy by moving object
If pairs of regenerative burners are installed for heat recovery, then thermal efficiency is improved, but device dimensions and complexity increase
Solution Approach 1:
The system combines primary and secondary burners into a single integrated combustion device rather than using separate regenerative burners. The burners share common piping for fuel and oxydizing agent supply, and a single control system manages both combustion and preheating functions, significantly reducing system complexity while maintaining thermal efficiency.
Solution Approach 2:
The burners are designed to perform multiple functions: main combustion, oxydizing agent preheating, and waste heat recovery. This multi-functionality eliminates the need for separate dedicated regenerative burners and their associated complex piping and control systems, reducing overall device complexity while preserving thermal efficiency benefits.
3Loss of energy
If pairs of regenerative burners are used for combustion and waste gas aspiration, then heat recovery is improved, but the number of components and installation space increase
Solution Approach 1:
The system merges the combustion and waste gas aspiration functions into a single integrated burner unit. The secondary burners handle both the preheating of oxydizing agent and the aspiration of waste gases, eliminating the need for separate burners and reducing the overall installation space required while maintaining effective heat recovery.
Solution Approach 2:
The secondary burners are positioned within or adjacent to the primary burners, creating a nested configuration. This nesting allows the preheating and aspiration functions to be incorporated into the existing burner structure without requiring additional installation space, while still achieving effective heat recovery.
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 system achieves compactness, high efficiency, flexible heat distribution, simplified management, and reduced NOx emissions, minimizing plant design complications and fuel consumption compared to traditional regenerative systems.
Implementation Method 1
preheat the oxydizing agent by means of heat exchange devices with the waste gases produced within the furnaces
Implementation Method 2
heat treatment furnaces heat the charge in a free atmosphere by convection through the high speed of the waste gases lapping it
Implementation Method 3
a single burner configured to introduce fuel in a combustion chamber
Implementation Method 4
heating furnaces heat the charge by radiation
Data Source
AI summary
A self-regenerative combustion system comprising a single burner, capable of operating both during the combustion step and the waste gas aspiration step, and a valve with four ways and three positions, capable of switching the regeneration and the on/off control (oxydizing agent end and waste gas end). The system is provided for obtaining the maximum efficiency, flexibility, minimum fuel consumption and minimum environmental impact with reduced NOx emissions.