U.S. patent application number 11/294073 was filed with the patent office on 2007-03-01 for fuel burner.
This patent application is currently assigned to General Electric Company. Invention is credited to Glenn Howard Kuenzler, Michael Peter Winnen.
Application Number | 20070048685 11/294073 |
Document ID | / |
Family ID | 37804645 |
Filed Date | 2007-03-01 |
United States Patent
Application |
20070048685 |
Kind Code |
A1 |
Kuenzler; Glenn Howard ; et
al. |
March 1, 2007 |
Fuel burner
Abstract
A fuel burner comprises a body including at least one burner
port. Embodiments of the fuel burner can include a fluid coolant
system, a mixing device adapted to mix a fuel and oxidizer and/or
an apparatus adapted to prevent flashback through the at least one
burner port.
Inventors: |
Kuenzler; Glenn Howard;
(Macedonia, OH) ; Winnen; Michael Peter;
(Lakewood, OH) |
Correspondence
Address: |
GEAM - QUARTZ;IP LEGAL
ONE PLASTICS AVENUE
PITTSFIELD
MA
01201-3697
US
|
Assignee: |
General Electric Company
|
Family ID: |
37804645 |
Appl. No.: |
11/294073 |
Filed: |
December 5, 2005 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60713533 |
Sep 1, 2005 |
|
|
|
Current U.S.
Class: |
431/328 ;
431/160; 431/350; 431/354 |
Current CPC
Class: |
F23D 14/78 20130101;
F23D 14/82 20130101; F23D 2900/00003 20130101; F23D 2213/00
20130101; F23D 2203/102 20130101; F23D 2212/20 20130101 |
Class at
Publication: |
431/328 ;
431/354; 431/160; 431/350 |
International
Class: |
F23D 11/36 20060101
F23D011/36; F23D 14/12 20060101 F23D014/12; F23D 14/46 20060101
F23D014/46; F23D 14/62 20060101 F23D014/62 |
Claims
1. A fuel burner comprising: a body including at least one burner
port, at least a portion of the body is fabricated from a material
having a thermal conductivity greater than about 80 W/mK; and a
fluid coolant system for removing heat from the body, wherein the
fuel burner is capable of producing a flame having a temperature of
at least about 2000.degree. C.
2. The fuel burner of claim 1, wherein the thermal conductivity is
greater than about 100 W/mK.
3. The fuel burner of claim 2, wherein the material comprises
aluminum.
4. The fuel burner of claim 1, wherein the burner is capable of
producing a flame having a laminar flow portion with a length of at
least about 5 centimeters.
5. The fuel burner of claim 1, wherein the burner is adapted to
operate at a power output of greater than about 75 KW.
6. The fuel burner of claim 1, wherein the burner is adapted to
operate with an average flow velocity of a fuel mixture through the
at least one burner port is less than about 40 m/s.
7. The fuel burner of claim 1, wherein the burner includes a burner
face surface including an opening of the at least one burner port,
a peripheral surface circumscribing the burner face surface, and a
chamfer surface extending between at least a portion of the burner
face surface and the peripheral surface.
8. The fuel burner of claim 1, wherein the fluid coolant system
includes a coolant passage positioned less than about 1 centimeter
from a peripheral burner port of the at least one burner port.
9. The fuel burner of claim 1, wherein the fluid coolant system
includes a coolant passage circumscribing a substantial portion of
the at least one burner port.
10. The fuel burner of claim 9, wherein the at least one burner
port comprises a plurality of burner ports.
11. The fuel burner of claim 1, wherein the at least one burner
port comprises a plurality of burner ports.
12. The fuel burner of claim 11, wherein the plurality of burner
ports include at least a first set of burner ports and a second set
of burner ports, and the fluid coolant system includes a coolant
passage extending through a portion of the body that extends
between the first set of burner ports and the second set of burner
ports.
13. A fuel burner comprising: a body including a cavity and at
least one burner port in communication with the cavity; an
apparatus positioned in the cavity and adapted to prevent flashback
through the at least one burner port, wherein a fuel mixture is
adapted to pass through the apparatus, the cavity and the at least
one burner port in use.
14. The burner of claim 13, wherein the apparatus comprises a
member extending across the cavity, the member including a
plurality of passages for the fuel mixture.
15. The burner of claim 14, wherein the member comprises a plate
and the plurality of passages comprises through passages extending
through the plate.
16. A fuel burner comprising: a body including a cavity and at
least one burner port in communication with the cavity; and a
mixing device positioned in the cavity and adapted to mix a fuel
and oxidizer prior to flowing through the at least one burner port,
wherein the mixing device defines a fluid path having a plurality
of angular turns.
17. The fuel burner of claim 16, wherein the mixing device
comprises a flow divider.
18. The fuel burner of claim 17, wherein the flow divider is
adapted to divide an upstream flow into two downstream flows
traveling in substantially opposite directions.
