Twin-Fluid Burner Atomizer with Composite Cooling Jacket
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Solution Overview
Problem
Existing burners are not suitable for high-temperature and high-pressure applications due to lack of cooling and are prone to heat damage, especially during shutdown when flames can retract into orifices, posing safety risks.
Innovation Solution
A burner design with coaxial channels for separate liquid fuel and oxygen supply, featuring a twin-fluid atomizer head with a cooling jacket made of lower thermal conductivity metal and an atomizer head of higher thermal conductivity metal, maintaining a distance between orifices and the cooling jacket to prevent heat damage, and using a copper alloy for enhanced cooling and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling jacket is added to protect the burner from heat, then the burner can withstand high temperature loads, but the device complexity increases
Solution Approach 1:
The cooling jacket is nested coaxially around the tubular supply channel walls, with the atomizer head positioned at a distance from the cooling jacket. This nested arrangement allows the cooling system to be integrated within the existing burner structure without requiring separate external cooling components, thus protecting against heat while minimizing additional structural complexity.
2Volume of moving object
If the orifices are placed close to the cooling jacket for compact design, then the device size is reduced, but heat damage risk increases
Solution Approach 1:
The cooling jacket acts as an intermediary protective barrier positioned between the high-temperature combustion zone and the orifices. By maintaining a specific distance between the orifices and the cooling jacket, the system allows the cooling jacket to absorb and dissipate heat, protecting the orifices from direct heat exposure while enabling a compact overall design.
3Loss of energy
If a single high thermal conductivity metal is used for the atomizer head, then heat dissipation is improved, but mechanical strength under high temperature decreases
Solution Approach 1:
The burner employs a composite construction with the atomizer head made of a first metal and the cooling jacket made of a second metal with lower thermal conductivity. This composite material approach allows optimization of each component: the atomizer head uses high thermal conductivity metal for heat dissipation, while the cooling jacket uses a metal that provides both cooling and mechanical strength under high temperature conditions.
4Productivity
If the burner operates at high pressure for efficient combustion, then productivity increases, but the risk of flame blowout and instability increases
Solution Approach 1:
The twin-fluid atomizer head utilizes the high-velocity oxygen-containing gas flow to automatically atomize the liquid fuel into fine droplets. This self-atomizing mechanism ensures consistent fuel vaporization and mixing under high pressure conditions, maintaining stable combustion and preventing flame blowout while preserving combustion efficiency.
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 design effectively reduces the risk of heat damage and maintains a stable flame at high pressures, ensuring burner integrity and safety during operation and shutdown, with optimized heat dissipation and mechanical strength.
Implementation Method 1
a cooling jacket is coaxially disposed to envelope the tubular supply channel walls
Implementation Method 2
the cooling jacket is made of a second metal with a lower thermal conductivity than the first metal
Implementation Method 3
a twin-fluid atomizer head fixed to the discharge end comprising one or more first flow-through passages in register with the supply channel for oxygen containing gas and second flow-through passages in register with the supply channel for the liquid fuel
Implementation Method 4
the atomizer head is made of a first metal and the cooling jacket is made of a second metal with a lower thermal conductivity than the first metal, wherein copper alloy is used for enhanced cooling and mechanical strength
Data Source
Figure 1A
Figure 1B~1F
Figure 1C
AI summary
Burner (1) comprising channels (2, 3) for the separate supply of a liquid fuel and an oxygen-containing gas. The burner (1) comprises a twin-fluid atomizer head (4) comprising first flow-through passages (37) in register with the supply channel (3) for oxygen- containing gas and second flow-through passages (34) in register with the fuel supply channel (2). The second flow-through passages (34) exit into the first flow- through passage (37) at a point before the first flow- through passage exits into a coaxial ring of orifices (38). A cooling jacket (11) envelopes the supply channel walls (9, 10). The orifices (38) run through the atomizer head (4) at a distance from the cooling jacket (11). The atomizer head (4) can, e.g., be made of a first metal, such as a copper alloy, and the cooling jacket (11) can be made of a second metal with a lower thermal conductivity than the first metal, e.g., steel.