U.S. patent number 3,741,166 [Application Number 05/225,259] was granted by the patent office on 1973-06-26 for blue flame retention gun burners and heat exchanger systems.
Invention is credited to Frank W. Bailey.
United States Patent |
3,741,166 |
Bailey |
June 26, 1973 |
BLUE FLAME RETENTION GUN BURNERS AND HEAT EXCHANGER SYSTEMS
Abstract
Blue flame retention gun burners and heat exchanger process and
apparatus for burning liquid hydrocarbon fuel to produce a stable
blue flame with low nitric oxide and low particulate (Bachrach)
emissions. A major portion of the combustion air is passed in a
vigorous jet action directed through a vitiation zone positioned
upstream from a fuel injection region leading into a combustion
chamber. The vigorous jet action creates a reduced pressure in
entering the vitiation zone causing a portion of the gaseous
products of combustion from the combustion chamber to be
recirculated into this zone in which the combustion air is vitiated
and chemically altered before encountering the fuel spray. During
recirculation the combustion products therein undergo useful heat
exchange so that they are cooled below 800.degree.F. before
entering the vitiation zone. A minor portion of the combustion air
is utilized to cool the fuel nozzle and then enters the fuel
injection region as a plurality of diverging jets aimed toward the
combustion chamber. An efficient stable blue flame is produced with
relatively low excess oxygen and involving diffuse combustion
without allowing localized hot zones which would cause augmented NO
formation and without ignition or starting transient instabilities.
Many conventional air and oil handling components may be directly
utilized in the practice of this invention, such as fuel pumps,
blowers, motors, and fuel atomizing nozzles.
Inventors: |
Bailey; Frank W. (East Orange,
NJ) |
Family
ID: |
22844192 |
Appl.
No.: |
05/225,259 |
Filed: |
February 10, 1972 |
Current U.S.
Class: |
122/23; 431/116;
431/9; 431/156 |
Current CPC
Class: |
F23C
9/006 (20130101); F23C 9/00 (20130101) |
Current International
Class: |
F23C
9/00 (20060101); F22b 031/00 () |
Field of
Search: |
;122/4,23,149
;431/9,116,156 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Sprague; Kenneth W.
Claims
I claim:
1. The process of burning liquid hydrocarbon fuel to produce a
stable blue flame with low nitric oxide and low particulate
emission level comprising the steps of
a. spraying fine droplets of liquid fuel into a fuel injection
region in a direction toward a combustion chamber positioned
downstream from said fuel injection region,
b. pressurizing air to provide a source of combustion air,
c. dividing the pressurized combustion air into a minor proportion
and a major proportion,
d. feeding the minor proportion of the combustion air into the fuel
injection region near said spraying of the fuel,
e. igniting the spray of fuel to produce combustion,
f. feeding the major proportion of the combustion air through a
plurality of spaced orifices providing multiple jets of air
directed into an air vitiation and chemical alteration zone
positioned upstream from said fuel injection region with said jets
of air being directed through said zone toward said fuel injection
region,
g. arranging said multiple jets of air to create a region of
reduced pressure near said multiple orifices relative to the
pressure within said combustion chamber, said region of reduced
pressure being located at the entrance to the air vitiation and
chemical alteration zone,
h. flowing a portion of the gaseous products of combustion being
generated in said combustion chamber through a recirculation path
extending in heat exchange relationship with a heat exchanger being
cooled by fluid for cooling the recirculant gaseous products to a
temperature below 800.degree.F.,
i. introducing the cooled recirculant gaseous products into said
region of reduced pressure,
j. mixing said cooled recirculant gaseous products with said
multiple jets of air in said air vitiation and chemical alteration
zone as the major proportion of the combustion air is passing
through said zone, and
k. introducing the vitiated air into said fuel injection region for
mixing the vitiated and chemically altered air with said fuel spray
and with the minor proportion of combustion air in said region for
preparation and mixing of the fuel spray with the vitiated air,
whereby the prepared mixture of fuel spray and vitiated air passes
from said region into said combustion chamber to burn therein with
a stable blue flame providing a low nitric oxide and low
particulate emission level.
2. The process of burning liquid hydrocarbon fuel to produce a
stable blue flame with low nitric oxide and low particulate
emission level as claimed in claim 1, in which:
said minor proportion of the combustion air is fed into the fuel
injection region as a plurality of air jets directed outwardly for
enhancing radial diffusion of the fuel spray.
3. The process of burning liquid hydrocarbon fuel to produce a
stable blue flame with low nitric oxide and low particulate
emission level as claimed in claim 2, in which:
there is provided an abrupt increase in cross sectional area of the
flow path in passing from the fuel injection region into the
combustion chamber creating a back eddying vortex of generally
annular configuration in the combustion chamber downstream from the
fuel injection region, and
said plurality of air jets fed into the fuel injection region are
directed outwardly and aimed generally toward said back eddying
vortex to provide a slight oxygen enrichment associated with said
back eddying vortex for producing a stable blue flame retention
action.
4. The process of burning liquid hydrocarbon fuel to produce a
stable blue flame with low nitric oxide and low particulate
emission level as claimed in claim 2, in which:
the fine droplets of liquid fuel are sprayed in a pattern diverging
downstream in a direction toward the combustion chamber,
said plurality of air jets fed into the fuel injection region are
spaced around said diverging pattern of fuel spray and are aimed
outwardly in a configuration diverging downstream, and
igniting said spray of fuel at a point intermediate said diverging
pattern of fuel spray and said diverging configuration of air
jets,
whereby said diverging configruation of air jets pull a mist of
fine fuel droplets from the spray pattern into the vicinity of said
igniting point to aid in establishing prompt ignition of the
fuel.
5. The process of burning liquid hydrocarbon fuel to produce a
stable blue flame with low nitric oxide and low particulate
emission level as claimed in claim 1, in which:
said air vitiation and chemical alteration zone has an annular
configuration,
feeding said major proportion of the combustion air as multiple
jets spaced in a generally circular configuration directed into
said annular zone,
feeding said minor proportion of the combustion air axially through
said annular zone, and
then feeding said minor proportion of the combustion air into the
fuel injection region as a plurality of jets positioned about the
fuel spray.
6. The process of burning liquid hydrocarbon fuel to produce a
stable blue flame with low nitric oxide and low particulate
emission level as claimed in claim 5, including the steps of:
dividing the annular air vitiation and chemical alteration zone
into a plurality of sectors, and
feeding said major proportion of the combustion air as multiple
jets and aiming each of said jets generally along the centerline of
a respective one of said sectors.
7. The process of burning liquid hydrocarbon fuel to produce a
stable blue flame with low nitric oxide and low particulate
emission level as claimed in claim 1, including the steps of:
flowing said portion of the gaseous products of combustion through
a recirculation path starting from a position near said back
eddying vortex and ending near said region of reduced pressure,
said recirculation path including a portion extending inwardly from
a larger diameter and then a cylindrical portion extending back
toward said region of reduced pressure, and
cooling the recirculant gaseous products by passing them in heat
exchange relationship in said inwardly extending portion.
8. The process of burning liquid hydrocarbon fuel to produce a
stable blue flame with low nitric oxide and low particulate level
as claimed in claim 1, in which:
said minor proportion and major proportion of the pressurized
combustion air constitute substantially all of the air which enters
the combustion chamber,
whereby substantially all of the combustion air enters the fuel
injection region.
9. The process of burning liquid hydrocarbon fuel to produce a
stable blue flame with low nitric oxide and low particulate
emission level as claimed in claim 1, including the step of:
preferably providing a fuel injection region having a cylindrical
configuration in which its diameter is greater than its length
L.
10. The process of burning liquid hydrocarbon fuel to produce a
stable blue flame with low nitric oxide and low particulate
emission level comprising the steps of
a. spraying fine droplets of liquid fuel into a fuel injection
region in a direction toward a combustion chamber positioned
downstream from said fuel injection region,
b. pressurizing air in an unthrottled manner to provide a source of
combustion air of full pressure,
c. dividing the pressurized combustion air into a minor proportion
and a major proportion,
d. feeding the minor proportion of the combustion air into the fuel
injection region near said spraying of the fuel,
e. igniting the spray of fuel to produce combustion,
f. applying the full pressure of a major proportion of the
pressurized combustion air to a plurality of spaced orifices
providing vigorous multiple jets of air directed into an air
vitiation and chemical alteration zone positioned upstream from
said fuel injection region with said jets of air being directed
through said zone toward said fuel injection region,
g. arranging said multiple jets of air to create a region of
reduced pressure near said multiple orifices relative to the
pressure within said combustion chamber, said region of reduced
pressure being located at the entrance to the air vitiation and
chemical alteration zone,
h. flowing a portion of the gaseous products of combustion being
generated in said combustion chamber through a recirculation path
extending in heat exchange relationship with a heat exchanger being
cooled by fluid for cooling the recirculant gaseous products to a
temperature below 800.degree.F.,
i. introducing the cooled recirculant gaseous products into said
region of reduced pressure,
j. mixing said cooled recirculant gaseous products with said
multiple jets of air in said air vitiation and chemical alteration
zone as the major proportion of the combustion air is passing
through said zone, and
k. introducing the vitiated air into said fuel injection region for
mixing the vitiated and chemically altered air with said fuel spray
and with the minor proportion of combustion air in said region for
preparation and mixing of the fuel spray with the vitiated air,
whereby the prepared mixture of fuel spray and vitiated air passes
from said region into said combustion chamber to burn therein with
a stable blue flame providing a low nitric oxide and low
particulate emission level.
11. The process of burning liquid hydrocarbon fuel to produce a
stable blue flame with low nitric oxide and low particulate
emission level as claimed in claim 10, including the step of:
throttling the flow of the major proportion of the combustion air
at said plurality of spaced orifices for regulating the burning
process.