19. The fuel burner of claim 17, wherein the flow divider comprises
at least a first plate and a second plate offset from the first
plate in a direction towards the at least one burner port.
20. The fuel burner of claim 19, wherein the first plate has at
least one aperture.
21. The fuel burner of claim 20, wherein the second plate includes
a plurality of apertures greater in number than the at least one
aperture of the first plate.
22. The fuel burner of claim 21, wherein the plurality of apertures
of the second plate are not axially aligned with any aperture of
the at least one aperture of the first plate.
23. The fuel burner of claim 16, wherein the mixing device further
comprises a plate positioned within the cavity, wherein the plate
includes a peripheral edge that forms a channel with the body.
24. The fuel burner of claim 23, wherein the channel defines a
portion of the fluid path having at least one angular turn of at
least 90 degrees.
25. A fuel burner comprising: a body including a cavity and at
least one burner port in communication with the cavity, at least a
portion of the body fabricated from a material having a thermal
conductivity greater than about 80 W/mK; an apparatus positioned in
the cavity and adapted to prevent flashback through the at least
one burner port; and a fluid coolant system adapted to remove heat
from the body, wherein the fluid coolant system is adapted to
prevent the body from melting in use.
26. The fuel burner of claim 25, further comprising a mixing device
positioned in the cavity and adapted to mix an oxygen-fuel mixture
prior to flowing through the apparatus and the at least one burner
port, wherein the mixing device defines a fluid path having a
plurality of angular turns.
27. A fuel burner comprising: a body including a cavity and a
plurality of burner ports in communication with the cavity, wherein
at least a portion of the body is fabricated from a material having
a thermal conductivity greater than about 80 W/mK; a mixing device
positioned in the cavity and adapted to mix a fuel and oxidizer
prior to flowing through the plurality of burner ports, wherein the
mixing device defines a fluid path having a plurality of angular
turns; and a fluid coolant system for removing heat from the body,
wherein the fuel burner is capable of producing a flame having a
temperature of at least about 2000.degree. C.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority of U.S. Application No.
60/713533, filed on Sep. 1, 2005, which patent application is fully
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates fuel burners, for example,
fuel burners for use during various material processing
procedures.
BACKGROUND OF THE INVENTION
[0003] Conventional burners are frequently used to heat objects for
processing materials. When carrying out the process, the burner
must be effective to apply heat while maintaining sufficient
clearance to avoid contamination of the material and/or burner.
There is a continuing need for functional burner designs that
operate to transfer heat during various material processing
procedures.
SUMMARY OF THE INVENTION
[0004] In accordance with one aspect, a fuel burner comprises a
body including at least one burner port. The body is fabricated
from a material having a thermal conductivity greater than about 80
W/mK. The fuel burner further comprises a fluid coolant system for
removing heat from the body. The fuel burner is capable of
producing a flame having a temperature of at least about
2000.degree. C.
[0005] In accordance with another aspect, a fuel burner comprises a
body including a cavity and at least one burner port in
communication with the cavity. The fuel burner includes an
apparatus positioned in the cavity and adapted to prevent flashback
through the at least one burner port. The fuel mixture is adapted
to pass through the apparatus, the cavity and the at least one
burner port in use.
[0006] In accordance with still another aspect, a fuel burner
comprises a body including a cavity and at least one burner port in
communication with the cavity. The fuel burner further includes a
mixing device positioned in the cavity and adapted to mix a fuel
and oxidizer prior to flowing through the at least one burner port.
The mixing device defines a fluid path having a plurality of
angular turns.
[0007] In accordance with yet another aspect, a fuel burner
comprises a body including a cavity and at least one burner port in
communication with the cavity. The body is fabricated from a
material having a thermal conductivity greater than about 80 W/mK.
The fuel burner further includes an apparatus positioned in the
cavity and adapted to prevent flashback through the at least one
burner port. The fuel burner further comprises a fluid coolant
system adapted to remove heat from the body. The fluid coolant
system is adapted to prevent the body from melting in use.
[0008] In accordance with a further aspect, a fuel burner comprises
a body including a cavity and a plurality of burner ports in
communication with the cavity. The body is fabricated from a
material having a thermal conductivity greater than about 80 W/mK.
The fuel burner further includes a mixing device positioned in the
cavity and adapted to mix a fuel and oxidizer prior to flowing
through the plurality of burner ports. The mixing device defines a
fluid path having a plurality of angular turns. A fluid coolant
system is also provided for removing heat from the body. The fuel
burner is capable of producing a flame having a temperature of at
least about 2000.degree. C.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a fuel burner in accordance
with an exemplary embodiment of the present invention with portions
broken away to depict interior portions of the fuel burner.
[0010] FIG. 2 illustrates an exemplary fluid coolant path for the
burner of FIG. 1.
