TECHNICAL FIELD
The present invention relates generally to the combustion of solid fuel for heating purposes,
and specifically relates to a method of discharging products of combustion from a burner pipe
of a solid fuel burner, as specified in the preamble of the attached claim 1, a combustion
system or installation having a solid fuel burner, as specified in the preamble of the attached
claim 6 and a solid fuel burner as specified in the preamble of the attached claim 12.
BACKGROUND
Burners and other equipment for burning different kinds of solid fuel, predominantly pellets,
but also wood chips and to a certain degree also residual materials such as sawdust and certain
types of waste, have been developed for a long time within the technical field in question.
Said development has basically aimed at improving the burner designs as such for the purpose
of theoretically optimizing the combustion of solid fuel, and not at finding new total solutions
such as combinations of burner, boiler and possibly accumulator tank that are adapted to each
other and that are optimized for the combustion of the type of fuel in question.
This has lead to the fact that although a very large number of burner designs have been
developed, which in many cases have presented very good theoretical properties with regard
to the combustion, said burners have with few exceptions been designed for the purpose of
being installed in a traditional multi-fuel boiler or oil-fired boiler, as a replacement for the oil
burner initially intended for the boiler. This is a bad starting-point when designing a combustion
installation or system intended to be employed mainly for burning the type of fuel in
question. In practice this approach leads to the fact that such a combination of a novel burner
and a traditional boiler will suffer from a number of unfortunate limitations.
One problem encountered in this connection is the fact that regarding the size and configuration
of the combustion chamber and of the heat exchanger surface the traditional boilers
are not designed specifically for burning pellets. In particular they are designed having a large
water-cooled surface that in practical operation easily leads to an incomplete combustion in
combination with for instance a pellet burner. When the burner pipe of the burner is
positioned horizontally the incomplete combustion in turn often leads to residual unburned
particles accumulating in the boiler. Finally, the combustion residue, that is residual products
of combustion in the form of ash, may conventionally be a source of problem, both with
regard to the produced amount and to the actual ash-discharge, that is the removal of ash from
the combustion chamber or fire.
As was mentioned above, very little has therefore been done to find total solutions that are
specifically directed towards the combustion of solid fuel of the kind in question, and towards
the subsequent heat exchange, instead of being compromises in the form of burners adapted to
an application in conventional boilers.
SUMMARY OF THE INVENTION
A basic object of the invention is to find a simple and comparatively very inexpensive method
of enabling the production of a combustion installation for solid material that is designed
based on the current demands for functionality, compactness and possibility of integrating
different heat sources. Expressed otherwise the object is to provide a method of solving the
above discussed problems, starting directly from the conditions applicable to the combustion
of the fuel in question, instead of the usual adjustment of a traditional combustion installation.
The invention is based on the insight that a very efficient cooling of the combustion gases in
combination with an unprecedented functionality can be obtained by redirecting the combustion
gases immediately after they have left the burner, and by passing them back a long
path along the outer side of the burner pipe, in a direction opposite the in-feed direction of the
fuel. In particular, the invention suggests subjecting the combustion gases to a helical motion
around the outer side of the burner pipe while being simultaneously passed back along the
outside of the burner pipe, in a direction generally opposite that of the fuel in-feed direction,
and emitting heat to a surrounding heat absorbing medium. The burner pipe is caused to rotate
and a first feed screw is provided at the outer periphery of the burner pipe, fixed to the burner
pipe. In addition to the efficient cooling of the combustion gases this provides for an
improved discharge of combustion residue in a very compact design that is very well suited
for integration into installations or systems having anything from a very small water-filled
jacket or cassette to an accumulator tank, for instance in a heating system designed for several
different heat sources.
In accordance with the embodiments specified in claims 2 and 3 a very efficient and complete
combustion may be obtained by subjecting a fuel-air mixture and the combustion gases as
well as possible combustion residue to a rotary motion by means of a tangential secondary-air
supply and/or by means of a formation on the inner surface of the burner pipe, which also
supports the discharge of the combustion gases and combustion residue from the burner pipe.