12. A blue flame retention burner for burning liquid hydrocarbon
fuel to produce a stable blue flame with low nitric oxide and low
particulate emission level comprising
a burner housing having air chamber means,
blower means associated with said housing providing combustion air
under pressure in said chamber means,
baffle means having orifice means communicating with said chamber
means for providing a first flow of air jetting forwardly in front
of said baffle means,
an air tube communicating with said chamber means such that
combustion air under pressure can pass from said chamber means into
said air tube, said air tube extending out in front of said baffle
means,
said orifice means being spaced about said air tube for providing
said first flow of air jetting forwardly around said air tube,
a fuel line extending forward within said air tube to a fuel spray
nozzle for feeding liquid hydrocarbon fuel to said nozzle,
said fuel spray nozzle being located at the forward end of said air
tube for spraying a pattern of fuel spray forwardly beyond the end
of said air tube,
said air tube having a ring portion at its forward end surrounding
said fuel spray nozzle,
said ring portion having opening means therein spaced about said
fuel nozzle for forming the combustion air passing through said air
tube into a second flow of air jetting about said fuel spray
pattern,
said orifice means and said openings being sized such that said
first air flow comprises a major proportion of the combustion air
and said second air flow comprises a minor proportion of the
combustion air, and
ignition means for igniting the fuel in said spray pattern,
whereby:
a. when said air tube and nozzle are inserted into a large sleeve
having a forward end directed into a combustion chamber of abruptly
larger cross sectional area than said sleeve and said combustion
chamber is associated with a fluid cooled heat exchanger, and
b. when said orifice means are positioned to direct said first flow
of air jetting forwardly into the annular space within said sleeve
surrounding said air tube, and
c. when means are provided defining a recirculation path for
gaseous products of combustion extending from said combustion
chamber back to the end of said sleeve near said orifice means,
and
d. when said recirculation path passes in heat exchange
relationship with respect to said heat exchanger so as to cool the
recirculated gaseous products of combustion to a temperature below
800.degree.F. before they reach the end of said sleeve near said
orifice means,
then a stable blue flame is produced in said combustion chamber
downstream from said sleeve with low nitric oxide and low
particulate emission level.
13. A blue flame retention burner for burning liquid hydrocarbon
fuel to produce a stable blue flame with low nitric oxide and low
particulate emission level as claimed in claim 12 in which:
said opening means in said ring portion at the forward end of said
air tube are arranged to direct said second flow of air as a
plurality of air jets aimed outwardly around said fuel spray
pattern.
14. A blue flame retention burner for burning liquid hydrocarbon
fuel to produce a stable blue flame with low nitric oxide and low
particulate emission level as claimed in claim 13, in which:
said openings direct said plurality of air jets outwardly around
said fuel spray pattern to diverge at an included angle from
30.degree. to 60.degree..
15. A blue flame retention burner for burning liquid hydrocarbon
fuel to produce a stable blue flame with low nitric oxide and low
particulate emission level as claimed in claim 12 in which:
said housing means has untrhrottled openings associated with said
blower means for allowing unobstructed entry of air to said blower
means to provide full blower output pressure in said chamber
means.
16. A blue flame retention burner for burning liquid hydrocarbon
fuel to produce a stable blue flame with low nitric oxide and low
particulate emission level, as claimed in claim 12 in which:
said orifice means include a plurality of orifices in said baffle
means,
adjustable air metering means associated with said orifices for
metering the first flow of combustion air jetting forwardly in
front of said baffle means,
and adjustment means for adjusting said metering means relative to
said orifices.
17. A blue flame retention burner for burning liquid hydrocarbon
fuel to produce a stable blue flame with low nitric oxide and low
particulate emission level, as claimed in claim 16, in which:
said adjustable air metering means are rotatably adjustable,
and
said adjustment means serve to turn said adjustable air metering
means relative to said baffle means.
18. A blue flame retention burner for burning liquid hydrocarbon
fuel to produce a blue flame with low nitric oxide and low
particulate emission level, as claimed in claim 16, in which:
said adjustable air metering means are longitudinally adjustable
relative to said baffle means, and
said adjustment means serve to move said adjustable air metering
means longitudinally.
19. A blue flame retention burner for burning liquid hydrocarbon
fuel to produce a stable blue flame with low nitric oxide and low
particulate emission level as claimed in claim 12 in which:
said baffle means include a fixed baffle having a plurality of
orifices therein forming first air jets,
a rotatable metering baffle member positioned adjacent to said
fixed baffle having a plurality of companion orifices spaced to
align with the orifices in the fixed baffle, and
control means for turning said rotatable baffle member relative to
said fixed baffle member for metering the combustion air passing
through said orifices to said first air jets.
20. A blue flame retention burner for burning liquid hydrocarbon
fuel to produce a stable blue flame with low nitric oxide and low
particulate emission level as claimed in claim 19, in which:
said control means include a control arm for turning said rotatable
metering baffle member, and
an adjusting element extending through said housing for moving said
control arm.
21. A blue flame retention burner for burning liquid hydrocarbon
fuel to produce a stable blue flame with low nitric oxide and low
particulate emission level as claimed in claim 19, in which:
said fixed baffle has a central opening,
said air tube extends forwardly through said central opening and is
rotatable in said central opening,
said rotatable metering baffle member is secured to said air tube
and is positioned behind said fixed baffle, and
spring means removabley urge said rotatable baffle member forward
against said fixed baffle member.
22. A blue flame retention burner for burning liquid hydrocarbon
fuel to produce a stable blue flame with low nitric oxide and low
particulate emission level as claimed in claim 21, in which:
said ignition means include an electrode support associated with
said air tube, said electrode support being positioned behind said
rotatable baffle member with electrode means mounted on said
electrode support and extending forward through said rotatable
baffle member and through said fixed baffle to a position near said
fuel spray pattern,
said rotatable baffle member and said fixed baffle have openings
therein for accommodating the forward extension of said electrode
means and for accommodating the rotatable adjustment of said
rotatable baffle member, and
said rotatable baffle member, said air tube, said electrode support
and said electrode means are removable together as an assembly from
said housing.
23. A blue flame retention burner for burning liquid hydrocarbon
fuel to produce a stable blue flame with low nitric oxide and low
particulate emission level as claimed in claim 21, in which,
said fuel line is removably held in said housing,
said spring means surrounds said fuel line while urging said
rotatable baffle member forward,
whereby removal of said fuel line from said housing releases the
spring force for enabling removal of said rotatable baffle and said
air tube together with said fuel line and nozzle.
24. A blue flame retention burner for burning liquid hydrocarbon
fuel to produce a stable blue flame with low nitric oxide and low
particulate emission level, as claimed in claim 18, in which:
said adjustable air metering means include a plurality of tapered
valve plugs adapted to extend into respective orifices in said
baffle means,
a support member for supporting said valve plugs in spaced parallel
relationship adapted to be aligned with the respective orifices,
and
said support member being moved by said adjustment means.
25. A blue flame retention burner for burning liquid hydrocarbon
fuel to produce a blue flame with low nitric oxide and low
particulate emission level, as claimed in claim 24, in which:
spring means urge said fuel nozzle forward against said ring
portion of said air tube,
said air tube is connected to said baffle means,
means are provided for retaining said baffle means in position
against the forward thrust of said spring means, and
said fuel line, nozzle, air tube, baffle means, support member and
valve bodies are removable.
26. A blue flame retention burner for burning liquid hydrocarbon
fuel to produce a stable blue flame with low nitric oxide and low
particulate emission level, as claimed in claim 24, in which:
said ignition means include a pair of electrodes mounted on said
support member and extending forward through a pair of said
orifices.
27. A blue flame retention burner adapted to operate with a
combustion chamber associated with a fluid heater including a
fluid-cooled heat exchanger to burn liquid hydrocarbon fuel to
produce a stable blue flame with low nitric oxide and low
particulate emission level, said burner comprising:
a cylindrical sleeve having a rear end which defines a breech and a
front end which defines a mouth, said cylindrical sleeve defining a
fuel injection region adjacent to said mouth,
fuel nozzle means positioned within said sleeve and a fuel line for
feeding liquid fuel to said nozzle means, said nozzle means being
directed to form a fuel spray in said fuel injection region with
said fuel spray travelling forward toward said mouth,
a burner housing having air chamber means,
a blower means associated with said housing providing combustion
air under pressure in said chamber means,
an air tube communicating with said chamber means and extending
through the breech of said cylindrical sleeve into said sleeve for
conducting air from said chamber means to the vicinity of said fuel
nozzle means for cooling said nozzle means,
said cylindrical sleeve being larger diameter than said air tube
defining an annular zone within said sleeve and surrounding said
air tube and communicating with said fuel injection region,
orifice means positioned near to the breech of said cylindrical
sleeve communicating with said chamber means and providing a
jetting flow of combustion air directed into and through said
annular zone toward said fuel injection region, and
ignition means for igniting said fuel spray,
said burner being adapted to operate with said mouth of said
cylindrical sleeve being directed into a combustion chamber having
a larger cross sectional area than said mouth associated with a
fluid heater including a fluid-cooled heat exchanger and with means
defining a recirculation path for conducting a portion of the
gaseous products of combustion formed in said combustion chamber
back to the breech of said cylindrical sleeve with said
recirculation path passing in heat exchange relationship with said
fluid-cooled heat exchanger for cooling the recirculated gases
before they reach the breech of said cylindrical sleeve,
whereby a stable blue flame is produceable in said combustion
chamber downstream from said mouth of said cylindrical sleeve, such
blue flame having low nitric oxide and low particulate emission
level.
28. A blue flame retention burner adapted to operate with a
combustion chamber associated with a fluid heater including a
fluid-cooled heat exchanger to burn liquid hydrocarbon fuel to
produce a stable blue flame with low nitric oxide and low
particulate emission level, as claimed in claim 27, in which:
said air tube has a forward portion surrounding said fuel nozzle
means with opening means in said forward portion for discharging
the combustion air which has cooled said nozzle means as jetting
air issuing from said air tube into said fuel injection region
about said fuel spray, and
said opening means and said orifice means are sized for discharging
a minor proportion of the combustion air as said jetting air
issuing into said fuel injection region.
29. A blue flame retention burner adapted to operate with a
combustion chamber associated with a fluid heater including a
fluid-cooled heat exchanger to burn liquid hydrocarbon fuel to
produce a stable blue flame with low nitric oxide and low
particulate emission level, as claimed in claim 27, in which:
the breech of said cylindrical sleeve is flared out.