[0011] FIG. 3 is a top view of the fuel burner of FIG. 1.
[0012] FIG. 4A is a sectional view along line 4A-4A of FIG. 3.
[0013] FIG. 4B is a sectional view along line 4B-4B of FIG. 3.
[0014] FIG. 5 is a sectional view along line 5-5 of FIG. 3.
[0015] FIG. 6 is a sectional view along line 6-6 of FIG. 3.
[0016] FIG. 7 is an exploded view of the fuel burner of FIG. 1.
[0017] FIG. 8 is a perspective view of a fuel burner in accordance
with another exemplary embodiment of the present invention.
[0018] FIG. 9 is an exploded view of the fuel burner of FIG. 8.
[0019] FIG. 10 is a perspective view of a fuel burner in accordance
with another exemplary embodiment of the present invention.
[0020] FIG. 11 is a top view of the fuel burner of FIG. 10.
[0021] FIG. 12 is a sectional view along line 12-12 of FIG. 11.
[0022] FIG. 13 is a sectional view along line 13-13 of FIG. 11.
[0023] FIG. 14 is a sectional view along line 14-1 of FIG. 11.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
[0024] Certain terminology is used herein for convenience only and
is not to be taken as a limitation on the present invention.
Further, in the drawings, the same reference numerals are employed
for designating the same elements. Also as used herein,
approximating language may be applied to modify any quantitative
representation that may vary without resulting in a change in the
basic function to which it is related. Accordingly, a value
modified by a term or terms, such as "about" and "substantially,"
may not to be limited to the precise value specified, in some
cases. In at least some instances, the approximating language may
correspond to the precision of an instrument for measuring the
value.
[0025] FIG. 1 depicts a perspective view of an exemplary fuel
burner 20 in accordance with aspects of the present invention. FIG.
1 further depicts portions of the fuel burner 20 are shown broken
away to depict interior areas of the fuel burner. The fuel burner
includes a body 22 with at least one burner port. Although a single
burner port may be used, the illustrated embodiments depict the at
least one burner port comprising a plurality of burner ports 24.
Although any number of ports may be used, exemplary embodiments
include at least 100 burner ports. Burner ports of each embodiment
of the present invention may comprise various shapes and may be
arranged in various patterns to control the burner flame
characteristics and/or heat loading within the burner body. As
shown in FIG. 1, the body 22 may include a burner face surface 26
including openings of the burner ports 24. A peripheral surface 28
can circumscribe the burner face surface 26 and a chamfer surface
30 can extend between at least a portion of the burner face surface
26 and the peripheral surface 28. As shown, the chamfer surface 30
can extend about the entire periphery of the fuel burner. The
optional chamfer surface 30 may facilitate air movement from a
location behind the burner surface to help release the flame from
the burner face surface 26.
[0026] The body of fuel burners in accordance with the various
embodiments of the present invention can comprise a one-piece
member or may be assembled from a plurality of body portions. As
shown in FIG. 1, for example, the body 22 can include a central
portion 22a, a first end portion 22b and a second end portion
22c.
[0027] In each fuel burner described throughout this application,
portions of the body can comprise a wide variety of materials while
incorporating aspects of the present invention. For example, the
body of exemplary fuel burners may comprise a material having a
thermal conductivity that is greater than about 80 W/mK. The body
of further fuel burners may comprise a material having a thermal
conductivity greater than about 100 W/mK. Still further, the body
of additional fuel burners may comprise a material having a thermal
conductivity greater than about 120 W/mK. Exemplary body portions
of each fuel burner described herein may be formed from a variety
of materials including, but not limited to, one or more of
aluminum, copper, tungstein, iron, gold and/or nickel or the like.
Composites, alloys, coatings and/or other various material
characteristics or types may also be used to provide a body with
satisfactory thermal performance. Further aspects of the invention
may be practiced with a body or a portion of a body having a lower
thermal conductivity. For example, further fuel burners may include
a body or portions of a body formed from a material having a
thermal conductivity that is less than 80 W/mK. In one embodiment,
the fuel burners may include a body or portions of a body having a
thermal conductivity that is less than 80 W/mK, but having a
coating layer comprising a material having a thermal conductivity
that is greater than about 80 W/mK.
[0028] Exemplary fuel burners of each embodiment of the present
invention may include a fluid coolant system to remove heat from
the fuel burner body. The fluid coolant system may allow use of
materials that might otherwise degrade under temperature conditions
that exceed the melting point of the material. Moreover, using
materials with a higher thermal conductivity (e.g., greater than
about 80 W/mK) can more efficiently conduct heat through the body
for removal by the fluid circulating in the fluid coolant system,
if provided.
