EP0284209A1 - Infra-red burner system for furnaces - Google Patents
Infra-red burner system for furnaces Download PDFInfo
- Publication number
- EP0284209A1 EP0284209A1 EP88301584A EP88301584A EP0284209A1 EP 0284209 A1 EP0284209 A1 EP 0284209A1 EP 88301584 A EP88301584 A EP 88301584A EP 88301584 A EP88301584 A EP 88301584A EP 0284209 A1 EP0284209 A1 EP 0284209A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- furnace
- burner
- pyrometer
- flue
- gas burner
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Images
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D99/00—Subject matter not provided for in other groups of this subclass
- F27D99/0001—Heating elements or systems
- F27D99/0033—Heating elements or systems using burners
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23N—REGULATING OR CONTROLLING COMBUSTION
- F23N1/00—Regulating fuel supply
- F23N1/08—Regulating fuel supply conjointly with another medium, e.g. boiler water
- F23N1/082—Regulating fuel supply conjointly with another medium, e.g. boiler water using electronic means
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D19/00—Arrangements of controlling devices
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D21/00—Arrangements of monitoring devices; Arrangements of safety devices
- F27D21/0014—Devices for monitoring temperature
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D19/00—Arrangements of controlling devices
- F27D2019/0006—Monitoring the characteristics (composition, quantities, temperature, pressure) of at least one of the gases of the kiln atmosphere and using it as a controlling value
- F27D2019/0025—Monitoring the temperature of a part or of an element of the furnace structure
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D99/00—Subject matter not provided for in other groups of this subclass
- F27D99/0001—Heating elements or systems
- F27D99/0033—Heating elements or systems using burners
- F27D2099/0043—Impulse burner
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27M—INDEXING SCHEME RELATING TO ASPECTS OF THE CHARGES OR FURNACES, KILNS, OVENS OR RETORTS
- F27M2001/00—Composition, conformation or state of the charge
- F27M2001/04—Carbon-containing material
Definitions
- This invention relates to a gas burner for a furnace, and more particularly, to a gas burner incorporating a temperature sensing means for the automatic control of a baking furnace.
- the present invention has particular application to the production of carbon anodes for use in producing aluminum, e.g. for automatically controlling the baking temperature of raw anodes within close tolerances to produce uniformly baked anodes.
- the production of such carbon anodes has for many years been done in a so-called ring type baking furnace.
- Such furnaces consist of a honeycomb of rectangular refractory pits in which the carbons are baked, heat being applied to the carbons for preheating and baking, and removed after cooling, by suitable gas flow through flues in the walls of the pits.
- the pits are arranged in small groups known as sections, and these sections are arranged as a complete system in the form of a ring.
- the flues are usually built in the longitudinal walls of each pit and are arranged for communication with the flues of adjoining pits.
- gas preferably cold air
- enters the flue system adjacent the last of the pits under cooling passes the series of pits under preheating and then the region of the final baking pits where the highest temperature heat, e.g. fire from burners, is injected into the gas stream.
- each filled pit is subjected to the entire series of steps over a total period of many days.
- the pits are arranged in sections of several pits each and many sections are disposed for lengthwise alignment of the pits, with the complete structure providing in effect several rows of many endwise successive pits, each with heat exchange gas flues between the rows and along the outside rows.
- a plurality of temporary baking units can be arranged at any one time in each row and conveniently the fire burner means is arranged as manifolds or burner bridges crossing the array of rows and movable to successive positions along the array.
- a number of such manifolds may be provided whereby a number of successive baking units can be set up in each row, and parallel such units in several units can simultaneously be advanced, section by section.
- the automatic controller may vary the fuel supply in order to correct any discrepancies.
- the fuel supply is usually pulsed into the flue at varying rates depending on the difference between the actual flue temperature and the target.
- the present state of the art with respect to automatic ring furnace control systems requires an additional set of equipment which must be moved each time the burner system equipment is moved, and must act on information obtained from sensors that are remote from their critical areas of the furnace, i.e. the combustion areas.
- This information may have been influenced by many variables within the burner system, such as draught conditions, heat transfer rates, combustion characteristics, etc., and hence the automatic controller is required to predict these variables in order to properly control the furnace conditions.
- the present invention in its broadest aspect relates to a gas burner assembly for a furnace comprising a burner tube having an open outer end and an open inner end, with the inner end being adapted to extend through a furnace wall into the interior thereof.