30. A blue flame retention burner adapted to operate with a
combustion chamber associated with a fluid heater including a
fluid-cooled heat exchanger to burn liquid hydrocarbon fuel to
produce a stable blue flame with low nitric oxide and low
particulate emission level, as claimed in claim 27, in which:
said cylindrical sleeve has a relatively large diameter and a short
over-all length with a length to diameter ratio no more than 2 to
1.
31. A blue flame retention burner adapted to operate with a
combustion chamber associated with a fluid heater including a
fluid-cooled heat exchanger to burn liquid hydrocarbon fuel to
produce a stable blue flame with low nitric oxide and low
particulate emission level as claimed in claim 27, in which:
adjustable air metering means are associated with said orifice
means for adjustably throttling the flow of combustion air through
said orifice means, and
control means are provided for adjusting said air metering
means.
32. A blue flame retention burner adapted to operate with a
combustion chamber associated with a fluid heater including a
fluid-cooled heat exchanger to burn liquid hydrocarbon fuel to
produce a stable blue flame with low nitric oxide and low
particulate emission level as claimed in claim 27, in which:
means are provided to divide said annular zone within said
cylindrical sleeve and surrounding said air tube into a plurality
of sectors, and
said orifice means include a plurality of orifices, each of said
orifices being positioned generally in alignment with the
centerline of a respective one of said sectors for directing jets
of combustion air generally along the centerlines of the respective
sectors.
33. A method of converting an existing oil-fired fluid heater
having a fluid-cooled heat exchanger with an insulation-lined
combustion chamber and a burner port extending into the combustion
chamber and with a conventional yellow flame oil burner associated
with said burner port, into: a liquid hydrocarbon fueled fluid
heater capable of operating with a stable blue flame having low
nitric oxide and low particulate emission level comprising the
steps of
removing the conventional burner from said burner port,
removing some of the insulation lining from the combustion chamber
to expose a metal wall of the fluid-cooled heat exchanger in a
region adjacent to the burner port,
inserting a cylindrical sleeve into the burner port and positioning
a deflecting baffle in the combustion chamber extending around the
mouth of said sleeve,
said sleeve and baffle being positioned such that said baffle is
spaced from the exposed metal wall of the fluid-cooled heat
exchanger near said burner port for defining a portion of a
recirculation path communicating with the combustion chamber and
extending inwardly toward said sleeve and such that said sleeve is
spaced within said burner port to define a cylindrical portion of
the recirculation path extending out to the opposite end of said
sleeve from the mouth thereof, and
positioning a blue flame retention burner in cooperative
relationship with said sleeve, said burner including a burner
housing having air chamber means, blower means associated with said
housing providing combustion air under pressure in said chamber
means, baffle means having orifice means communicating with said
chamber means for providing a first flow of air jetting forwardly
in front of said baffle means, an air tube communicating with said
chamber means such that combustion air under pressure can pass from
said chamber means into said air tube, said air tube extending out
in front of said baffle means, said orifice means being spaced
about said air tube for providing said first flow of air jetting
forwardly around said air tube, a fuel line extending forward
within said air tube to a fuel spray nozzle for feeding liquid
hydrocarbon fuel to said nozzle, said fuel spray nozzle being
located at the forward end of said air tube for spraying a pattern
of fuel spray forwardly beyond the end of said air tube, said air
tube having a ring portion at its forward end surrounding said fuel
spray nozzle, said ring portion having opening means therein spaced
about said fuel nozzle for forming the combustion air passing
through said air tube into a second flow of air jetting about said
fuel spray pattern, said orifice means and said opening means being
sized such that said first air flow comprises a major proportion of
the combustion air and said second air flow comprises a minor
proportion of the combustion air, and ignition means for igniting
the fuel in said spray pattern, and
positioning said burner with said air tube and nozzle inserted into
said opposite end of said sleeve with said nozzle and said opening
means being located intermediate said opposite end and said forward
end of said sleeve and said orifice means positioned to direct said
first flow of air jetting forwardly into the annular space within
said sleeve surrounding said air tube,
whereby a stable blue flame is produced in said combustion chamber
downstream from said sleeve with low nitric oxide and low
particulate emission level.
34. The method of converting an oil-fired fluid heater as claimed
in claim 33 including the step of
providing an insulation layer on said deflecting baffle positioned
around the mouth of said sleeve and facing toward the combustion
chamber.
35. A method of converting an existing oil-fired water heater
having a hot water storage tank with a concave bottom surface
defining a head space and an annular heat exchange passage
surrounding the tank and a combustion chamber beneath said head
space and with a burner port extending into the combustion chamber
and with a conventional yellow flame oil burner associated with
said burner port, into: a liquid hydrocarbon fueled water heater
capable of operating with a stable blue flame having low nitric
oxide and low particulate emission level comprising the steps
of
removing the conventional burner from said burner port,
inserting a cylindrical sleeve into the burner port,
surrounding the outer end of said sleeve with a hollow member of
generally annular configuration including an upstanding duct
extending up toward said head space for providing a recirculation
path for gaseous products of combustion after they have come into
heat exchange relationship with said concave bottom surface,
and
positioning a blue flame retention burner in cooperative
relationship with said sleeve, said burner including a burner
housing having air chamber means, blower means associated with said
housing providing combustion air under pressure in said chamber
means, baffle means having orifice means communicating with said
chamber means for providing a first flow of air jetting forwardly
in front of said baffle means, an air tube communicating with said
chamber means such that combustion air under pressure can pass from
said chamber means into said air tube, said air tube extending out
in front of said baffle means, said orifice means being spaced
about said air tube for providing said first flow of air jetting
forwardly around said air tube, a fuel line extending forward
within said air tube to a fuel spray nozzle for feeding liquid
hydrocarbon fuel to said nozzle, said fuel spray nozzle being
located at the forward end of said air tube for spraying a pattern
of fuel spray forwardly beyond the end of said air tube, said air
tube having a ring portion at its forward end surrounding said fuel
spray nozzle, said ring portion having opening means therein spaced
about said fuel nozzle for forming the combustion air passing
through said air tube into a second flow of air jetting about said
fuel spray pattern, said orifice means and said opening means being
sized such that said first air flow comprises a major proportion of
the combustion air and said second air flow comprises a minor
proportion of the combustion air, and ignition means for igniting
the fuel in said spray pattern, and
positioning said burner with said air tube and nozzle inserted into
the outer end of said sleeve with said nozzle and said opening
means being located intermediate said outer end and the end of said
sleeve toward said combustion chamber, with said orifice means
positioned to direct said first flow of air jetting forwardly into
the annular space within said sleeve surrounding said air tube,
whereby a stable blue flame is produced in said combustion chamber
downstream from said sleeve with low nitric oxide and low
particulate emission level.
36. A blue flame retention burner and fluid-cooled heat exchanger
system adapted to burn liquid hydrocarbon fuel to produce a stable
blue flame with low nitric oxide and low particulate emission level
comprising:
a cylindrical sleeve having a rear end which defines a breech and a
front end which defines a mouth, said cylindrical sleeve defining a
fuel injection region adjacent to said mouth, said mouth being
directed into a combustion chamber defined by a fluid-cooled heat
exchanger,
fuel nozzle means positioned within said sleeve and a fuel line for
feeding liquid fuel to said nozzle means, said nozzle means being
directed to form a fuel spray in said fuel injection region with
said fuel spray travelling forward toward said mouth,
a burner housing having air chamber means,
a blower means associated with said housing providing combustion
air under pressure in said chamber means,
in air tube communicating with said chamber means and extending
through the breech of said cylindrical sleeve into said sleeve for
conducting air from said chamber means to the vicinity of said fuel
nozzle means for cooling said nozzle means,
said cylindrical sleeve being larger diameter than said air tube
defining an annular zone within said sleeve and surrounding said
air tube and communicating with said fuel injection region,
orifice means positioned near to the breech of said cylindrical
sleeve communicating with said chamber means and providing a
jetting flow of combustion air directed into and through said
annular zone toward said fuel injection region, and
ignition means for igniting said fuel spray,
said combustion chamber having a larger cross sectional area than
said mouth, and
means defining a recirculation path for conducting a portion of the
gaseous products of combustion formed in said combustion chamber
back to the breech of said cylindrical sleeve with said
recirculation path passing in heat exchange relationship with said
fluid-cooled heat exchanger for cooling the recirculated gases
before they reach the breech of said cylindrical sleeve,
whereby a stable blue flame is produced in said combustion chamber
downstream from said mouth of said cylindrical sleeve, such blue
flame having low nitric oxide and low particulate emission
level.
37. A blue flame retention burner and fluid-cooled heat exchanger
system as claimed in claim 36, in which:
said means defining the recirculation path includes a deflection
baffle extending out about the mouth of said sleeve and positioned
in spaced relationship with a surface of said fluid-cooled heat
exchanger to define a portion of the recirculation path behind said
baffle near said surface and includes support means spacing said
sleeve from the heat exchanger to provide a cylindrical space about
said sleeve defining a second portion of the recirculation path
communicating with the portion thereof behind said baffle.
38. A blue flame retention burner and fluid-cooled heat exchanger
system as claimed in claim 36 in which:
said means defining the recirculation path includes a hollow member
of generally annular configuration surrounding the breech of said
sleeve,
said hollow member having a duct associated therewith extending to
a position near the heat exchanger for recirculating a portion of
the gaseous products of combustion after they have passed in heat
exchange relationship with the heat exchanger.
39. A blue flame retention burner and fluid-cooled heat exchanger
system as claimed in claim 36, in which:
said fluid-cooled heat exchanger includes a first elongated
cylindrical member of thermally resistant insulation defining the
combustion chamber,
said mouth of said sleeve extending through a port in an end wall
of said member with said combustion chamber being of larger cross
sectional area than said mouth,
a second larger elongated cylindrical member of insulation material
positioned around said first member, said first and second members
being radially and axially spaced to define a generally annular
cylindrical passage communicating with the opposite end of said
combustion chamber from the mouth of said sleeve,
a casing, preferably of heat resistant metal, positioned around
said second member, said casing and second member being radially
and axially spaced to define a generally annular space
communicating with said annular passage,
a coil section positioned in said annular space adapted for fluid
flow through said coil section to be heated,
said means defining the recirculation path providing communication
between the breech of said sleeve and a point near said coil
section.