[0029] Coolant systems may be provided as a separate component of
the fuel burner or may be integrated with the fuel burner body. As
shown in the figures, the coolant system 40 may be integrated with
the fuel burner body 22. The fluid coolant system may also include
various alternative fluid paths through the body 22 of the fuel
burner. FIGS. 1, 2, 4A and 4B depict an exemplary fluid path for a
fluid coolant system in accordance with exemplary embodiments of
the present invention.
[0030] As shown in FIG. 4A, the central portion 22a may be provided
with an inlet socket 42 configured to receive in inlet fitting (not
shown) of the fluid coolant system. The central portion 22a of the
body 22 is also provided with a first lower horizontal bore 44 in
fluid communication with the inlet socket 42. The second end
portion 22c of the body 22 is provided with a first vertical bore
46 in fluid communication with the first lower horizontal bore 44.
The central portion 22a of the body 22 is also provided with a
first upper horizontal bore 48. The first upper horizontal bore 48
is placed in fluid communication with the first vertical bore 46
and a transverse bore 50 formed in the first end portion 22b of the
body 22.
[0031] As shown in FIG. 4B, the central portion 22a can also
include a second upper horizontal bore 52 providing fluid
communication between the transverse bore 50 and a second vertical
bore 54 defined in the second end portion 22c. The central portion
22a can further include a second lower horizontal bore 56 providing
fluid communication between the second vertical bore 54 and an
outlet socket 58. The outlet socket 58 is configured to receive an
outlet fitting (not shown) of the fluid coolant system. Seals, such
as an O-rings 45, can be provided at interfaces between the central
portion 22a and each end portion 22b, 22c to prevent fluid leakage
from the bores formed in the body 22. The first and second vertical
bores 46, 54 may each be provided with a respective plug 47a, 47b
adapted to close the open end of the respective vertical bore.
[0032] With reference to FIG. 2, the fluid coolant system 40 can
include a supply line 41a providing a conduit for fluid to travel
from a fluid reservoir 49 to the inlet socket 42. The fluid coolant
system 40 can further include a return line 41b providing a conduit
for fluid to travel from the outlet socket 58 back to the fluid
reservoir 49. The supply line and/or return line may also comprise
a fluid pump 43 adapted to cause fluid to circulate through the
coolant circuit. For example, as shown in FIGS. 2 and 4A, the pump
43 may cause fluid to circulate along path 42a while entering the
inlet socket 42. Next, the fluid circulates along path 44a while
passing through the first lower horizontal bore 44. The fluid then
circulates vertically along path 46a while passing through the
first vertical bore 46. As shown in FIGS. 2, 4A and 4B, the fluid
then circulates about the burner ports 24 along circulation paths
48a, 50a, 52a while respectively passing through bores 48, 50 and
52. As shown in FIGS. 2 and 4B, the fluid then circulates
vertically along path 54a while passing through the second vertical
bore 54. The fluid then circulates horizontally along path 56a
while passing through the second lower horizontal bore 54 prior to
exiting through the outlet socket 58. The thermally loaded fluid
stream then passes through the return line 41b and dumped into the
fluid reservoir 49. The size of the fluid reservoir 49 may permit
the reservoir to act as a heat sink. Alternatively, a refrigeration
or other cooling arrangement (not shown) may remove heat from the
fluid reservoir 49.
[0033] As shown in FIGS. 1 and 2, the upper paths 48a, 50a, 52a
define a U-shaped coolant passage the circumscribes a substantial
portion of the burner ports 24. It will be appreciated that
substantially circumscribing the burner ports can facilitate heat
removal from the body away from the burner face of the body. The
fluid paths can also be located in close proximity to one or more
burner ports to increase the rate of heat removal from the burner
port area. For example, as shown in FIG. 6, the U-shaped coolant
passage can be positioned a distance "d" from a peripheral burner
port. In exemplary embodiments, the distance "d" can be less than
about 1 centimeter although other distances may be incorporated in
further embodiments of the present invention.
[0034] Forming the fuel burner with a body fabricated from a
material having a thermal conductivity greater than about 80 W/mK
in combination with a fluid coolant system can produce flames
having enhanced flame characteristics without damaging the body of
the fuel burner. For example, such fuel burners can produce a flame
having a temperature of at least about 2000.degree. C. to
sufficiently heat materials during various material processing
procedures. In one embodiment, the flame temperature is at least
2400.degree. C. In a second embodiment, a flame temperature of at
least 2600.degree. C. In a third embodiment, a flame temperature of
at least 2800.degree. C.
[0035] The fuel burners of the invention can also have enhanced
power output. In exemplary embodiments, fuel burners may have a
power output of greater than about 75 KW although fuel burners may
be designed with other power output levels. In one embodiment, the
fuel burners have a controllable power output of greater than 100
KW. In a second embodiment, the fuel burners have a controllable
power output of greater than 120 KW. In a third embodiment, the
fuel burners have a controllable power output of greater than 150
KW. In a fourth embodiment, the fuel burners have a controllable
power output of greater than 500 KW.