According to a further embodiment of the invention, which is specified in claim 4, the
combustion gases and the combustion residue is transported back along substantially the entire
length of the burner pipe and is diverted from the burner in connection with a first end thereof,
where the fuel supply is provided. This creates a possibility of designing an extremely
compact unit consisting of an integrated burner and boiler, designed as a cassette that may be
installed for instance in an accumulator tank or other water container.
In accordance with an embodiment of the invention specified in claim 5 the design in
accordance with the basic object of the invention is combined with such a dimensioning and
insulation of the burner pipe that a substantially complete combustion of the fuel takes place
in the burner pipe, which will thereby practically form the burner as well as the heater.
In accordance with another aspect of the invention, specified in claim 6, a combustion
installation of the kind stated in the introduction is provided, which employs the principles of
the present invention. In this installation according to the invention, the combustion gas duct
is substantially helical and consists of an outer duct wall that surrounds the outer circumference
of the burner pipe, that is provided with an end wall at a distance outside one end of
the burner pipe, that extends along the outer side of the burner pipe and that is in contact with
a heat absorbing medium at its outer side. When the combustion gases have left said end of
the burner pipe they are redirected 180° and are thereby lead back along the outer side of the
burner pipe while emitting heat to the surrounding heat absorbing medium. The burner pipe is
provided with an outer helix forming the helical duct as well as a feed screw is rotatably
journalled and is caused to rotate by a drive means, thereby enhancing the discharge of
combustion residue.
Embodiments of this second aspect of the invention are specified in the dependent claims 7-11.
Yet another aspect of the invention, as specified in claim 12, relates to a solid fuel burner
designed in accordance with the basic principles of the invention. According to the invention
the burner pipe of the burner is provided with a first feed screw at its outer circumference, said
feed screw being rigidly attached thereto. The burner pipe is rotatably journalled and is
connected to a drive means for rotating the burner pipe around its longitudinal center axis.
Embodiments of this last mentioned aspect of the invention are specified in the dependent
claims 13-18.
Other objects, features and advantages of the invention will be readily appreciated upon
reading the dependent claims and the below description of exemplifying embodiments of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in detail below, with reference to the accompanying
drawings, in which:
- Fig. 1
- illustrates a longitudinal section through a burner according to the present invention,
in an embodiment where it is installed as a cassette in an accumulator tank, and
- Fig. 2
- illustrates a cross section through the burner illustrated in fig. 1, along the line I-I.
DETAILED DESCRIPTION
With reference primarily to figure 1 the basic principles of the invention will now be described
with the aid of an embodiment thereof. Simultaneously the advantages of the invention
over conventional installations will be explained. In both drawing figures the basic
principles of the invention are illustrated by means of a very schematically illustrated embodiment.
Fig. 1 illustrates a longitudinal section through a burner that is generally designated by the
reference numeral 1 and that in its illustrated design is intended for burning pellets. However,
with small modifications that are not specifically illustrated or described herein the burner
may be adapted for burning other solid fuels, such as chips and sawdust.
The burner 1 is illustrated in fig. 1 in an application for integration into an accumulator tank 10,
which is only schematically indicated, or other corresponding water volume. For this application
the burner 1 is designed as a unit, such as a cassette that may be inserted into a cavity 6 in the
accumulator tank 10. In a manner that will be described more closely below the wall 7 of the
cavity 6 in the accumulator tank 10 forms an outer duct wall of a combustion gas duct that leads
out from the burner 1 and the inner channel wall of which is formed by the outer side of the
burner pipe 2 of the burner 1. An end wall 7a closes the cavity or combustion gas channel 6
inwardly. With this design the effect is achieved that after having left the burner pipe 2 the
combustion gases are redirected substantially 180° and are subjected to a helical motion around
the outer side of the burner pipe 2, as will be described below. Simultaneously the combustion
gases are lead back along the outer side of the burner pipe 2, in a direction B that is generally
opposite to an in-feed direction A for fuel, while emitting heat to the surrounding heat absorbing
medium in the tank 10.
In its installed condition the burner pipe 2 extends into the cavity 6, and a forward end 2b
thereof ends at a distance from the end wall 7a of the combustion gas duct 6. At a rear end 2a
thereof the burner pipe 2 is rotatably journalled in a base unit 12 through appropriate bearings
13. In the embodiment of fig. 1 the configuration of the base unit 12 is illustrated in principle.
It shall be obvious though, that the details of the base unit design can be changed and modified
to a great extent within the scope of the invention, for adaptation to the application in
question.