40. A blue flame retention burner and fluid-cooled heat exchanger
system as claimed in claim 39 in which:
said point is located near the juncture of said annular passage and
said annular space, and
said coil section is shaped to extend into said recirculation
path.
41. A sleeve and deflector baffle assembly for use in the burner
port and combustion chamber of a blue flame retention burner and
fluid-cooled heat exchanger system comprising:
a sleeve having smaller diameter than said burner port,
a deflector baffle extending out around one end of said sleeve
a layer of insulation on said deflector baffle on the side thereof
facing away from said sleeve, and
support means for mounting said sleeve concentrically within said
burner port with said deflector baffle spaced away from the wall of
the combustion chamber near the burner port.
Description
BACKGROUND OF THE INVENTION
The present invention relates to a blue-flame retention gun burner
and heat exchanger process and apparatus for burning liquid
hydrocarbon fuel to produce a stable blue flame with low pollutant
emission levels. This invention also enables unusually efficient
heat exchange systems to be achieved.
Process and apparatus embodying the present invention provide
almost all of the features and advantages of the embodiments of the
earlier invention disclosed and claimed in my U.S. Pat. No.
3,545,902, issued Dec. 8, 1970, and entitled "Blue-Flame Gun Burner
Process and Apparatus for Liquid Hydrocarbon Fuel", and in
addition, process and apparatus embodying the present invention
provide numerous other important features and advantages, as will
be explained.
SUMMARY OF THE PRIOR ART
Conventional gun-type burners which have been in use prior to said
earlier invention and prior to the present invention produce yellow
or yellowish-orange flames which are noisy, are characterized by
incomplete combustion, and often deposit soot in the flue or
chimney or discharge particulate matter into the atmosphere. Also,
any cool areas within the firebox tend to quench the yellow flame,
stopping further combustion in localized regions and leading to the
precipitation of unburned carbon on the cooler areas of the heat
exchange surfaces of the firebox. These carbon deposits impede heat
transfer and reduce efficiency.
Such yellow flame prior art burners have localized regions of high
temperature combustion such that they tend to produce undesirably
large amounts of oxides of nitrogen and particulate emissions.
SUMMARY OF FEATURES AND ADVANTAGES OF THE PRESENT INVENTION IN
COMMON WITH THE EARLIER INVENTION
Among the advantages of the process and apparatus of the present
invention in common with my earlier invention are those resulting
from the fact that they enable liquid hydrocarbon fuel, such as
fuel oil, to be burned with a quiet, stable blue flame in which
substantially complete combustion occurs. The firebox and heat
exchange surfaces remain cleaner than with conventional
yellow-flame gun burners, improved heat transfer occurs, and
reduced maintenance and down time are achieved. The blue flame
produced by utilizing this invention to burn fuel oil has
characteristics similar to those which are present in conventional
gas burners. Accordingly, this invention opens up the possibility
of utilizing fuel oil in various installations which have
heretofore been limited to gas burners.
The invention provides a compact, inexpensive burner unit adapted
to be used in a wide variety of new installations as well as being
adapted for use as an improvement replacement unit for existing
yellow-flame gun burner installations.
A listing of the features and advantages of the process and
apparatus embodying the present invention in common with my earlier
invention includes the following:
1. The process and apparatus are versatile for use in many
different applications and environments including many of those
which have heretofore been limited to gas burners.
2. A clean blue flame is produced, contributing to substantially
reduced air pollution.
3. The noise level of the blue flame is lower than that for
yellow-flame combustion. Moreover, the burner starts without a loud
pressure pulse or bang because there is no substantial pressure
build-up during transient starting conditions.
4. The process and apparatus are reliable in operation.
5. The burner unit is easy to service. It is so compact and light
weight that it can quickly and conveniently be replaced by another
burner unit so that the original can be returned to the maintenance
plant, thus providing centralized servicing using interchangeable,
compact burner units.
6. The apparatus and systems shown are simple, reliable and low in
cost.
7. A multi-fuel burning capability is provided by the process and
apparatus. Fuel oil, kerosene or gasoline may be used while
providing substantially the same blue flame characteristics,
thereby being convenient for mobile home applications, garages,
remote locations where fuel availability is limited, etc.
8. The present invention enables fuel oil and other liquid
hydrocarbon fuels to be utilized as efficiently and economically as
the earlier invention.
DISTINCTIONS, FEATURES AND ADVANTAGES OF THE PRESENT INVENTION
RELATIVE TO THE EARLIER INVENTION AND OTHER PRIOR ART
In accordance with the present invention, the following
distinctions, features and advantages are among those which are
provided relative to the earlier invention and other prior art:
1. The cooled recirculated gaseous products of combustion are
thoroughly intermixed with a major portion of the combustion air in
a zone for vitiation and chemical alteration of the air located
upstream from the fuel spray means, so that most of the combustion
air is vitiated and intermixed with chemically altering
constituents before it arrives in the vicinity of the fuel
spray.
2. This zone for vitiation and chemical alteration of the major
portion of the combustion air has a substantially annular
configuration surrounding an axial cylindrical flow path through
which a minor proportion of the combustion air is passed to cool
the fuel spray means.
3. The fuel is injected into a downstream fuel injection region
located downstream from said annular zone for vitiation and
chemical alternation of the combustion air.
4. Only a minor proportion of the combustion air is non-vitiated
and not chemically altered and it is segregated and carefully
controlled by passage along a central air flow path so as to be
introduced near the beginning of the fuel spray pattern. Thus, this
non-vitiated and unaltered air cools the fuel spray means, and it
is injected into the vitiated and chemically altered air in a
manner to assist in retention of the blue flame near the entrance
to combustion chamber. It also aids in establishing ignition
quickly and reliably when the electrodes are energized.
5. All of the combustion air and fuel can be passed through the
downstream fuel injection region. There is no need for introduction
of additional air to provide complete combustion. By virtue of the
fact that all of the combustion air and fuel can be passed through
this region, a wide adjustment range, or tolerance, is achieved so
that the blue-flame combustion continues to occur even though the
burner firing rate is adjusted over a wide range. Moreover, all the
oxidant is efficiently utilized for combustion and for momentum
interchange with recirculated products of combustion. Thus, there
is no need for any substantial amounts of excess air to assure that
complete combustion occurs.
6. By virtue of the vitiation and chemical alteration of the
combustion air, the blue-flame combustion is achieved at a
relatively low flame temperature. As a result of this controlled
flame temperature and the small amount of excess air achieved, the
oxides of nitrogen (NO.sub.x) and particulate pollution emission
levels are very low, as compared with a conventional yellow-flame
gun burner, as shown by the graphs discussed hereinafter.
7. By virtue of the fact that all of the combustion air and fuel
can be passed through the downstream fuel injection region, the
components in the barrel of a burner embodying this invention can
be made readily removable.
8. Impingement of the fuel spray upon the cylindrical member
defining the downstream fuel injection region is avoided. Even
though the spray pattern has a relatively wide conical angle, for
example 60.degree., it does not impinge directly upon this member
and thus avoids the problems which are otherwise encountered when
unburned fuel collects upon cold wall surfaces during the start-up
and warm-up phases of burner operation.
9. The downstream fuel injection region can open directly into the
combustion chamber without passing through a subsequent confining
shell member. This free flow directly into the combustion chamber
reduces the back pressure occurring at the mouth of the fuel
injection region and hence minimizes any tendency for flash back of
flame into this region.
10. The burner can be adjusted conveniently while it is in
operation so that the operator can directly observe the results of
the adjustments as they are being made, thus leading to quick,
convenient and proper (not hit or miss) adjustment in actual
installed usage. The burner firing rate can be accurately matched
to the requirements of the associated heat exchanger.
11. The burner of the present invention can utilize conventional
air and oil handling accessory components which are readily
available, such as fuel pumps, electric motors, blower wheels, and
fuel oil atomizing nozzles.
12. The air metering function is provided downstream from the
blower. The blower intake can remain unimpeded, i.e. unthrottled,
at all times. This arrangement means that the full blower output
pressure is available at all times. This full blower pressure is
applied directly to adjustable air-metering orifices thus
generating vigorous jets of air issuing from the orifices and
directed into the air vitiation and chemical alteration zone. These
multiple vigorous jets create a region of reduced pressure at the
breech of this zone. Thus, there is achieved a vigorous
recirculation of gaseous products of combustion through a low
pressure drop path leading into this zone. As a consequence, the
burner is stable in operation in spite of changes in the flue
pressure, for example, as can occur when a strong puffy wind is
blowing over or across the discharge end of the chimney or flue
pipe.
The various other aspects, objects and advantages of the present
invention will, in part, be pointed out and will, in part, become
apparent from the following description when considered in
conjunction with the accompanying drawings, in which:
FIG. 1 is a side elevational sectional view of a presently
preferred embodiment of the present invention for burning liquid
hydrocarbon fuel. FIG. 1 shows a blue-flame retention gun burner
and an associated heat exchanger system embodying and for
practising the process of the present invention;
FIG. 2 is a cross-sectional view of the burner taken along the line
2--2 of FIG. 1 looking toward the right;
FIG. 3 is a top plan sectional view taken along the line 3--3 in
FIG. 1;
FIG. 4 is an enlargement of portions of FIG. 1 for purposes of more
fully illustrating and explaining the process and apparatus
embodying the present invention;
FIG. 5 is a cross-sectional view of the burner taken along the line
5--5 in FIG. 1 looking toward the left;
FIG. 6 is a perspective view of a fixed member of an adjustable
air-metering baffle arrangement;
FIG. 7 is an exploded perspective view of an adjustable (rotatable)
air-metering baffle member and fuel nozzle support and air flow
tube, together with the electrode support having an arm which
serves for adjusting the rotatable metering member;
FIG. 8 is a side elevational sectional view of a modified liquid
hydrocarbon fuel burner having similarities to that shown in FIG. 1
and associated with a heat exchanger and fluid heater system as
shown in FIG. 1;
FIG. 9 is an enlarged cross sectional view taken along the line
9--9 in FIG. 8;
FIG. 10 is an exploded perspective view of a protion of the burner
of FIG. 8, showing axially an adjustable air-metering assembly and
the fuel nozzle support and air 1 tube, together with the electrode
assembly;
FIG. 11 is a side elevational sectional view of a burner embodying
the invention associated with a different heat exchanger and fluid
heater system from that shown in FIG. 1 or 8;
FIG. 12 is an exploded perspective view of parts of the heat
exchanger system seen in FIG. 11;
FIG. 13 is a side elevational sectional view of a burner embodying
the invention associated with a different heat exchanger and fluid
heater system from that shown in FIG. 1, 8 or 11; and
FIGS. 14 and 15 are copies of graphs which show the results of
evaluation tests comparing an oil burner embodying the present
invention with a conventional yellow flame gun burner of the prior
art to show the reduced pollution and increased possible efficiency
provided by the combustion of liquid hydrocarbon fuel using a
burner embodying the present invention.