[0036] Still further, fuel burners of the present invention can be
designed to produce a flame having a laminar flow portion with a
length of at least about 5 centimeters. Increasing the length of
the laminar flow portion of the flame can provide sufficient
clearance between the material being processed and the fuel burner
while reducing the power loss as the flame propagates toward the
material being processed. Still further, fuel burners of the
present invention can be designed to produce a flame adapted to
operate with an average flow velocity of a fuel mixture through the
at least one burner port of less than about 40 n/s. In this regard,
the average flow velocity is the volume flow rate of the fuel and
oxidizer mixture divided by the area of the burner ports through
which the mixture is flowing. Providing an average flow velocity
that is less than about 40 m/s can reduce turbulent flow that can
otherwise lead to inefficiencies of heat loss to the surrounding
environment.
[0037] To further enhance the flame characteristics, each
embodiment of the invention described and illustrated herein may
include a mixing device adapted to more thoroughly mix a fuel and
an oxidizer prior to flowing through the at least one burner port
of the fuel burner. If provided, the mixing device defines a fluid
path having a plurality of angular turns. Mixing devices in
accordance with the present invention can define a plurality of
angular turns in a wide variety of ways. Providing angular turns in
the fluid path is believed to promote further mixing of the fuel
and oxidizer as the fluid mixture propagates through the fuel
burner. The angular turns may be gradual; however, abrupt angular
turns are believed to provide more thorough mixing of the fuel and
oxidizer. The fluid path direction can change through various
angles to promote mixing of the fluid. For example, the fluid path
may have at least one angular turn of at least 90 degrees. In
further examples, the fluid path can have at least one angular turn
of from about 90 degrees to about 180 degrees. In further examples,
the fluid path may have at least one angular turn of less than 90
degrees.
[0038] The mixing device, if provided, may include various features
adapted to promote mixing of the fuel and oxidizer within the fuel
burner. For example, the mixing device can include one or more flow
dividers. The flow divider, if provided, is adapted to divide an
upstream flow into at least two downstream flows. Although not
required, the two downstream flows can each take an angular turn of
approximately 90 degrees such that the two downstream flows travel
in substantially opposite directions. The divided fuel flow streams
can be subsequently recombined to provide a shuffling effect for
more thorough mixing of the fuel and oxidizer.
[0039] Flow dividers, if provided, can comprise a variety of shapes
and configurations to selectively divide an upstream fluid flow
into at least two downstream fluid flows. For example, the flow
divider can divide the flow as it passes through and/or around the
flow divider. In the illustrated embodiment, the fuel burner 20
includes a first flow divider comprising a first plate 62 and a
second flow divider comprising a second plate 64. The second plate
64 is offset from the first plate 62 in a direction toward the
burner ports 24. The first plate 62 can comprise at least one
aperture to selectively allow fluid communication through the first
plate 62. To facilitate flow division, the second plate 64 can
include a plurality of apertures greater in number than the
aperture(s) of the first plate 62. For example, as shown, the first
plate 62 comprises first and second apertures 62a, 62b while the
second plate 64 comprises four apertures 64a, 64b, 64c, 64d. As
illustrated, the apertures of the second plate 64 are not aligned
with any aperture of the first plate 62 to encourage a desired flow
division between the downstream apertures.
[0040] As shown in FIG. 5, the an upstream flow path 72 enters
through an inlet socket 69. The upstream flow path 72 then divides
into two downstream flow paths 74, 76 traveling in substantially
opposite directions toward respective apertures 62a, 62b in the
first flow divider 62. The fuel and oxidizer mixture flowing along
path 74 is then further divided into two additional downstream flow
paths 78, 80 traveling in substantially opposite directions toward
respective apertures 64a, 64b in the second flow divider 64.
Likewise, the fuel and oxidizer mixture flowing along path 76 is
further divided into two additional downstream flow paths 82, 84
traveling in substantially opposite directions toward respective
apertures 64c, 64d in the second flow divider 64.
[0041] As further shown in FIGS. 5 and 6, the mixing device 60 can
include a third flow divider 66. The third flow divider 66 is
adapted to divide a flow of fuel into two paths that travel about a
peripheral edge of the flow divider. For example, the third flow
divider 66 can comprise a plate having opposed peripheral edges 68
(see FIG. 7). As shown in FIG. 6, each edge 68 is adapted to
cooperate with the body 22 to define a pair of flow channels 70
that permit each of the downstream flows 78, 80, 82, 84 to be
further divided into two additional flow paths 86, 88 that travel
about the periphery of the third flow divider 66.
