Surface Stabilized Combustion Burner with Coated Permeable Matrix
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Solution Overview
Problem
Existing combustion technologies for pre-mix gas mixtures on permeable matrices face inefficiencies in heat transfer and pollutant emission reduction, with issues such as insufficient ignition and degradation of ceramic fiber layers, and inadequate heat exchange between combustion products and the matrix surface.
Innovation Solution
A method involving a high thermal conductivity metal matrix coated with a low thermal conductivity ceramic layer, applied via a dense and ductile ceramic coating, which preheats the gas mixture and relocates the combustion zone beneath the matrix surface, enhancing heat exchange and radiation efficiency while reducing pollutant emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick layer of ceramic fibers and polymers is used to prevent corrosion heating of the mesh screen, then corrosion resistance is improved, but the gas mixture is preheated and burnt within the thick layer causing degradation and reduced service life
Solution Approach 1:
The patent uses a porous ceramic layer with controlled porosity (30-70%) that allows combustion to occur within the porous structure rather than degrading the material. The porous structure enables oxygen diffusion and combustion product passage while maintaining structural integrity, preventing the degradation issue of thick non-porous layers
Solution Approach 2:
The patent changes the thermal and physical parameters of the ceramic layer by controlling its thickness (0.5-5mm), porosity (30-70%), and thermal conductivity. These parameter optimizations allow the layer to provide corrosion protection while enabling controlled combustion within the layer structure, preventing material degradation
2Stability of the object's composition
If a sleeve of woven ceramic fibers is used for surface combustion, then combustion stability is improved, but heat transfer between combustion products and the carrier surface is prevented requiring auxiliary triggering devices
Solution Approach 1:
The patent extracts the combustion stabilization function from the ceramic fiber sleeve alone and transfers it to the porous ceramic layer on the metal matrix. This allows the metal carrier surface to remain thermally conductive for ignition while the ceramic layer provides combustion stability, eliminating the need for auxiliary triggering devices
Solution Approach 2:
The porous ceramic layer acts as an intermediary between the metal carrier and the combustion process. It allows heat transfer from the metal carrier to initiate combustion while providing a stable surface for sustained combustion, replacing the need for separate triggering mechanisms
3Reliability
If a thin film of aluminum oxide is developed on the matrix surface, then protection from oxidation and corrosion is improved, but heat exchange between combustion products and the surface is significantly affected
Solution Approach 1:
The patent creates a composite structure with a metal matrix core providing thermal conductivity and a porous ceramic outer layer providing oxidation protection. This composite structure combines the advantages of both materials: the metal core maintains heat exchange efficiency while the porous ceramic layer provides corrosion resistance without significantly blocking heat transfer
4Stability of the object's composition
If the flame is located at some distance from the matrix surface due to high thermal conductivity of the gas mixture exit layer, then combustion stability is improved, but most energy is carried by combustion products rather than transferred to the matrix
Solution Approach 1:
The porous ceramic layer creates a controlled distance between the combustion zone and the metal matrix surface. The porosity allows combustion to occur within the layer while maintaining thermal contact with the matrix, ensuring stable combustion while maximizing energy transfer to the matrix for radiation heat flux
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 increases radiation energy flux and reduces NOx and CO concentrations in combustion products, improving thermal efficiency and extending burner lifespan while maintaining stable combustion across varying conditions.
Implementation Method 1
a high thermal conductivity permeable matrix base material
Implementation Method 2
coated by a layer of low thermal conductivity material having high optical transmittance in the infrared spectrum
Implementation Method 3
increase radiation density... radiation heat flux from the matrix surface can be increased up to 80% of the heat flux providing from 20 to 40% of the total energy released from combustion by infrared radiation
Implementation Method 4
Combustion of the gas mixture near the surface of the permeable matrix
Data Source
AI summary
Methods of burning combustible gas mixtures on a surface of a permeable matrix providing surface stabilized combustion (SSC) with increasing amounts of radiation energy emitted by the surface of the permeable matrix and decreasing concentrations of pollutant components in the combustion products are provided. The gas mixture is fed to a burner that includes a permeable matrix material having a first thermal conductivity. The gas mixture is preheated as it travels through the permeable matrix material. The gas mixture is then combusted at or near exit pores and channels formed at a combustion surface of the permeable matrix material, the combustion surface at least in part coated with a coating material having a thermal conductivity less than the permeable matrix material thermal conductivity and a high optical transmittance in the infrared spectrum.