As shown in FIG. 1, a blue-flame retention gun burner and heat
exchanger system embodying the present invention include a burner,
generally indicated at 10, having an overall gun shape with the gun
barrel aimed into a heat exchanger 12 associated with a
conventional residential or industrial water heater 14. The water
heater 14 may serve to provide hot water or it may serve as a
boiler to provide steam. This invention may be employed to
advantage regardless of whether hot water or steam is being
produced or whether the heater 14 is a hot air furnace, and it is
to be understood that the term "fluid heater" is intended to
include heaters for heating any one or more of the fluids water,
steam and air, or other heat exchange fluids.
The burner 10 includes a housing assembly 16 which is removably
attached as by bolts to a mounting flange 18 on an adapter section
20 extending out from the water heater. In effect, the adapter
section 20 defines the barrel of the gun-shaped burner. This
adapter section 20 with a mounting flange 18 can be secured into
the conventional circular opening 22 in the fluid heater 14 into
which was previously inserted the muzzle of a conventional
yellow-flame gun burner. Thus, the burner of the present invention
enables convenient conversion to be made in such a water heater
from sooty yellow-flame combustion to blue-flame combustion. The
burner housing assembly 16 can be quickly and conveniently detached
from the mounting 18, so that the working parts of the burner can
be serviced or replaced.
The housing assembly 16 includes a lower housing section 24 on one
side of which is mounted an electric motor 26 (FIG. 2) with a
blower wheel 28 attached to the motor shaft 30 and being located
within the lower housing section 24. On the other side of the lower
housing section 24 from the motor is mounted a fuel delivery unit
32, including a fuel pump which is driven by the motor shaft
30.
It is an advantage of the present invention that a conventional
motor 26, conventional blower wheel 28, and conventional fuel
delivery unit 32 can be employed, if desired. This delivery unit
supplies liquid hydrocarbon fuel, for example such as No. 2 fuel
oil or kerosene, or gasoline, to the burner 1, the liquid fuel
being supplied through a fuel line 34 (FIG. 2). The fuel may be
pumped or gravity fed through the line 34 to the delivery unit
32.
A fuel feed control screw 36 can be adjusted by a screw driver to
control the fuel delivery pressure and hence flow rate through a
flexible metal line 38, such as a soft copper tube, into a rigid
pipe 40 (FIG. 2) extending transversely across the burner housing.
Near the center of the transverse pipe 40 is a Tee connection 42 to
an axial fuel line 44 (FIG. 1) which extends forward to fuel spray
means 46, shown as a conventional high pressure spray nozzle
producing a suitable conical fuel spray pattern, for example having
an included angle of 60.degree., as shown. The fuel delivery unit
32 delivers fuel under high pressure, for example in the range from
80 pounds per square inch (p.s.i.) to 300 p.s.i., and the finely
atomized spray 48 is produce solely by the pressurized fuel issuing
through the nozzle 46.
For conveniently removing the fuel spray nozzle and ignition
electrode assembly, as will be explained in detail further below,
the transverse fuel pipe 40 removably seats in notches 49 (FIG. 1)
in the upper edges of the upper section of the housing assembly 16,
and a detachable coupling 39 (FIG. 3) may be included between the
lines 38 and 40.
The housing assembly 16 includes an upper housing section 50 which
is detachably secured to the lower housing section 24 by means of a
skirt which overlaps the upper edge of the lower housing section,
as shown. An ignition tranaformer 52 is mounted upon a lid 54 which
is hinged at 56 to the upper housing section. For securing the
burner to the mounting 18, there is a similar mounting flange 58 on
the projecting front portion of the upper housing section 50.
As can be seen in FIG. 2, the upper housing section 50 has a
generally rectangular cross section and forms a conduit for
pressurized air generated by the blower wheel 28. Air is admitted
to the interior of the centrifugal blower wheel 28 through
unobstructed (unthrottled) air intake means 60 in the side of the
lower housing 24 near the fuel delivery unit 32. The blower wheel
is partially encompassed by a generally spiral-shaped scroll 62
located within the lower housing and arranged to discharge the
pressurized air through the blower outlet 64 into the upper housing
50.
By virtue of the fact that the blower inlet ports are unthrottled,
the full output pressure from the blower 28 is available at all
times during normal operation in a plenum chamber 66 defined by the
upper housing. There may be a gasket not shown, at the joint
between the lid 54 and the upper housing 50 and also a gasket, not
shown, at the joint between the lower and upper housing sections 24
and 50. These gaskets prevent loss of air pressure from the plenum
chamber 66.
In order to meter the feeding of combustion air from the plenum
chamber 66, there is a fixed baffle 68 (FIG. 1; please see also
FIG. 7) having a generally cup-shape and nesting within the outer
end of the tubular adapter section 20 near the mounting flange 18.
In the end wall 70 of this fixed metering baffle 68 there are a
plurality of orifices 72 arranged in an arc concentric about a
larger central opening 74. An arcuate clearance slot 76 also
extends part way about the central opening. The cylindrical side
wall 78 of the fixed baffle 68 has a diameter to fit snuggly within
the tube section 20. A flange 80 on this metering baffle is sized
to match with the mounting flange 18, as seen in FIG. 1. In the
preferred embodiment, as shown, this fixed baffle member is stamped
from sheet metal with the respective openings 72, 74 and 76 being
punched out during the stamping operation. As can be seen from FIG.
1, the interior, i.e. upstream side, of the baffle 68 communicates
with and forms an extension of the plenum chamber 66 such that
pressurized air fills the interior of the baffle 68.
Associated with this fixed baffle 68 is an adjustable (rotatable)
baffle member 82 which is securely mounted upon a support tube 84
(see also FIG. 7) to project radially therefrom near the mid-point
of the support tube 84. There are a plurality of orifices 86 in the
adjustable baffle which are spaced to align with the companion
orifices 72 in the fixed baffle member. The support tube 84 extends
forward through the central opening 74 (see also FIG. 4) in the
fixed baffle such that the support tube is concentric about the
axis of the tubular adapter section 20.
As shown in FIG. 4, at the forward end of the support tube 84,
there is secured an inwardly extending ring 88 with a sleeve 90
fastened to the ring such that the sleeve 90 is concentric within
the support tube 84. This sleeve 90 is sized to fit snuggly about
the fuel nozzle (but loose enough to permit the nozzle to slide
within the sleeve) and thus serves to support the nozzle 46 and its
fuel line 44 concentrically with respect to, i.e. axially within,
the main mounting tube 20.
In order to press the rotatable baffle 82 firmly against the end
wall 70 of the fixed baffle and to hold the support tube 84 in
place, there is a compression spring 92 which is positioned about
the rear portion of the nozzle fuel line 44. The back end of this
spring seats against a spring retention boss 94 (see also FIG. 3)
mounted upon the nozzle fuel line 44 near the Tee connection 42.
Because the transverse pipe 40 is seated down in the notches 49,
the Tee connection, the nozzle fuel line 44, and retention boss 94
are held in place and cannot be moved in an axial direction with
respect to the fixed baffle. The front end of the spring 92 presses
forward against a seat 95 (FIG. 4) on an electrode support member
96 (FIG. 7) which has a socket 97 (FIG. 4) embracing the back end
of the support tube 84. The electrode support 96 is keyed at 93 to
the tube 84 for reasons as will be explained later. This electrode
mounting member 96 is preferably formed as a die cast metal unit,
for example, of aluminum. This member 96 serves to apply the
forward acting spring force to the support tube 84 and hence
presses the rotatable baffle 82 forward against the fixed baffle
68. A hole 98 (FIGS. 4 and 7) in the electrode support member
receives the nozzle fuel line 44 in a sliding fit and serves to
hold this line concentric within the support tube 84.
From the foregoing description, it will be appreciated that the
fuel nozzle 46 is supported by the sleeve 90 in the front end of
the support tube 84, and the nozzle fuel line 44 is supported by
the cross pipe 40 seating in the notches 49. Moreover, the movable
baffle 82 is spring-biased against the fixed baffle 68. Thus, this
advantageous arrangement avoids any requirement for precise fitting
or positioning of the nozzle 46, nozzle fuel line 44, support tube
84, movable baffle 82, and electrode support member 96. For
example, if either the support tube or nozzle fuel line happen to
be slightly too long or too short relative to each other, or
relative to the distance between the notches 49 and the end wall 70
of the fixed baffle, such tolerance variations are accommodated by
the spring 92 and by the nozzle sliding slightly forward or
backward within its support sleeve 90 and by the nozzle fuel line
44 sliding within the hole 98. Consequently, none of these
dimensions is critical and mass production techniques can be used
to fabricate these various components.
Moreover, any relative changes in dimensions due to differential
thermal expansions of the various components are readily
accommodated by these structural arrangements, as described
above.
In operation, as shown in FIG. 4, the pressurized air in the plenum
chamber 66 is divided into two portions, a minor portion 99 of this
air flows into the support tube 84 through a plurality of small
apertures 100 located behind the baffle member 82. A major
proportion at 101 of the pressurized air flows forward through the
metering orifices 72 and thus forms a plurality of concentrically
spaced vigorous air jets 102 which are directed forward into an
annular air vitiation and chemical alteration zone 104 that
encircles the support tube 84 in front of the baffle 68. The minor
portion 99 of this combustion air flow is preferably less than
approximately 15 percent of the major portion 101 of the total
combustion air flow. Preferably, the two air flows 99 and 101
comprise the total combustion air being supplied to the combustion
chamber 106 associated with the heat exchanger 12 (FIG. 1).