[0042] Fuel burners in accordance with aspects of the present
invention can also include an optional apparatus 90 positioned
within a cavity 91 of the fuel burner and adapted to prevent
flashback through the at least one burner port 24. Once installed,
the fuel mixture is adapted to pass through the apparatus 90, the
cavity 91 and the at least one burner port 24 in use. In
conventional burners, flashback might result from uneven flow
through the burner ports. A relatively low fuel/oxygen flow through
one burner port may allow the flame to propagate back through the
corresponding burner port. As a result, the fuel and oxidizer
mixture within the cavity may combust. Combustion of the fuel and
oxidizer mixture within the cavity can interfere with the burner
performance and can potentially lead to a dangerous explosion. The
optional apparatus 90 may function to more evenly distribute the
fuel and oxidizer mixture to travel at substantially the same
velocity through each of the plurality of burner ports. With equal
velocity passage through the burner ports, the probability of
flashback through one of the burner ports may be reduced.
[0043] Apparatus adapted to prevent flashback can comprise a wide
range of structures within the cavity of the fuel burner. For
example, the apparatus can comprise a member extending across the
cavity wherein the member includes a plurality of passages to allow
passage of the fuel and oxidizer mixture. The member can comprise a
mesh, fabric or other member adapted to provide a uniform fluid
flow.
[0044] In the illustrated embodiment, the member comprises a plate
92 with a plurality of passages extending through the plate. FIGS.
1 and 7 depict the plate 92 including several exemplary apertures
94. It is understood that the entire plate 92 can include the
aperture pattern illustrated in FIGS. 1 and 7. The apertures can be
substantially evenly distributed along the entire surface area of
the plate to encourage uniform flow through substantially the
entire surface area of the plate. Although the apparatus may also
comprise a single plate, further exemplary apparatus can include
two or more plates that are offset from one another in a direction
toward the burner ports.
[0045] For example, as shown, the apparatus 90 comprises three
plates 92 that are offset from one another in a direction toward
the burner ports 24. The plates 92 are shown as identical however
it is contemplated that the plates may have different aperture
patterns. For example, the density of the apertures may increase
from one plate to the next in a direction toward the burner
ports.
[0046] Assembly of the burner is now described with reference to
FIG. 7. As shown, the first plate 62 and the second plate 64 are
inserted within slots 32 formed along the length of the central
portion 22a of the body 22. The third plate 66 is then inserted
within slots 34 also formed along the length of the central portion
22a. Enlarged ends 66b of the third plate 66 are dimensioned to
substantially match the slots 34 such that the reduced central
portion 66a of the third plate 66 forms the channel 70 as
previously described. The three plates 92 of the apparatus 90 are
then inserted within the slots 36 formed along the length of the
central portion 22a. Threaded inserts 96 are positioned within
bores 98 to facilitate threaded engagement with bolts 99. The lower
seals 45 are positioned within seats 38 defined in the central
portion 22a of the body 22 while upper seals are positioned within
seats 25 defined in the first and second end portions 22b, 22c of
the body 22. The bolts 99 are then inserted through respective
bores 23 defined in the end portions and threaded with a respective
threaded insert 96 to fasten the end portions 22b, 22c with respect
to the central portion 22a.
[0047] FIGS. 8 and 9 depict a fuel burner 120 in accordance with
another exemplary embodiment of the present invention. As shown,
the fuel burner 120 includes a body 122 with at least one burner
port 124. The body can be constructed from the same materials as
the body 22 of the fuel burner 20 discussed above. Moreover, the
fuel burner 120 can cooperate with a fluid coolant system 140 to
provide desirable flame characteristics as also described with
respect to the fuel burner 20 above. The body 122 includes a front
portion 122a and a rear portion 122b. The rear portion 122b is
provided with a supply line 141a and a return line 141b. The front
portion 122a is provided with a peripheral groove 129 that may be
sealed by a shroud 127 to define a circumferential fluid path 146
in communication with the supply line 141a and the return line
141b. As shown, the circumferential fluid path 146 forms a
substantial C-shaped coolant passage that circumscribes a
substantial portion of the at least one burner port 124. The
C-shaped coolant passage can be positioned such that it is
positioned less than about 1 centimeter from a peripheral burner
port of the plurality of burner ports 124.
[0048] The shroud 127 also includes a peripheral surface 128 that
circumscribes a burner face surface 126. A chamfer surface 130 can
extend between at least a portion of the burner face surface 126
and the peripheral surface 128. The chamfer surface 130 can
facilitate air movement from a location behind the burner surface
to help release the flame from the burner face surface 126.
[0049] The rear portion 122b is further provided with a fuel line
132 adapted to provide the burner with a fuel and oxidizer mixture.
The fuel burner 120 may also be provided with a supplemental line
134 defining an internal conduit 135. The internal conduit 135 is
adapted to communicate with a central aperture 125 by way of a
funnel 138. Additives may be introduced through internal conduit
135 to pass through an aperture 139 of the funnel 138 and out the
central aperture 125 in the burner face surface 126. Various
additives may pass through the central aperture 125 to impact flame
characteristics and/or to provide a coating to the material being
processed.