The base unit 12 basically consists of a support pipe 14 on which the burner pipe 2 is rotatably
journalled. A centre -pipe 11 coinciding with the longitudinal centre axis C of the burner 1 is
provided in the interior of the support pipe 14, and serves to supply air, preferably primary air,
to the combustion/gasification zone X of the burner 1. Furthermore, the support pipe 14
communicates with a fuel supply, generally designated by the reference numeral 5, through an
infeed pipe 15. Thus, the fuel supply 5 is a gravity feed which, when required, may be supplemented
by an active feeding by means of a screw or the like in the support pipe 14. An
example of this is indicated in fig. 1 and is described more closely below. The fuel is fed from
a storage container, not shown, for the type of fuel in question, into the support pipe 14 and
further into the burner pipe 2. The fuel feed in the burner pipe is then performed in a manner
described below.
A drive motor 8 is also supported by the base unit 12 to transmit rotation to the burner pipe 2
through a transmission 16 provided in a transmission housing 17. As is indicated in fig. 1, the
transmission is suitably of the type including an endless chain or belt passed over corresponding
wheels attached to the output shaft of the motor 8 and to the outer side of the burner pipe 2
respectively, but other types of appropriate transmissions may also be employed.
The transmission housing 17 is built together with a connecting portion 18, a connecting wall
18a of which is intended to form a fluid tight connection with the outer wall of the accumulator
10, surrounding the cavity 6. For this purpose the connecting wall 18a is formed having a
central opening surrounded by a flange 18b that is intended to be inserted into the cavity 6.
The base unit is then connected to the accumulator tank 10 by means of suitable connecting
means, not shown, for instance in the shape of bolt connections. In order to provide the fluid-tight
connection the connecting wall 18a and/or the connecting flange 18b are at their outer
side provided with a suitable sealing material, as is indicated at 19.
At its upper part the connecting portion 18 is connected to a combustion gas pipe 20 through
which the combustion gases are lead out to the atmosphere. Through the measures that are
suggested according to the invention and that are described more closely below, the
combustion gas temperature has been lowered so substantially in this stage that, if so desired,
no chimney is required. At its lower part the connecting portion 18 is furthermore formed
having an ash-collecting pocket 21, see fig. 2. Combustion residue that is discharged from the
burner 1 and the cavity 6 in the manner described below, is collected in said pocket 21 so that
it may be removed through a door that is not illustrated in the drawings,
The actual burner pipe 2 shall now be described. As is clear from the above, the burner pipe 2
is rotatably supported on the support pipe 14 with its rear or first end 2a. In its installed
condition the burner pipe 2 is inserted into the cavity 6 in the accumulator tank 10, so that its
second or forward end terminates at a relatively short distance from the end wall 7a of the
cavity 6. In the illustrated embodiment the burner pipe 2 basically consists of a cylindrical
steel pipe that at its inner surface may be provided with a thermal insulation 9 preferably
consisting of a ceramic material. The fact that the combustion gases are passed on the outside
of the burner pipe 2, creates a kind of "insulation zone" between the combustion in the burner
pipe 2 and the comparatively cold water in the tank 10. This may also be expressed so that the
combustion zone is "insulated"- compared to a situation where it was directly surrounded by
air or water - which results in a higher temperature in the afterburning zone X1 - Y. By virtue
of this insulation 9, or alternatively solely by the insulation of the burner pipe achieved by the
surrounding combustion gas duct, and a corresponding dimensioning of the burner pipe 2 the
gasification of the fuel as well as the afterburning may take place in the burner pipe 2, which
does thereby also serve as a heater from which the combustion gases may be discharged
directly to the combustion gas duct formed in the cavity 6.
In this connection it shall also be mentioned that within the scope of the invention it is
conceivable to rotatably journal the burner pipe 2 directly in the cavity 6, that is without any
specific bearings. Naturally, this can be done under the presumption that problems relating to
friction and wear can be solved in the application in question.