In order to adjust the major air flow 101 through the metering
orifices while the burner is in operation, there is an arm 108
which extends rearwardly from the electrode support member 96.
Adjusting means in the form of a knurled headed machine screw 110
(FIGS. 2, 3, and 7) is screwed through a threaded opening in the
wall of the upper housing 50. The end of this adjusting screw 110
bears against one side of the arm 108. A lock nut 112 holds the
adjusted position. A plunger 114 extends through an opening in the
opposite wall of the upper housing 50 and bears against the
opposite side of the arm 108. This plunger 114 has an enlargement
115 (FIG. 7) on its inner end, and a compression spring 116
encircling the shank of this plunger presses against the
enlargement 115, so as to urge the plunger 114 against the arm 108.
By turning the screw 110, the electrode support 96 is turned, and
because it is keyed to the support tube 84, the tube 84 is rotated
together with the adjustable baffle. Thus, the position of the
orifices 86 (FIG. 7) relative to the fixed orifices 72 is
conveniently adjusted to increase or decrease the amount of
combustion air flowing through the air metering assembly 68, 82
into the annular air vitiation zone 104. The resulting air jets 102
are vigorous because the full output pressure of the blower is
applied to the plenum chamber 66 to drive the air through the
orifices in the metering baffle assembly.
By virtue of the fact that the full output pressure of the blower
is available in the plenum chamber 66 for producing the jets 102,
any fluctuation in pressure in the combustion chamber 106 has an
insignificant effect on these jets. Accordingly, sudden downdrafts
in the chimney or flue on windy days causing fluctuations in the
pressure in the combustion chamber 106 do not adversely affect the
burner operation.
A pair of ignition electrode rods 118 extend through ceramic
insulating sleeves 120 which are clamped in mounting notches 122 of
the support member 96 by a clamp bar 124 secured by a screw 126.
The rear ends of these electrode rods 118 are bent up to form
resilient contacts 128 which are engaged by the respective high
voltage terminals 130 (FIG. 1) of transformer 52, when the lid 54
is closed. The resilience of the contacts 128 and their sliding
engagement with the high voltage terminals 130 permits the support
member 96 to be rotatably adjusted in position without breaking
contact with these terminals 130.
The electrode rods 118 extend forward through a pair of orifices 86
(FIG. 7) in the rotatable baffle 82 and through the arcuate slot 76
in the fixed baffle member 68. The arcuate slot 76 provides
clearance so that the support member 96 can be rotatably adjusted
to adjust the amount of combustion air flowing through the orifices
72. In this illustrative embodyment five of the orifices 72 are
arranged for adjustable damper action by the orifices 86.
Three of the orifices 86, including two through which the electrode
rods 118 extend, are aligned with the arcuate slot 76, and the
combustion air through these three orifices is not adjustable so
that they always provide three vigorous air jets 102. Accordingly,
this arrangement provides air metering from full blower capacity
down to approximately three-eighths of blower capacity. The fuel
feed rate is matched to the amount of combustion air by adjusting
the fuel pressure adjustment screw 36 and/or by removing the nozzle
46 and replacing with a nozzle having a different size of nozzle
tip orifice.
At their front ends the electrode rods 118 are bent toward each
other and radially inwardly to form converging electrode tips 132,
as seen most clearly in FIGS. 3 and 7, and the ignition spark forms
between these electrode tips. In FIG. 4 the electrodes 118 are
omitted in order to illustrate the operation more clearly. The
location of the ignition spark is shown by the plus sign within a
small circle.
As shown in FIG. 4, a minor proportion 99 of the pressurized air in
the plenum volume 66 flows into the nozzle support tube 84. This
atmospheric (non-vitiated) air 99 flows forward in the space
surrounding the fuel line 44 within the tube 84, thus serving to
cool the fuel line 44 and also to cool the nozzle. This cooling air
99 enters the space around the nozzle support sleeve 90 and issues
through a plurality of small holes 133 drilled in the nose ring 88.
This nose ring 88 is preferably sloped backwardly in the direction
radially out from the tip of the nozzle so that the air jets 135 of
non-vitiated air preferably diverge in a downstream direction.
These jets 135 of non-vitiated air aid in establishing ignition and
also aid is providing retention of a stable blue flame in the
combustion chamber 106 beyond the mouth 136 of the fuel injection
region 105. It is possible to have the small holes 133 aimed
directly downstream so that the air jets 135 travel parallel to
each other downstream, but the resulting blue flame tends to be
more localized along the axis of the cylindrical combustion chamber
106. By diverging the jets 135 as shown in FIG. 4 a more diffuse
and uniform blue flame is obtained which more nearly fills the
chamber 106, providing better heat transfer action and more stable
combustion over a larger range of firing rates.
Within the adapter tube 20 is located a concentric sleeve 134 of
metal which encircles the front portion of the tube 84 to define
the annular air vitiation zone 104 and also to define a portion of
a recirculation path, as will be explained further below. This
fluid mixing sleeve 134 extends downstream beyond the fuel nozzle
46 to define a downstream fuel injection region 105 into which the
fuel spray pattern 48 is projected. Preferably the sleeve 134 has a
relatively large diameter and a relatively short over-all length
such that its length to diameter ratio is no more than 2 to 1.
Also, preferably the fuel injection region 105 has a relatively
large diameter relative to its length L such that the fuel spray
pattern 48 misses the lip 136 at the mouth of the sleeve 134. The
length L of the fuel injection region 105 is measured in an axial
direction from the end of the fuel nozzle 46 to the lip 136. In
this illustration embodiment the diameter of the fuel injection
region 105 is greater than the length L.
Attached to the sleeve 134 at its mouth 136 is a radial flange or
disc 138 of metal whose front surface facing the combustion chamber
106 is covered by a refractory insulation layer 137. This
insulation layer 137 is in the form of a flat ring retained in
place by a metal shoulder ring 141 secured to the flange 138 around
the mouth 136. This disc 138 serves as a deflecting baffle for
causing the combustion products to recirculate over heat exchanger
surfaces of the fluid heater 14 from which insulation has been
removed, as will be explained. The disc 138 and sleeve 134 serve to
define a low pressure drop recirculation path 139 and 140 for
gaseous combustion products which are recirculated back into the
annular air vitiation zone 104. These recirculating combustion
products are indicated by the successive arrows 142-1, 142-2 and
142-3.
It is noted that the recirculation path 139 and 140 includes an
annular portion 139 extending radially inwardly between the disc
baffle 138 and the exposed metal wall 144 of the water jack 146 of
the fluid heater. Then there is the cylindrical portion 140 of the
recirculation path which resides between the sleve 136 and the tube
20 which fits snuggly into the burner port 148 of the fluid heater
14.
As shown in FIG. 1, there is insulation 150 of low density
refractory lining the water-backed heat exchanger 12 surrounding
the combustion chamber 106. The back of the combustion chamber 106
is covered by a removable back panel 152 which has an insulation
coating. This removable back panel 152 is spaced away from the main
water jacket of the heater 14 to define a back passage 154 for the
hot combustion gases to flow up and into a plurality of "fire" tube
heat exchanger elements 156 extending forward through the top of
the water jacket 146 of the heater 14. The combustion gases are
collected in a flue box 158 and pass up through a flue duct 160
which may be connected into a chimney or may lead directly out of
doors without using a chimney.
The back panel 152, fire tube elements 156, flue box 152 and flue
duct 160 can be conventional elements as used with conventional
yellow flame gun burners today.
When incorporating the present invention in an existing fluid
heater 14, the insulation 150 is scraped away and removed from the
heater wall 144 and near by surfaces 151 of the combustion chamber
106 in the vicinity of the recirculation path 139 and 140 before
the sleeve 134 and deflector disc 138 are installed. The fluid
mixing sleeve 134, baffle disc 138, and facing insulation 137,
together with the spacer fins 162 can conveniently be supplied in
kit form for field installation in existing fluid heaters 14. When
incorporating the present invention in a new fluid heater 14, the
insulation 150 is omitted from those surfaces of the heater as
shown in FIGS. 1 and 4.
The way in which the baffle disc 138 and sleeve 134 are installed
is to remove the back panel 152, and then the sleeve 134 is
inserted into the burner port 148 by reaching inward through the
now opened back of the combustion chamber. There are a plurality of
thin L-shaped spacer fins 162 which are secured to the water jacket
wall 144. Three or four of these spacer fins 162 are usually
sufficient to make a reliable installation. The baffle disc 138 is
secured to these spacer fins 162 by sheet metal screws or pop
rivets or the like, and then the insulation facing ring 137 is
fitted into place around the shoulder ring 141. After this
installation has been made, the back panel 152 is reattached. There
is a small clearance between the portions of the spacer fins 162
within the burner port 148 and this port itself such that the
forward end of the adapter tube 20 can be slid and attached into
the burner port 148 without interference from the previously
installed spacer fins 162.
Although the fluid heater 14 is described as having a water jacket
146, it will be understood that this description is for
illustrative purposes. The heater 14 can be supplied with any
suitable heat exchange fluid within the jacket spaces 146 such as
water, steam or air, as may be desired for any given
installation.
In operation, as shown in FIG. 4, the multiple vigorous jets 102
with their high velocity flow entering the breech of the annular
air vitiation zone 104 create a low pressure in the region 164 near
the multiple orifices 72. This low pressure region 164 causes the
gaseous products of combustion 142-1 near the rim of the deflecting
disc 138 to be drawn inward and then back through the recirculation
path 139, 140 as indicated by the successive arrows 142-1, 142-2
and 142-3. These recirculating gases 142 pass in effective heat
exchange relationship with the exposed metal walls 151 and 144 both
of which are backed by water, and in heat exchange with the
mounting tube 20. Such an effective cooling action is obtained that
the recirculated gases 142-3 at the breech of the sleeve 134 are at
a temperature below 800.degree.F.
