Sparkless Igniter Nozzle Design for Heater Treater Firetube Durability

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Solution Overview

Problem

Commercially available spark igniters in heater treaters suffer from premature failure due to localized hotspots caused by flame impingement on the U-shaped firetube bends, leading to inefficient heating and high fuel consumption, necessitating the development of a more durable and efficient ignition system.

Innovation Solution

A sparkless igniter design featuring a nozzle with apertures of varying diameters and a hot surface igniter assembly, combined with a burner management system, which generates a flame plume matching the firetube diameter and providing uniform heating, reducing hotspot formation and increasing durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If spark igniters are used in heater treaters, then ignition function is achieved, but localized hotspots are caused due to flame impingement on firetube bends leading to premature failure

Engineering Contradiction:

Improvefiretube durabilityVSAvoidlocalized hotspots

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The igniter assembly is segmented into multiple separate burners arranged in a circular pattern, with each burner having its own nozzle pointing toward the firetube. This segmentation distributes the flame sources across multiple locations, preventing concentrated heat impingement on any single area of the firetube bend.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each individual burner nozzle is specifically oriented to direct its flame at a different angular position around the firetube, creating localized heating zones that are distributed uniformly around the circumference rather than concentrated at one spot. This ensures each portion of the firetube receives appropriate heat without excessive localized stress.

Inventive Principle:

Principle #3Local quality

2Use of energy by moving object

If conventional igniters are used, then ignition is achieved, but flame plume does not match firetube diameter resulting in inefficient heating and high fuel consumption

Engineering Contradiction:

Improvefuel consumptionVSAvoidheating efficiency

Core Design Contradiction:

Use of energy by moving objectVSProductivity

Solution Approach 1:

The nozzle design incorporates specific geometric parameters including a curved trajectory that directs the flame plume to match the firetube diameter. The nozzle outlet angle and curvature radius are optimized to ensure the flame expands to the appropriate size, maximizing heat transfer efficiency and reducing fuel waste.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The flame plume is directed not just radially outward but also with a controlled angular distribution around the firetube circumference. This three-dimensional flame configuration ensures comprehensive coverage of the firetube surface area, improving heating efficiency by utilizing spatial distribution in addition to radial expansion.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 sparkless igniter design enhances firetube durability, reduces fuel consumption by 30-35%, and ensures uniform heat distribution along the firetube length, improving the overall efficiency and reducing maintenance costs.

Implementation Method 1

a hot surface igniter assembly removably disposed in the igniter such that a portion of the hot surface igniter assembly protrudes into the fuel-air mixture conduit to ignite the fuel-air mixture when the assembly is energized

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

a plurality of apertures characterized by a first diameter and arranged substantially in a first row in the neck region and disposed proximate to the boundary, a plurality of apertures characterized by a second diameter and arranged substantially in a second row in the throat region

Methodology Applied

Scientific EffectFluid flow through apertures:

Data Source

PatentUS10844293B2Sparkless igniters for heater treaters and methods for using same

Publication Date: 2020.11.24 SUREFIRE PILOTLESS BURNER SYST LLC

AI summary

Sparkless igniters comprising a hot surface igniter assembly and a nozzle that produce a flame plume with diameter substantially similar to the diameter of the fire tube, and flame length less than the length of each leg of the U-shaped fire tube in heater treaters are applicable to both vertical and horizontal heater treaters and improve the durability of fire tubes while reducing igniter fuel consumption by at least 30%.