- Connector means are provided for connecting the burner tube to a fuel supply.
- An infra-red pyrometer is mounted at the outer end of the burner tube and in axial alignment with the tube such that in use the pyrometer is sighted axially through the burner tube and onto an internal furnace wall.
- the gas burner assembly of the invention also includes a fuel supply flow controller for the burner and a data processer for receiving temperature signals from the pyrometer and adjusting the flow controller.
- This flow controller is preferably in the form of a pulsing valve.
- the present invention uses a simple piece of tubing which merely acts as a duct to transport the fuel, preferably natural gas, into the flue thereby producing a long, lazy flame.
- the gas is supplied into the flue in pulses, each pulse providing an amount of fuel in excess of the locally available oxygen supply. Due to this lack of oxygen, high flame temperatures are not produced and complete combustion of the gas occurs only after it has travelled some distance along the flue. These factors result in a much more even heating along the flue, so that hot spots adjacent to the burner flame are far less likely to occur.
- Temperature readings are not taken while the fuel is being combusted, and the fuel flow is interrupted for a short period of time, e.g. about 10 seconds, at regular intervals, e.g. every 4 to 10 minutes, to take brick temperature readings from within the flue.
- the incoming fuel supply preferably comes into contact with, and hence assists in the cooling of the pyrometer thereby eliminating the need for any special water or air cooling systems.
- the temperature readings from the infra-red pyrometer are sent to a fully programmable controller of known type where each reading is compared with a preset target value for that stage of the baking process. Any discrepancies between these two values results in a proportional/integral control loop of the controller regulating the fuel supplied to the flue burner via the pulsing valve to counteract the discrepancy.
- the fuel pulsing is preferably of a low frequency type, providing a compromise between continuous flow and rapid pulsing.
- An important advantage of the gas burner system of the present invention with an integral infra-red pyrometer is that it eliminates the problem of moving both a burner assembly and the temperature sensor separately and furthermore permits the direct measurement of the flue brick temperature in the combustion zone, thereby providing a more accurate and efficient means for controlling the baking process.
- a furnace wall 10 is shown with a flue 11.
- a service opening 12 extends from the flue through the furnace wall 10.
- a burner tube 13 mounted in the service opening 12 is a burner tube 13 in the form of a hollow tube having a nominal bore of about 25 mm.
- This tube 13 has an inner end portion 14 and an outer end portion 15, with a collar 23 positioned adjacent the furnace wall 10 to cover opening 12.
- a handle 16 is positioned at the outer portion 15 of tube 13 and above this handle is mounted an infra-red pyrometer 17 within a tubular casing 35.
- the pyrometer includes an optical lens 18 at the lower end thereof and an annular space 34 is provided between the pyrometer 17 and the tubular case 35 therefor.
- a connector cable 20 is connected to the upper end of pyrometer 17 via plug 19 and this cable connects to a computer for controlling the system.
- a gas supply connector tube 22 is connected to each burner tube 13 via coupling 21 and with this arrangement the gas circulates in the annular space 34 around the pyrometer thereby assisting in the cooling of the pyrometer.
- a series of burner units are arranged in the form of a portable burner bridge as can best be seen from Figures 2, 3 and 4.
- the gas connector tubes 22 connect to a main gas pipe 25 and the pulsing flow is controlled by pulsing solenoids 27.
- a connector cable 26 provides control signals to the pulsing solenoids 27 from a microcomputer 29.
- thermocouples may be provided in the system, e.g. in sockets 31 and these are connected via electrical conduit 32. These thermocouples may be used to monitor pit temperatures between anodes.
- the flue pressure may also be monitored by the system and for this purpose the system includes a flue pressure transmitter control box 33. This can detect possible hazardous situations, usually as a result of blocked flues, and shut down the burners if the draught falls below a critical value.
Abstract
Description
- This invention relates to a gas burner for a furnace, and more particularly, to a gas burner incorporating a temperature sensing means for the automatic control of a baking furnace.
- The present invention has particular application to the production of carbon anodes for use in producing aluminum, e.g. for automatically controlling the baking temperature of raw anodes within close tolerances to produce uniformly baked anodes. The production of such carbon anodes has for many years been done in a so-called ring type baking furnace. Such furnaces consist of a honeycomb of rectangular refractory pits in which the carbons are baked, heat being applied to the carbons for preheating and baking, and removed after cooling, by suitable gas flow through flues in the walls of the pits. The pits are arranged in small groups known as sections, and these sections are arranged as a complete system in the form of a ring. The flues are usually built in the longitudinal walls of each pit and are arranged for communication with the flues of adjoining pits.