The multiple vigorous jets 102 are highly effective in providing
momentum interchange with the recirculating gases 142-3, thus
causing a large recirculation of combustion gases to occur and
propelling these recirculated gases forward through the annular air
vitiation zone 104. A thorough intermixing occurs between the
combustion air in the eight jets 102 and the recirculant gases
142-3. In this way the combustion air becomes vitiated and its
composition is chemically altered by intermixture with the cooled
recirculated gases.
It is noted that this vitiation and chemical alteration of the
major portion of the combustion air is carried out in the annular
zone 104 before the vitiated air reaches the downstream fuel
injection region 105. The vitiated air and fuel spray 48 are
brought into intimate intermixture in the region 105. Because the
major proportion, namely approximately 80 to 90 percent of the
combustion air has been vitiated before it reaches the vicinity of
the fuel, there is very little opportunity for this burner 10 to
lapse into yellow flame combustion due to puffy wind conditions at
the flue outlet or in spite of adjustment over a wide range of
firing rates.
The non-vitiated air jets 135 produce an eddying flow 166 near the
nose ring 88 which serves to pull a mist of fine fuel droplets from
the spray pattern 48 into the vicinity of the ignition spark, thus
aiding in establishing prompt ignition of the fuel. The flame front
quickly moves downstream, and the flame becomes established in the
combustion chamber downstream from the mouth 136 of the fuel
injection region 105.
There is an abrupt increase in cross sectional area of the flow
path downstream from the mouth 136, such that a backward eddying
vortex 168 of the blue flame occurs in the combustion chamber 106
near the insulated face 137 of the baffle disc 138. This backward
eddying vortex 168 extends around the mouth 136 and serves a flame
retention function to stabilize and hold the blue flame in the
combustion chamber 106. It will be seen that the diverging
non-vitiated air jets 135 are preferable aimed so that they just
clear the lip 136 and thus pass close to the flame stabilizing
vortex 168. In this way there is provided a very slight oxygen
enrichment associated with the stabilizing vortex 168, which I have
found to be of advantage in retention of the blue flame and in
diffusing the blue flame throughout much of the volume of the
combustion chamber 106. The air jets 135 preferable diverge at an
included angle from 30.degree. to 60.degree., and these diverging
jets also cause the fuel spray to diffuse advantageously into
substantially the entire cross section of the vitiated air stream
issuing from the burner mouth 136.
MODIFIED EMBODIMENT OF THE INVENTION
In illustrating the modified burner 10A shown in FIGS. 8, 9 and 10,
corresponding reference numbers will be used for parts performing
functions corresponding to those in the burner 10. In general, the
burner 10A is similar to the burner 10, except that the air
metering assembly is operated by an axial movement instead of a
rotary motion. Accordingly, only the differences will be
described.
The fixed baffle member 68 has a cup section with an inturned lip
170 which engages and retains the periphery of a fixed circular
metering baffle wall 70 (FIG. 10). This circular wall member 70 is
secured to the upstream end of the fuel nozzle support tube and air
cooling conduit 84 and contains eight stationary orifices 72.
In order to adjust the amount of combustion air flowing through the
fixed orifices 72, there are a plurality of longitudinally movable
tapered cylindrical damper valve plugs 172 each of which is
inserted into a respective one of the orifices 72. As seen in FIGS.
9 and 10, two of these tapered damper plugs are formed by the
insulating sleeves 120 which surround the electrode rods 118 that
extend through two of the orifices 72. The six damper plugs 172 are
fastened to the perimeter of the support member 96. The two
electrode insulating sleeves 120 are held clamped in position by
encircling bands 174 attached to opposite ends of a clamp bar 124.
A clamp screw 126 is threaded through a screw hold in the uppermost
plug 172 and presses against the clamp bar 124. When the screw 126
is loosened, the electrodes 118 can be adjusted longitudinally and
rotatably by moving the insulating sleeves 120 with respect to
their mounting saddles 122 on the support member 96 for positioning
the electrode tips 132 as desired.
For simultaneously moving all of the damper plugs 172 and
insulating sleeves 120 longitudinally, the support member 96 is
slidable along the nozzle fuel line 44. A compression spring 176
seats against a busing 178 secured to the fuel line, and this
spring presses forward against the slidable support member 96 to
urge it forward with respect to the fuel line. As adjusting rod 180
is secured to the support member 96 and extends back through a hole
in a mounting block element 182. This adjusting rod 180 and also
the fuel line 44 are slidable through the mounting element 182. By
tightening a nut 184 the user moves the support member 96 and all
of the valve plugs rearwardly in unison against the action of
spring 176, thus increasing the amount of combustion air issuing in
the multiple air jets 102, and vice versa to decrease the
combustion air flow.
The full blower air pressure is available in the plenum 66, so that
the air jets 102 are vigorous and effective in creating a low
pressure region 164 (FIG. 8) near the multiple orifices 72. In
addition, the tapered valve plugs 172, 120 with their forwardly
projecting pintle sections 186 are effective in reducing the amount
of the major combustion air flow 101 while retaining symmetrical
energetic jets 102. These multiple vigorous jets 102 achieve a
large momentum interchange with the gaseous products that have been
recirculated through the recirculation path 189, 140, thereby
effectively vitiating the air in the annular air vitiation zone 104
before the downstream fuel injection region 105 is reached. The
recirculant in the path 139, 140 is cooled to a temperature below
800.degree.F by the exposed metal wall section 151 and 144 of the
fluid heater 14.
A minor proportion 99 of the combustion air flows forward through
the support tube and air duct 84 so as to cool the nozzle 46. This
air 99 issues through multiple small holes 133 (FIG. 10) in the
nose ring 88. These holes 133 preferably diverge outwardly in a
downstream direction at an included angle in the range from
30.degree. to 60.degree. to create a plurality of non-vitiated
diverging air jets 135 directed to miss the lip of the sleeve 134
near the annular vortex 168, thereby providing a stable and
generally diffuse blue flame in the combustion chamber 106.
In order to further increase the proportionate amount of
recirculant being pumped into the annular zone 104, the tube 134
can be flared out at its breech, as shown in FIG. 8. This same
flaring of the breech of the tube 134 can be incorporated in the
burner 10 of FIGS. 1 - 7, for the same reasons.
For accurately aligning and centering the tapered valve plugs 172,
120 with the orifices 72, three or more centering vanes or flutes
188 can be provided on the forward end of one or more of the valve
plugs. These flutes 188 define a uniform outside diameter and are
sized to slide freely in the orifice 72 to serve as centering
guides.
The resilient leaf spring electrode contacts 128 remain in
engagement with cooperating leaf spring extensions of the
transformer terminals 130 in spite of the fact that the whole vane
plug assembly is longitudinally adjustable in position.
The spring 92 between the mounting element 182 and the bushing 178
urges the fuel line forwardly, thus pressing the nozzle means 46
against the inside of the nose ring 88. The resulting forward
pressure on the front end of the tube 84 holds the priphery of the
baffle member 70 firmly seated against the retainer lip 170.
Advantageously, the whole air metering and electrode assembly shown
in FIG. 10 can be removed from the burner 10A in the field for
inspection or servicing and can be reinserted into the burner 10A
without altering the original adjustment of the damper elements.
The lid 54 is swung up and open in a forward direction about the
hinge 56. The mounting element 182 is moved forward against the
action of spring 92 to clear the wall of the housing so that the
projecting fuel line 44 and adjusting rod 180 can be lifted up from
a notch 49 in the housing wall. Then the whole assembly of FIG. 10
can be removed in a rearward and upward direction to withdraw the
baffle member 70 from engagement with the fixed member 68.
The springs 92 and 176 accommodate tolerance variations and
differential expansions of the various parts so that they can be
readily mass produced. This axially adjustable air metering damper
assembly as shown in FIG. 10 has the advantage that it is capable
of being embodied with only minor alterations in various blue flame
retention gun burners having different designs but embodying the
present invention as described in connection with the burners 10
and 10A.
FURTHER EMBODIMENT OF THE INVENTION
FIGS. 11 and 12 show the burner 10 or 10A associated with a
different fluid heater 14A from the fluid heaters shown in FIGS. 1,
4 and 8. This fluid heater 14A is shown as being a domestic
oil-fired water heater with a water feed line 190 extending into
the bottom of a heat exchange water tank 146 and a hot water supply
line 192 from the top of the tank. The shape of the hot water
storage tank 146 is typical of many conventional water heaters and
includes a bare metal bottom surface 151.
The combustion chamber 105 is defined by a low density high
temperature insulation material 150 which may be supported in a
metal pan 196. A glass fiber insulation material 198 or similar
insulation surrounds the combustion chamber 106 for heat insulation
and sound deadening purposes. A metal deflector panel 200 extends
as a shelf around the top of the combustion chamber.
The hot gaseous products of combustion rise up into a head space
194 in heat exchange relationship with the exposed concave surface
151 and are deflected downwardly. The deflector panel 200
re-directs the hot gases up into an annular heat exchange passage
202 surrounding the tank 146 and communicating with the flue duct
160. An outer insulated casing 204 surrounds the heat exchange
passage 202.
As seen most clearly in FIG. 11, there is a hollow member 206 of
generally annular configuration which surrounds the breech end of
the mixing tube 134 so as to define an annular recirculation
chamber 140 for the cooled combustion gases. The annular member 206
includes an upstanding duct portion 208 which provides a
recirculation flow passage 139 interconnecting the recirculation
chamber 140 with the head space 194 above the combustion chamber
106. A recess 210 in the shelf panel 200 received the duct section
208.
For attachment of the burner mounting flange 58, there are a
plurality of bolt studs 212 on the recirculation chamber 206 which
extend through bolt holes in a burner bracket mount 214. This
bracket 214 includes a burner port 22 for receiving the tubular
adapter section 20 (FIG. 10) of the burner which is aligned with a
corresponding burner port 22A in the recirculation chamber 206. A
port 216 in the wall of the combustion chamber receives the mixing
tube 134 which projects through a port 218 in the opposite wall of
the mixing chamber from the port 22A.
It is noted that there is an abrupt increase in cross sectional
area of the combustion chamber 106 beyond the lip 136 at the mouth
of the fuel injection region 105 producing the back eddying annular
vortex 168. As discussed above in connection with FIGS. 1, 4 and 8
such a back eddy aids in retention of a stable blue flame in the
combustion chamber 106.
