Staged Premix Furnace Burner Assembly for Low-NOx Combustion
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Solution Overview
Problem
Staged fuel burners in petroleum refining and petrochemical processes face issues with high NOx emissions, overheating, plugging, and complex maintenance, leading to increased production downtime and costs.
Innovation Solution
A burner design featuring a premixer for fuel and air downstream of the fuel source, with a candelabra piece and header system that delivers premixed fuel and air in a staged combustion process, reducing NOx emissions and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If staged fuel burners with multiple tips and manifolds are used to reduce NOx emissions, then NOx emissions are minimized, but the device complexity increases and maintenance requirements increase
Solution Approach 1:
The burner is divided into multiple independent tips, each with its own fuel manifold connection. This segmentation allows each tip to be independently replaced without affecting other tips, simplifying maintenance while maintaining the staged combustion capability for NOx reduction.
Solution Approach 2:
The burner tips are designed as universal components that can be interchanged between different burner assemblies. The standardized tip design with consistent mounting features and fuel port configurations allows a single tip design to serve multiple functions across different burner locations, reducing overall system complexity.
2Object-generated harmful factors
If multiple fuel manifolds and tips are used for staged combustion, then NOx emissions are reduced, but the ease of manufacture decreases
Solution Approach 1:
The burner system is segmented into modular components: individual tips, manifolds, and burners. Each tip can be manufactured separately using standardized processes, and the modular design allows for simplified assembly where components are connected through standardized interfaces, improving ease of manufacture while maintaining staged combustion capability.
Solution Approach 2:
The design uses standardized parameter specifications for tip dimensions, fuel port sizes, and manifold connection interfaces. By establishing consistent parameters across all components, the manufacturing process is simplified through standardization, allowing for easier production while maintaining the multiple-tip staged combustion design for NOx reduction.
3Object-generated harmful factors
If complicated tips with small discharge ports are used, then NOx emissions are minimized, but the reliability decreases due to overheating and plugging
Solution Approach 1:
The tip design incorporates multiple small discharge ports distributed across the tip surface rather than a single large port. This segmentation of the fuel discharge function allows each small port to operate at lower individual flow rates, reducing overheating and clogging risks while collectively achieving the staged combustion pattern needed for NOx reduction.
Solution Approach 2:
The tip design includes preliminary cooling features such as cooling passages or heat sinks integrated into the tip structure. These features pre-cool the tip body before fuel discharge, preventing overheating of the small discharge ports and maintaining reliable operation throughout the staged combustion process.
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 burner produces minimal NOx and CO emissions, maintains a well-defined flame, and reduces maintenance needs, enhancing production efficiency and reducing costs by minimizing downtime.
Implementation Method 1
a pre-mixer (68) having a first end (70), a second end (72), and a wall extending between the first end and the second end, the pre-mixer being in communication with a source (62) of combustion air and fuel from the fuel line
Implementation Method 2
A header delivers premixed fuel and air to a primary stage of combustion through a first plurality of outlets in communication with the pre-mixer
Implementation Method 3
The interior chamber is heated by a plurality of burners which receive a fuel which combusts to produce heat
Data Source
Figure 1
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AI summary
Premixed fuel and air are emitted in a staged fashion from a burner. A header delivers premixed fuel and air to a primary stage of combustion through a first plurality of outlets in communication with the pre-mixer. The same or another header may deliver premixed fuel and air to a secondary stage of combustion through a second plurality of outlets. A tile wall is located on the tile between the first plurality of outlets and the second plurality of outlets. A candelabra piece made of metal may comprise the pre-mixer and the header. In assembly, the candelabra piece may be inserted into the burner tile.