Normally the infeed of the fuel is accomplished by the above mentioned gravity feed, possibly
in combination with a separate feed screw. However, fig. 1 illustrates an example of a
possible further alternative. A continuos inner helix 4 may be provided on the inner side of the
burner pipe 2, extending substantially from the first end 2a of the burner pipe to the
combustion zone X. This inner helix 4 forms a feed screw serving to continuously feed fuel
into and through the burner pipe 2, up to the combustion zone X, when the burner pipe is
rotated. As is indicated in fig. 1, it may be appropriate to perform the infeed of fuel from the
area below the infeed pipe 15 and up to the rear end 2a of the burner pipe 2 by forming the
inner feed screw 4 having an infeed portion 4". In the illustrated embodiment this infeed
portion is formed having a smaller diameter than the main portion of the feed screw 4 and is
extended in a cantilevered manner into the support pipe 14, almost up to the end wall thereof.
In another embodiment the infeed portion 4" may be formed having substantially the same
diameter as the main portion.
As is indicated with dash-dot lines in fig. 1, it is also possible to achieve a very favorable
influence on the combustion by providing a formation 4', for instance having a helical shape,
in the afterburning zone X1 - Y, at the inner side of the insulation 9. This provides for a
continuos "overturning" of the fuel such that new surfaces of unburned portions thereof are
continuously exposed, thereby obtaining a very clean combustion. Such a helical shape 4' may
also contribute to the discharge of the combustion gases and possible combustion residue, that
is ash, from the burner pipe 2, at Y. Thereby, the formations 4', possibly in combination with
a later described tangential secondary air supply, would serve the purpose of generating a
rotating air/fuel vortex inside the burner pipe, so that unburned particles will be present in a
hot environment along such a long and helical path that complete combustion is achieved.
An outer uninterrupted helix 3 is provided on the outer side of the burner pipe 2, likewise
extended substantially from the first end 2a to the second end 2b thereof. This outer helix 3
forms an outer feed screw serving the purpose of discharging the combustion gases formed
during combustion, upon rotation of the burner pipe 2. The combustion gases are discharged
along a helical path from the forward end 2b of the burner pipe 2 and to the connecting
portion 12 and further on to the combustion gas pipe 20. Moreover, the outer feed screw 3
serves the purpose of discharging the combustion residue that is brought out from the forward
end 2b of the burner pipe 2 and falls down onto the bottom of the substantially horizontally
provided cavity 6. This combustion residue, essentially in the form of ash, is pushed along the
bottom of the cavity 6 by the outer feed screw, in a direction towards the rear end 2a of the
burner pipe 2, until it falls down into the ash-collecting pocket 21, from which it can be
removed at regular intervals.
In the illustrated embodiment the outer feed screw 3 is formed having a differing pitch along
its length, as is clear from fig. 1. Here, the outer feed screw 3 has a decreasing pitch as seen in
a direction from the forward end 2b of the burner pipe 2 towards its rear end, and this
configuration is preferred in most cases, since the combustion gases have a higher temperature
and thereby a larger volume closer to the forward end of the burner pipe. The inner helical
formation 4'may likewise have a variable pitch.
In case an inner feed screw 4 is employed this may have a constant pitch that in itself is varied
depending upon the specific application, the employed fuel etc., since the pitch of the feed
screw in the rear area of the burner pipe 2 would determine the fuel feed rate at a fixed
rotational speed of the burner pipe 2, and thereby would determine the effective output of the
boiler.
The operation of the illustrated embodiment of the invention will now be briefly described.
Fuel is introduced from the storage container, not shown, to the burner pipe 2 through the
infeed pipe 15 and the support pipe 14. The fuel is fed into the burner pipe, in a direction
towards the combustion zone X. In this connection it shall be emphasized that the speed of the
motor 8 may be regulated by means of appropriate control equipment that forms no part of the
present invention. However, in the case where the burner is installed in an accumulator tank
the control equipment may be a simple on-off control, since the water volume of the tank
serves as a buffer and provides for reasonable operating times. In other applications it may be
justified to employ a more sophisticated control providing a continuos adjustment of the
effective output to the particular demand.