- During operation, several pits in each row are subjected to preheating of green or unbaked bodies, several pits receive highest baking heat and several pits undergo cooling, all based upon the condition of the gas flowing in the sequence of flues along the pits. Thus gas, preferably cold air, enters the flue system adjacent the last of the pits under cooling, passes the series of pits under preheating and then the region of the final baking pits where the highest temperature heat, e.g. fire from burners, is injected into the gas stream.
- For continuing operation, the circumstances of the flue portions adjacent the pits are altered intermittently, e.g. each 18 to 64 hours, with the locality of the fire injection being advanced concurrently with the direction of gas flow, whereby at each change a filled but unheated pit is added to and a pit with finished carbon bodies is removed from the sequence of pits under treatment. In this way each filled pit is subjected to the entire series of steps over a total period of many days.
- In a typical commercial operation, the pits are arranged in sections of several pits each and many sections are disposed for lengthwise alignment of the pits, with the complete structure providing in effect several rows of many endwise successive pits, each with heat exchange gas flues between the rows and along the outside rows. A plurality of temporary baking units can be arranged at any one time in each row and conveniently the fire burner means is arranged as manifolds or burner bridges crossing the array of rows and movable to successive positions along the array. A number of such manifolds may be provided whereby a number of successive baking units can be set up in each row, and parallel such units in several units can simultaneously be advanced, section by section. Such a system is described in considerable detail in Holdner, U.S. Patent 4,253,823 issued March 23, 1981.
- The rate of temperature change used to reach the finishing temperature on each baking cycle, as well as the temperature distribution in each flue, has traditionally been controlled by manual observation and adjustment of individual burners. This manual operation has, in the past, produced an adequate though inconsistent quality of carbon anodes. The current emphasis is on improved product quality and economic considerations dictate the need for more sophisticated control systems. By introducing automatic carbon body baked furnace control systems using relevant data collected from sensors within the furnace system, improvements in product quality, lower fuel requirements and longer flue life can be achieved.
- One such bake furnace control system is described in Benton et al U.S. Patent 4,354,828 issued October 19, 1982. That system utilizes infra-red temperature detectors which measure pit or anode temperatures, as well as infra-red temperature detectors for measuring the flue or brick temperature of the flue walls of the furnace. The information received from these sensors is then used to either increase or decrease the amount of air being fed to the burners.
- Systems of the above type have concentrated on obtaining information regarding the temperature of the flue gas or bricks in the flues downstream of the fire injection point, and using this information as the control variable. Depending upon how closely each temperature reading correlates with the corresponding predetermined target temperature for certain stages in the baking process, the automatic controller may vary the fuel supply in order to correct any discrepancies. In this type of automatic control, the fuel supply is usually pulsed into the flue at varying rates depending on the difference between the actual flue temperature and the target.
- In these prior systems no account was taken of the brick temperature at the fire entry point. Of course, the area of the flue close to the flame zone will reach higher temperatures than areas remote from the flame. The prior temperature monitoring systems do not directly measure the temperatures of such "hot spots" in the furnace flues. Other features of such furnaces, such as baffles in the flues which prevent infra-red radiation propagating very far along the flue wall, and lower heat transfer rates remote from the burner flame, make it difficult to predict upstream temperatures with any accuracy based upon downstream results.
- Furthermore, such prior systems have usually employed a rapidly pulsing flame which, depending upon oxygen supply, burns intensely under near ideal combustion conditions and will produce high flame temperatures in the order of 1,500°C. Consequently, problems with local overheating of the flue bricks may occur near the flame and this may not be detected by the downstream temperature sensors.
- By the nature of a ring furnace, as mentioned above, it is necessary to move the burner system on a regular basis intermittently approximately each 18 to 64 hours and the burner system must, therefore, be portable. Since the temperature sensors have typically been separate from the burner equipment and since they must also be moved each time the burner system is moved, they represent a further complication to the automatically controlled ring furnace process.
- In summary, the present state of the art with respect to automatic ring furnace control systems requires an additional set of equipment which must be moved each time the burner system equipment is moved, and must act on information obtained from sensors that are remote from their critical areas of the furnace, i.e. the combustion areas. This information may have been influenced by many variables within the burner system, such as draught conditions, heat transfer rates, combustion characteristics, etc., and hence the automatic controller is required to predict these variables in order to properly control the furnace conditions.