[0050] Examples of additives that can be added to the fuel included
detergents, stabilizers, metal-deactivators, (ashless) dispersants,
anti-oxidants, cold flow improvers, anti-corrosion, biocides,
lubricity enhancers, dehazers, antistatic agents, foam reducers,
etc.
[0051] In order to assemble the fuel burner 120, the supplemental
line 134 is attached to the rear portion 122b of the body 122 such
that the internal conduit 135 is in communication with an interior
area of the funnel 138. Seals 145 are then placed within seats (not
shown) in the back of the front portion 122a and then the rear
portion, together with the supplemental line 134, is positioned
with respect to the front portion 122a of the housing 122. Once
appropriately positioned, bolts 199 are passed through respective
bores 123 in the rear portion 122b and screwed into threaded
inserts (not shown) provided in bores (not shown) in the back of
the front portion 122a. The shroud 127 is then attached with
respect to the front portion 122a of the housing 122. Once
attached, the shroud 127 cooperates with the peripheral groove 129
to define the circumferential fluid path 146. Although not shown,
the fuel burner may comprise an apparatus positioned within a
cavity of the body 122 to prevent flashback through the at least
one burner port 124 such that the fuel mixture is adapted to pass
through the apparatus, the cavity and the at least one burner port
in use. Furthermore, although not shown, the fuel burner may
comprise a mixing device positioned within the cavity and adapted
to mix a fuel and oxidizer prior to flowing through the at least
one burner port 124. The mixing device, if provided, defines a
fluid path having a plurality of angular turns.
[0052] In use, the supply line 141a and the return line 141b may be
placed in communication with a reservoir and a pump in a similar
manner as described with respect to the fluid coolant system 40
discussed above. Once activated, fluid coolant travels along a
fluid supply path 148, about the circumferential fluid path 146,
and then along a fluid return path 150. While activated, the fluid
coolant system can provide a cooling function for the body 122 of
the fuel burner 120 A fuel and oxidizer mixture may also be
provided by way of the fuel line 132. The fuel and oxidizer mixture
passes through a cavity within the housing 122 and then out through
the burner ports 124. Although not shown, the fuel and oxidizer
mixture may pass through a mixing device and/or an apparatus to
prevent flashback located within the cavity prior to exiting
through the at least one burner port 124. Still further, additive
may also pass through the internal conduit 135, the funnel 138 and
the aperture 125 in the burner face surface 126 of the fuel burner
120.
[0053] FIGS. 10-14 depict a fuel burner 220 in accordance with a
further exemplary embodiment of the present invention. As shown,
the fuel burner 220 includes a body 222 with at least one burner
port 224. The body can be constructed from the same materials as
the body 22 of the fuel burner 20 discussed above. Moreover, the
fuel burner 220 can cooperate with a fluid coolant system 240 to
provide desirable flame characteristics as also described with
respect to the fuel burner 20 above.
[0054] The body 222 can include a burner face 226 including
openings of the burner ports 224. A peripheral surface 228 can
circumscribe the burner face surface 226 and a chamfer surface 230
can extend between at least a portion of the burner face surface
226 and the peripheral surface 228. The optional chamfer surface
230 may facilitate air movement from a location behind the burner
face surface to help release the flame from the surface 226.
[0055] The body 222 can comprise a one-piece member or may be
assembled from a plurality of body portions. As shown in FIG. 10,
for example, the body 222 can include a central portion 222a, a
first end portion 222b and a second end portion 222c. As shown, the
first and second end portions 222b, 222c can be attached to the
central portion 222a by way of bolts 229.
[0056] The fuel burner 220 can also comprise a fluid coolant system
240. As shown in FIG. 12, portions of the fluid coolant system
extend through the second end portion 222c of the body 222. For
example, the second end portion 222c can be provided with an inlet
socket 242 in communication with an first inlet bore 244. The
second end portion 222c can further include a second inlet bore 246
in fluid communication with the first inlet bore 244.
[0057] Likewise, portions of the fluid coolant system 240 extend
through the first end portion 222b of the body 222. For example,
with reference to FIG. 14, the first end portion 222b can be
provided with an outlet socket 258 in communication with a first
outlet bore 260. The first end portion 222b can further include a
second outlet bore 262 in fluid communication with the first outlet
bore 260. The second outlet bore 262 and the second inlet bore 246
are substantially parallel with respect to one another and extend
along respective outer peripheral portions of the fuel burner
220.