In the indicated manner primary air is supplied at the beginning of the combustion zone X
through the central pipe 11. In a manner not specifically illustrated, secondary air is supplied at
the arrows designated by L in the combustion zone, preferably through channels in the burner
pipe 2. The secondary air may advantageously be supplied in a tangential direction - with respect
to the circumference of the burner pipe - in order to cause rotation of the fuel-air mixture in the
burner pipe 2.
After the combustion zone X and the afterburning zone X1 - Y the combustion gases and ash
formed during combustion are brought out from the burner pipe 2 at Y and enter the cavity 6
in the accumulator tank 10. This cavity 6 together with the outer side of the burner pipe 2 and
the outer feed screw 3 formed there, form a combustion gas duct as well as an ash discharge
means or ash conveyor. Thus, through the rotation of the burner pipe and thereby also of the
screw 3, the combustion gases will be passed along a long helical path around the wall 7 of
the cavity so that they will be maximally cooled by the extended contact with the wall 7 in
turn being cooled by the water or a corresponding medium in the tank 10. This means that
when the combustion gases reach the connecting portion 18 and the combustion gas pipe 20
they have been cooled to such a low temperature that it does not present any problem to reach
a solution where no chimney is required for discharging the combustion gases to the
atmosphere, provided that the dimensioning and adjustment or setting is correct. As examples
of such dimensioning and setting can be mentioned the dimensioning/control of the primary
and secondary air blower, the selection of the pitch of the outer screw 3 or the radial size of
the combustion gas duct, that is the spacing between the burner pipe 2 and the outer wall 7.
Simultaneously the ash and other possible combustion residue collecting on the bottom of the
cavity 6, is discharged therefrom by the outer screw 3, to finally fall down into the ash
collecting pocket 21. In this connection, it shall be emphasized that in the drawing figures the
distance between the outer feed screw 3 and the wall 7 of the cavity 6 has been exaggerated
for the purpose of clarifying the illustration, and that the distance is in reality essentially
smaller.
In certain applications, especially in combination with an accumulator tank, where the
temperature of the combustion gases might be lowered so much that condensation within the
combustion gas duct would cause a serious problem, the pitch of the first outer helix 3 as well
as the distance between the burner pipe 2 and the duct wall 7 may be varied so that the desired
combustion gas temperature is achieved.
On the other hand, using corrosion resistant materials in combination with the provision of an
outlet for condensate, an efficient condensing burner may be designed by means of the
invention.
In view of the above description it is now clear that the characterizing feature of the invention,
in its basic scope, is the fact that the supply of fuel and the discharge of combustion gases as
well as the removal of ash is carried out generally from the same area of the installation, in
mutually opposite directions. Hereby, the burner may be designed to be very compact so that it
is very well suited for a direct installation in a water volume, the wall of which contributes to
forming the combustion gas duct. The burner may easily be installed in an accumulator tank
as a direct substitution for an electric heating element. In this manner is provided a possibility
of performing a very simple connection of the combustion gas discharge as well as of the fuel
supply.
Another advantage that is achieved by virtue of the design comprising one single moveable
part in the form of the rotary burner pipe being provided with outer and inner helixes, is a very
simple and service friendly design. Such a design is well suited for being produced as a
cassette that may be readily installed and replaced.
The feeding of the combustion gases in the helical combustion gas duct formed by the flange
is achieved through an appropriate setting and control of an appropriate separate blower or by
means of the blower performing the supply of primary and secondary air.
Furthermore, the invention is very well suited for an application in systems integrating several
heat sources and requiring an accumulation volume, such as a combination system utilizing
solar heat, solid fuel heating, preferably with pellets, and night tariff.
In an alternative use of the invention a combustion installation is provided having minimal
dimensions. This is accomplished by inserting the burner 1 into a cavity of a water cassette that
may have a minimal water volume of from for instance 10 liters and upwards. In the example of
a water volume of 10 liters the burner pipe 2 would be jacketed by a water gap of approximately
2 cm and would in practice function as a flow-through heater. This solution may well be applied
to anything from a tiled stove or an iron stove having a thin water jacket, to a boiler having a
small water volume and up to a cassette in an accumulator tank.
It will be understood by those skilled in the art that various modifications and changes may be
made to the present invention without departure from the scope thereof, which is defined by the
appended claims.