Wing Vaned Flame Shaper for Heat Exchanger Impingement
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Solution Overview
Problem
Burners in gas furnaces face inefficiencies due to flame impingement on heat exchanger tubes, leading to reduced heat transfer and shorter equipment lifespan, along with increased emissions and noise, which existing flame control methods fail to adequately address.
Innovation Solution
Incorporating a flame shaper downstream of ignition with a plurality of turning vanes that induce a swirl in the ignited flame, promoting improved mixing of fuel and air, reducing turbulence, and optimizing the flame's path to minimize impingement and enhance heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flame control methods are used, then the flame may be stable, but the flame impinges on the heat exchanger tube causing hot spots and reduced efficiency
Solution Approach 1:
The flame shaper divides the flame into multiple streams by passing it through multiple openings in the flame shaper body, which prevents the flame from impinging directly on the heat exchanger tube while maintaining stability
Solution Approach 2:
The patent applies different geometric characteristics to different parts of the flame shaper, including openings of different sizes and shapes, and a streamlined nose portion, to optimize both flame stability and heat transfer efficiency in different regions
2Device complexity
If the flame is directed straight into the heat exchanger, then the structure is simple, but turbulence increases causing noise and reduced mixing
Solution Approach 1:
The flame shaper includes a streamlined nose portion with a curved leading edge that gradually directs the flame into the heat exchanger, reducing turbulence and noise compared to sharp or straight edges
3Manufacturing precision
If the flame shaper opening is small to control the flame, then the flame is better controlled, but the pressure drop increases
Solution Approach 1:
The flame shaper uses multiple openings instead of a single small opening, which maintains precise flame control while reducing the overall pressure drop by distributing the flow through multiple paths
Solution Approach 2:
The streamlined nose portion with curved surfaces reduces flow separation and turbulence, allowing for better flame control with lower pressure drop compared to sharp-edged openings
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 solution results in improved heat transfer, reduced emissions, lower noise levels, and reduced pressure drop, leading to more efficient combustion and extended equipment lifespan by optimizing fuel-air mixing and reducing turbulence.
Implementation Method 1
a plurality of turning vanes, configured to induce a swirl in an ignited flame passing through the flame shaper
Implementation Method 2
Flame shaper embodiments may reduce emissions by improving mixing of fuel and air and thus also produce more efficient combustion. Flame shapers according to this disclosure may reduce noise by producing fuel-air mixing with less turbulence
Data Source
AI summary
This disclosure relates to flame shapers for use in gas burners, gas burner systems, and methods for operating gas burner systems. Flame shaper embodiments include an opening having an unobstructed center, and turning vanes that extend from the perimeter of the opening towards its center. The turning vanes are configured to induce swirling in an ignited flame. Burner systems include an ignition source, the flame shaper, and a heat exchanger. In method embodiments, a flame is formed by igniting fuel and air, the flame is directed through the flame shaper, and the flame is then directed into a heat exchanger.