[0058] As further shown in FIG. 13, portions of the fluid coolant
system 240 can also extend through the central portion 222a. For
example, the central portion 222a can include a first transverse
bore 248a, a second transverse bore 248b, a third transverse bore
248c, and a fourth transverse bore 248d. Each transverse bore is in
fluid communication with the second inlet bore 246 defined in the
second end portion 222c and the second outlet bore 262 defined in
the first end portion 222b. The transverse bores 248a-d are
substantially parallel with respect to one another and offset from
one another to allow the fluid coolant system 240 to circumscribe
sets of burner ports. For example, the first and second transverse
bores 248a, 248b extend substantially parallel with respect to one
another between the second inlet and outlet bores 246, 262 to
circumscribe a first set of burner ports 224a. The second and third
transverse bores 248b, 248c also extend substantially parallel with
respect to one another between the second inlet and outlet bores
246, 262 to circumscribe a second set of burner ports 224b.
Further, the third and fourth transverse bores 248c, 248d extend
substantially parallel with respect to one another between the
second inlet and outlet bores 246, 262 to circumscribe a third set
of burner ports 224c. As shown in FIG. 13, the second transverse
bore 248b extends through a portion 223a of the body that extends
between the first and second sets of burner ports 224a, 224b.
Likewise, the third transverse bore 248c extends through another
portion 223b of the body that extends between the second and third
sets of burner ports 224b, 224c.
[0059] One or more of the second inlet and outlet bores and/or
transverse bores may be positioned less than about 1 centimeter
from a peripheral burner port of one or more of the sets of burner
ports 224a, 224b, 224c. It will be appreciated that the arrangement
of bores can enhance heat transfer from central portions of a bank
of burner ports. Therefore, material within the center portion of
the burner face surface may be sufficiently protected from
excessive temperature conditions that might otherwise occur with a
large, unsegregated bank of burner ports. Although three sets of
burner ports are illustrated, it is understood that one set or any
number of sets of burner ports may be provided depending on the
size of the burner port area.
[0060] In use, the fuel burner 220 may be provided with a supply
line in communication with the inlet socket 242 and a return line
in communication with the outlet socket 258. The supply and return
lines may also be placed in communication with a reservoir and a
pump in a similar manner as described with respect to the fluid
coolant system 40 above. As shown in FIG. 12, fluid coolant can be
pumped through the first inlet bore 244 along a supply fluid path
245. Next, the fluid circulates along path 247 defined by the
second inlet bore 246 towards one of the transverse bores 248a-d.
The fluid then travels through one of the transverse bores 248a-d
and into the second outlet bore 262 (see FIG. 14). Next, the fluid
travels along path 263 defined by the second outlet bore 262
towards the first outlet bore 260. The fluid then travels through
the first outlet bore 260 along fluid path 261. The return line
then carries the heated coolant fluid back to the reservoir as
described with respect to the fluid coolant system 40 above.
[0061] The fuel burner 220 also includes fuel inlet fitting 270
defining a conduit 272 adapted to provide a path for a fuel and
oxidizer mixture. The fuel burner 220 can also be provided with
various mixing devices adapted to promote more thorough mixing of
the fuel and oxidizer within the fuel burner. For example, as shown
in FIG. 13, the fuel burner 220 can comprise a mixing device 280
comprising a flow divider 282 adapted to divide an upstream flow
284 into at least two downstream flows 286a, 286b. In the
illustrated embodiment, the flow divider 282 divides the upstream
flow 284 into four downstream flows radially offset equal distances
from one another. As shown, the downstream flows (e.g., 286a, 286b)
each take an angular turn of approximately 90 degrees with respect
to the upstream flow such that each pair of downstream flows travel
in substantially opposite directions. The angular turn can also be
from about 90 degrees to about 180 degrees. In further examples,
the angular turn may be less than 90 degrees.
[0062] The fuel burner 220 can also be provided with an apparatus
adapted to prevent flashback 290. The apparatus 290 can be
constructed in a similar manner and operates in a similar fashion
as the apparatus 90 described above. As shown, the apparatus 290
can include plates 292 with apertures that can be substantially
identical to the plates 92 described above.
[0063] The fuel burners described above are designed to be supplied
with a fuel and oxidizer mixture. Various fuels may be used for the
present invention to obtain a sufficiently high flame temperature.
For example, the fuel may comprise natural gas, hydrogen, methane,
ethane, propane, butane, or other fuel and combinations thereof.
The oxidizer can a mixture of nitrogen and oxygen (e.g., air), a
mixture of oxygen and another gas, pure oxygen, oxygen enriched
air, or other gases containing sufficient amounts of oxygen as the
oxidizer, or the like. The proportion of fuel to oxidizer may also
vary to provide desirable flame characteristics, from fuel rich to
one that is oxygen rich.
[0064] Various coolant fluids may be incorporated in the fluid
coolant systems discussed above. In one example, the fluid
comprises water or a water-based mixture to change the boiling
point.
[0065] From the above description of the invention, those skilled
in the art will perceive improvements, changes and modifications.
Such improvements, changes and modifications within the skill of
the art are intended to be covered by the appended claims. All
citations referred herein are incorporated by reference.
* * * * *