- It is the object of the present invention to overcome or substantially ameliorate the above mentioned problems.
- The present invention in its broadest aspect relates to a gas burner assembly for a furnace comprising a burner tube having an open outer end and an open inner end, with the inner end being adapted to extend through a furnace wall into the interior thereof. Connector means are provided for connecting the burner tube to a fuel supply. An infra-red pyrometer is mounted at the outer end of the burner tube and in axial alignment with the tube such that in use the pyrometer is sighted axially through the burner tube and onto an internal furnace wall.
- The gas burner assembly of the invention also includes a fuel supply flow controller for the burner and a data processer for receiving temperature signals from the pyrometer and adjusting the flow controller. This flow controller is preferably in the form of a pulsing valve.
- Rather than using a specialized gas burner such as a flame nozzle, the present invention uses a simple piece of tubing which merely acts as a duct to transport the fuel, preferably natural gas, into the flue thereby producing a long, lazy flame. The gas is supplied into the flue in pulses, each pulse providing an amount of fuel in excess of the locally available oxygen supply. Due to this lack of oxygen, high flame temperatures are not produced and complete combustion of the gas occurs only after it has travelled some distance along the flue. These factors result in a much more even heating along the flue, so that hot spots adjacent to the burner flame are far less likely to occur.
- Temperature readings are not taken while the fuel is being combusted, and the fuel flow is interrupted for a short period of time, e.g. about 10 seconds, at regular intervals, e.g. every 4 to 10 minutes, to take brick temperature readings from within the flue. The incoming fuel supply preferably comes into contact with, and hence assists in the cooling of the pyrometer thereby eliminating the need for any special water or air cooling systems.
- The temperature readings from the infra-red pyrometer are sent to a fully programmable controller of known type where each reading is compared with a preset target value for that stage of the baking process. Any discrepancies between these two values results in a proportional/integral control loop of the controller regulating the fuel supplied to the flue burner via the pulsing valve to counteract the discrepancy. The fuel pulsing is preferably of a low frequency type, providing a compromise between continuous flow and rapid pulsing.
- An important advantage of the gas burner system of the present invention with an integral infra-red pyrometer is that it eliminates the problem of moving both a burner assembly and the temperature sensor separately and furthermore permits the direct measurement of the flue brick temperature in the combustion zone, thereby providing a more accurate and efficient means for controlling the baking process.
- The foregoing and other features of the invention are explained in more detail in the description below, with illustration in the accompanying drawings.
-
- Figure 1 is a simplified, schematic view of a furnace flue with a burner assembly according to this invention in place;
- Figure 2 is a plan view of a burner bridge according to the invention;
- Figure 3 is a side elevation of the burner bridge of Figure 2; and
- Figure 4 is an end elevation of the burner bridge of Figure 2.
- Referring to the drawings, a
furnace wall 10 is shown with aflue 11. Aservice opening 12 extends from the flue through thefurnace wall 10. - Mounted in the
service opening 12 is aburner tube 13 in the form of a hollow tube having a nominal bore of about 25 mm. Thistube 13 has aninner end portion 14 and anouter end portion 15, with acollar 23 positioned adjacent thefurnace wall 10 to coveropening 12. Ahandle 16 is positioned at theouter portion 15 oftube 13 and above this handle is mounted an infra-red pyrometer 17 within atubular casing 35. The pyrometer includes anoptical lens 18 at the lower end thereof and anannular space 34 is provided between thepyrometer 17 and thetubular case 35 therefor. Aconnector cable 20 is connected to the upper end ofpyrometer 17 viaplug 19 and this cable connects to a computer for controlling the system. - A gas
supply connector tube 22 is connected to eachburner tube 13 viacoupling 21 and with this arrangement the gas circulates in theannular space 34 around the pyrometer thereby assisting in the cooling of the pyrometer. - A series of burner units are arranged in the form of a portable burner bridge as can best be seen from Figures 2, 3 and 4. The
gas connector tubes 22 connect to amain gas pipe 25 and the pulsing flow is controlled by pulsingsolenoids 27. Aconnector cable 26 provides control signals to thepulsing solenoids 27 from amicrocomputer 29. - Additional thermocouples may be provided in the system, e.g. in
sockets 31 and these are connected viaelectrical conduit 32. These thermocouples may be used to monitor pit temperatures between anodes. - The flue pressure may also be monitored by the system and for this purpose the system includes a flue pressure
transmitter control box 33. This can detect possible hazardous situations, usually as a result of blocked flues, and shut down the burners if the draught falls below a critical value. - It is to be understood that the invention is not limited to the specific steps, operations and means herein described and shown, but may be carried out in other ways without departing from its spirit.