A portion of the gaseous products of combustion after undergoing
useful heat exchange with the water backed surface 151 of the heat
exchanger 12 are drawn down through the recirculation flow passage
139 into the annular region 140. Advantageously, these recirculant
gases are drawn from a region near the downturned rim 220 where the
products of combustion are being deflected downwardly from the head
space 194 toward the shelf panel 200. The recirculant is drawn by
the multiple air jets of the burner 10 or 10A from the
recirculation region 140 into the air vitiation and chemical
alteration zone 104.
ANOTHER EMBODIMENT OF THE INVENTION
FIG. 13 shows the burner 10 or 10A associated with a compact fluid
heater 14B which is adapted to be connected with a remote storage
tank for the hot fluid (not shown) or connected directly with
equipment for utilizing the hot fluid. This fluid heater 14B is
shown as a compact water heater with a feed water line 190
connected to a monotube coil section 222 of a heat exchanger 12.
The other end of the coil section 222 connects to a hot water
supply line 192. This supply line 192 can be connected to a hot
water storage tank or directly to utilization equipment for using
the hot water or other hot fluid being produced by the fluid heater
14B.
This fluid heater comprises a first elongated cylindrical cup 224
formed of rigid low density thermally resistant insulation material
150 which defines the combustion chamber 106. The sleeve 134 of the
burner 10 or 10A extends through a port 216 in the circular end
wall 226 of the cylindrical insulation cup 224. There is an abrupt
increase in cross sectional area downstream from the lip 136 of the
sleeve 134 thus forming the back eddying vortex 168 in the
combustion chamber 106.
The first elongated cylindrical insulation cup 224 is supported
near its opposite ends by a plurality of radial spacer elements 228
formed of low density thermally resistant insulating material
similar to the lining 150 of the combustion chamber. The open end
230 of the first cylindrical cup 224 nests concentrically within a
second larger elongated cylindrical cup 232 formed of the same
insulation material 150. The first and second cylindrical
insulation members 224 and 232 are radially and axially spaced to
define a generally annular cylindrical passage 234 communicating
with the opposite end of the combustion chamber 106 from the fuel
injection region 105. The cylindrical member 234 is supported by a
jacket 236 of heat resistant metal, such as stainless steel,
secured by brackets 238 to the cylindrical casing 240 of the heater
14B. Preferably the casing 240 is also formed of similar heat
resistant metal.
The second elongated cylindrical member 232 and the casing 240 are
radially and axially spaced to provide an annular cylindrical space
241 for the coil section 222 communicating with an outlet end
chamber 242 connected to the flue duct 160.
At the burner end of the heater the casing is completed by an
extending cylindrical mounting section 20 integral with an end
cover disc 244. Between the cylindrical mounting section 20 and the
sleeve 134 is defined the annular recirculation path portion 140. A
radial recirculation path portion 139 is defined between the cover
244 and the end of the first cylindrical cup member 224. The coil
section 222 is shaped to fit into the recirculation path protions
139 and 140. Thus, useful heat exchange between the recirculated
gases and a fluid-cooled heat sink occurs such that these
recirculated gases are cooled to a temperature below 800.degree. F.
before they enter the air vitiation and chemical alteration zone
104.
Advantageously, the combustion products can diffuse and slow down
while passing through the annular passage 234 which has a
relatively large total cross sectional area. Thus, there is a
substantial differential in pressure occurring between a point at
the juncture of passages 234 and 139 and the low pressure region
164 near the multiple vigorous air jets aimed into the zone 104.
The recirculation path 139 and 140 is a low pressure drop path
because it is short and has a relatively large cross sectional
area; and so a highly effective recirculation of cooled combustion
products is produced through the path 139,140.
DISCUSSION OF GRAPHS
FIG. 14 graphs the effect of excess air on the amount of emissions
of nitric oxide (NO) and carbon monoxide (CO) for a conventional
commercially available fuel oil burner with a flame retention head
firing into a commercial outdoor water heater and also for a burner
embodying the present invention firing into the same water heater.
The conventional outdoor water heater was modified by scraping off
the insulation near the burner inlet port 22, as shown in FIG. 4 at
144 and 151. Both the conventional burner and the burner of the
present invention were tested in this water heater after the
insulation had been scraped off. (This modification reduced the NO
emissions for the conventional burner below that which occurred
when the insulation was present at 144 and 151, and thus this
modification did not adversely affect the performance of the
conventional burner.) Both the conventional burner and the burner
of the present invention were fired at a rate of 0.75 to 0.80
gallon of No. 2 fuel oil per hour utilizing conventional high
pressure fuel atomizing nozzles.
The excess air is plotted as the independent variable along the
horizontal axis, being expressed as a percentage above a
stoichiometric ratio of air to fuel. For example, 10 percent excess
air means that the amount of air being fed through the burner
exceeds a stoichiometric ratio by ten percent, and so forth.
The values plotted along the vertical axis in FIG. 14 are grams of
NO or CO produced per kilogram of fuel which was burned under
steady state operating conditions. This fuel was conventional No. 2
fuel oil purchased commercially.
The values plotted in FIG. 14 are averages compiled during a series
of tests. In any given instance the data actually measured was
within approximately plus or minus 10 percent from the curves shown
in FIG. 14. It is to be noted that the shape of the NO curve 252 in
FIG. 14 is not typical of all conventional burners, but the
emission data for NO lying above 0.07 grams of NO per Kg of fuel is
typical of all conventional flame retention head burners, in the
range of excess air shown in FIG. 14, as shown by David P. Howekamp
and Mark H. Hooper in Paper No. APCA No. 70-45 presented at the
annual meeting of the Air Pollution Control Association, in St.
Louis, Mo. on June 14 to 19, 1970, entitled Effects of Combustion
Improving Devices on Air Pollutant Emission From Residential
Oil-Fired Furnaces.
FIG. 15 graphs the dependence of smoke emissions and furnace
efficiencies on the amount of excess air under steady state
operating conditions. The smoke emissions are plotted along the
vertical axis at the left in terms of Bachrach Number. The furnace
efficiencies are plotted along the vertical axis at the right.
Taking into account the shape of the smoke emissions curve 250
(FIG. 15) for the conventional burner, it is seen that the least
smoky range of operation (for operation of the conventional burner
in this particular water heater) is from approximately 20 percent
to approximately 60 percent excess air. Over this range from
approximately 20 percent to approximately 60 percent excess air the
furnace efficiencies for the conventional burner as shown by curve
251 ranged from approximately 75 percent to approximately 66
percent.
As shown by the curve 252 (FIG. 14) over this same range from
approximately 20 percent to approximately 60 percent excess air the
NO emissions from the conventional burner ranged from approximately
1.18 to approximately 0.07 grams per kilogram of fuel burned. Over
this same range of excess air as shown by the curve 253 (FIG. 14)
the CO emissions from the conventional burner remained almost
constant at approximately 0.24 grams per Kg of fuel burned.
Taking into account the shape of the smoke emissions curve 254 for
the burner embodying the invention, it is seen that the least smoky
range of operation is from approximately 10% excess air up to
approximately 15 percent excess air or more, if desired. However,
considering the shape of the efficiency curve 255 for the burner
embodying the present invention, it is seen that higher
efficiencies are obtained by remaining in the range from
approximately 10 percent to approximately 15 percent excess air,
and over this range as shown by the curve 255 the furnace
efficiencies range from approximately 79 percent to approximately
77 percent.
Over this same range from approximately 10 percent to approximately
15 percent excess air, as shown by the curve 256 (FIG. 14), the NO
emissions from the burner of the present invention remained almost
constant at approximately 0.32 grams per Kg of fuel burned. Over
this same range the CO emissions as shown by the curve 257 ranged
from approximately 0.26 to approximately 0.25 grams per Kg of fuel
burned.
The actual comparison is somewhat more favorable to the burner of
the present invention than appears from a glance at these curves,
because of the somewhat greater efficiency obtained with the burner
of the present invention. By virtue of the fact that in the range
from approximately 10 percent to approximately 15 percent excess
air the burner of the present invention provides furnace
efficiencies from approximately 79 percent to approximately 77
percent a lesser consumption of fuel is required to produce the
same effective heating than with a conventional burner operating at
furnace efficiencies from approximately 75 percent to approximately
66 percent in the excess air range from approximately 20 percent to
approximately 60 percent. Accordingly, the amount of emissions
caused by the burner of the present invention in actual use would
be reduced in proportion to this reduction in fuel consumption
resulting from the increased efficiency.
The burner embodying the invention which was tested to produce the
graphs of FIGS. 14 and 15 was similar to that shown in FIGS. 1 - 8,
except that the air jet orifices 72 were fixed in size by drilling
in the baffle member 68. There was no means provided to adjust the
size of these orifices 72, and so I arranged to drill several
different baffle members with different sized orifices and selected
the best one for the tests. Since the time when these tests were
run, I conceived and developed the adjustable orifice mechanisms as
shown and described in the drawings. I intend to include a burner
having orifices 72 of fixed size in certain of the following
claims.
One other difference between the burner embodying the invention
which was tested to produce the graphs of FIGS. 14 and 15 and that
shown in FIGS. 1-8 was that the former had a plurality of radial
support fins in the zone 104 projecting inward from the sleeve 134
and located intermediate the jets 102. These radial fins defined a
plurality of sectors of the annular zone 104 with each of the jets
102 aimed generally along the centerline of these respective
sectors of the zone 104. I intend to include a burner having fins
in the annular zone 104 in certain of the claims. Tests have also
more recently been run on the burner of FIGS. 1-8, and the results
of these recent tests were comparable to those which were used to
produce FIGS. 14 and 15.
ADDITIONAL DISCUSSION
Although it is among the advantages of the present invention that
it enables many conventional air and oil handling components to be
directly utilized in the practice of the invention, there are
certain instances in which special components may be used. For
example, the blower 28 in the burner 10 or 10A may be a high
performance blower for supplying pressurized air at a higher
pressure than conventional for use with heat exchanger systems 12
requiring high velocity flow of the combustion products
therethrough to provide high convective heat transfer rates to the
fluid being heated.
* * * * *