Claims (7)
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AUPI064587 | 1987-03-03 | ||
AU645/87 | 1987-03-03 | ||
AU12300/88A AU595098B2 (en) | 1987-03-03 | 1988-02-25 | Infra red burner system for furnaces |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0284209A1 true EP0284209A1 (en) | 1988-09-28 |
EP0284209B1 EP0284209B1 (en) | 1993-05-12 |
Family
ID=3772047
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP88301584A Expired - Lifetime EP0284209B1 (en) | 1987-03-03 | 1988-02-24 | Infra-red burner system for furnaces |
Country Status (6)
Country | Link |
---|---|
EP (1) | EP0284209B1 (en) |
AU (1) | AU595098B2 (en) |
CA (1) | CA1325966C (en) |
DE (1) | DE3880867T2 (en) |
ES (1) | ES2040334T3 (en) |
NO (1) | NO168136C (en) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102021116344A1 (en) | 2021-06-24 | 2022-12-29 | Vaillant Gmbh | Method and arrangement for observing combustion processes and computer program product |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2963353A (en) * | 1957-06-20 | 1960-12-06 | Texaco Inc | Temperature measurement in reactors operating under high temperature and pressure |
DE2505335A1 (en) * | 1975-02-08 | 1976-08-19 | Manfred Leisenberg | Ring furnace fuelling and heating system - has several burners arranged around ring with combustion spaces at intervals between containers for furnace contents |
US4354828A (en) * | 1981-03-18 | 1982-10-19 | Southwire Company | Method and apparatus for producing uniformly baked anodes |
EP0064609A1 (en) * | 1981-05-07 | 1982-11-17 | Bergwerksverband GmbH | Device for measuring the temperature along the inner surfaces of flues of coking ovens |
US4547145A (en) * | 1983-03-09 | 1985-10-15 | Texaco Development Corporation | Combination with a high temperature combustion chamber and top burner |
-
1988
- 1988-02-24 EP EP88301584A patent/EP0284209B1/en not_active Expired - Lifetime
- 1988-02-24 ES ES198888301584T patent/ES2040334T3/en not_active Expired - Lifetime
- 1988-02-24 DE DE8888301584T patent/DE3880867T2/en not_active Expired - Fee Related
- 1988-02-25 AU AU12300/88A patent/AU595098B2/en not_active Ceased
- 1988-03-02 NO NO880932A patent/NO168136C/en unknown
- 1988-03-03 CA CA000560453A patent/CA1325966C/en not_active Expired - Fee Related
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2963353A (en) * | 1957-06-20 | 1960-12-06 | Texaco Inc | Temperature measurement in reactors operating under high temperature and pressure |
DE2505335A1 (en) * | 1975-02-08 | 1976-08-19 | Manfred Leisenberg | Ring furnace fuelling and heating system - has several burners arranged around ring with combustion spaces at intervals between containers for furnace contents |
US4354828A (en) * | 1981-03-18 | 1982-10-19 | Southwire Company | Method and apparatus for producing uniformly baked anodes |
EP0064609A1 (en) * | 1981-05-07 | 1982-11-17 | Bergwerksverband GmbH | Device for measuring the temperature along the inner surfaces of flues of coking ovens |
US4547145A (en) * | 1983-03-09 | 1985-10-15 | Texaco Development Corporation | Combination with a high temperature combustion chamber and top burner |
Also Published As
Publication number | Publication date |
---|---|
AU1230088A (en) | 1988-09-01 |
DE3880867D1 (en) | 1993-06-17 |
NO168136C (en) | 1992-01-15 |
EP0284209B1 (en) | 1993-05-12 |
CA1325966C (en) | 1994-01-11 |
ES2040334T3 (en) | 1993-10-16 |
NO880932L (en) | 1988-09-05 |
DE3880867T2 (en) | 1993-08-26 |
NO880932D0 (en) | 1988-03-02 |
AU595098B2 (en) | 1990-03-22 |
NO168136B (en) | 1991-10-07 |
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