US20150104752A1

US20150104752A1 - Smokeless flare burner

Info

Publication number: US20150104752A1
Application number: US14/515,358
Authority: US
Inventors: Jerry Lang; David Scott; Bradley C. Smith
Original assignee: JLCC Inc
Current assignee: JLCC Inc
Priority date: 2013-10-15
Filing date: 2014-10-15
Publication date: 2015-04-16

Abstract

A smokeless flare burner includes a housing, an orificed gas nozzle, a conical diffuser, two or more support members, and a retention cap. The housing has a longitudinal axis, a first cylindrical portion, a first tapered portion, a second cylindrical portion, a second tapered portion. The first tapered portion, the second cylindrical portion and the second tapered portion form a venturi. The orificed gas nozzle is aligned with the longitudinal axis and disposed within the housing. The conical diffuser is aligned with the longitudinal axis and has a vertex disposed within the second tapered portion and a base substantially perpendicular to the longitudinal axis. The two or more support members are attached to the second tapered portion and the conical diffuser to create a gap. The retention cap is attached to the base of the conical diffuser and extends beyond a perimeter of the base of the conical diffuser.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and is a non-provisional of U.S. provisional patent application Ser. No. 61/891,158 filed on Oct. 15, 2013 and entitled “Smokeless Flare Burner”, which is hereby incorporated by reference in its entirety.

INCORPORATION-BY-REFERENCE OF MATERIALS FILED ON COMPACT DISC

None.

TECHNICAL FIELD OF THE INVENTION

The present invention relates generally to the field of gas combustion devices and, more particularly, to a smokeless flare burner.

STATEMENT OF FEDERALLY FUNDED RESEARCH

None.

BACKGROUND OF THE INVENTION

Oil and gas production and refining operations produce gaseous emissions, which can be poisonous, malodorous, smokey, noisey and otherwise harmful to the environment. Over the years and especially more recently, governmental regulations require proper handling of these gaseous emissions while minimizing effects on the environment.
Accordingly there is a need for a smokeless flare burner.

SUMMARY OF THE INVENTION

The present invention provides a smokeless flare burner that includes a housing, an orificed gas nozzle, a conical diffuser, two or more support members, and a retention cap. The housing has a longitudinal axis, a first cylindrical portion, a first tapered portion connected to the first cylindrical portion, a second cylindrical portion connected to the first tapered portion, and a second tapered portion connected to the second cylindrical portion. The first tapered portion, the second cylindrical portion and the second tapered portion form a venturi. The orificed gas nozzle is aligned with the longitudinal axis and disposed within the housing proximate to the first cylindrical portion and the first tapered portion of the housing. The conical diffuser is aligned with the longitudinal axis and has a vertex disposed within the second tapered portion of the housing and a base substantially perpendicular to the longitudinal axis. The two or more support members are attached to the second tapered portion of the housing and the conical diffuser to create a gap between the second tapered portion of the housing and the conical diffuser. The retention cap is attached to the base of the conical diffuser and extends beyond a perimeter of the base of the conical diffuser.
In addition, the present invention provides a smokeless flare burner that includes a housing, two or more air intake openings, an orificed gas nozzle, a conical diffuser, two or more support members, and a retention cap. The housing has a longitudinal axis, a first cylindrical portion, a first tapered portion connected to the first cylindrical portion, a second cylindrical portion connected to the first tapered portion, and a second tapered portion connected to the second cylindrical portion. The first tapered portion, the second cylindrical portion and the second tapered portion form a venturi. The two or more air intake openings are disposed within the first cylindrical portion of the housing. The orificed gas nozzle is aligned with the longitudinal axis and disposed within the housing proximate to the first cylindrical portion and the first tapered portion of the housing. The conical diffuser is aligned with the longitudinal axis, has a vertex disposed within the second tapered portion of the housing, a base substantially perpendicular to the longitudinal axis, and a shape of the conical diffuser is substantially parallel to a shape of the second tapered portion of the housing. The two or more support members are attached to the second tapered portion of the housing and the conical diffuser to create a gap between the second tapered portion of the housing and the conical diffuser. The retention cap is attached to the base of the conical diffuser, extends beyond a perimeter of the base of the conical diffuser the retention cap, and has a diameter greater than or equal to a maximum diameter of the second tapered portion of the housing.
Moreover, the present invention provides a smokeless flare burner that includes a housing, two or more air intake openings, an orificed gas nozzle, a conical diffuser, two or more support members, a retention cap, an expansion chamber and a low pressure gas nozzle. The housing has a longitudinal axis, a first cylindrical portion, a first tapered portion connected to the first cylindrical portion, a second cylindrical portion connected to the first tapered portion, and a second tapered portion connected to the second cylindrical portion. The first tapered portion, the second cylindrical portion and the second tapered portion form a venturi. The two or more air intake openings are disposed within the first cylindrical portion of the housing. The orificed gas nozzle is aligned with the longitudinal axis and disposed within the housing proximate to the first cylindrical portion and the first tapered portion of the housing. The conical diffuser is aligned with the longitudinal axis, has a vertex disposed within the second tapered portion of the housing, a base substantially perpendicular to the longitudinal axis, and a shape of the conical diffuser is substantially parallel to a shape of the second tapered portion of the housing. The two or more support members are attached to the second tapered portion of the housing and the conical diffuser to create a gap between the second tapered portion of the housing and the conical diffuser. The retention cap is attached to the base of the conical diffuser, extends beyond a perimeter of the base of the conical diffuser the retention cap, and has a diameter greater than or equal to a maximum diameter of the second tapered portion of the housing. The expansion chamber is disposed around an exterior of the second cylindrical portion and has an exit proximate to the gap between the second tapered portion of the housing and the conical diffuser. The low pressure gas nozzle is connected to the expansion chamber using a tubing.
The present invention is described in detail below with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and further advantages of the invention may be better understood by referring to the following description in conjunction with the accompanying drawings, in which:

FIG. 1 is a diagram of a smokeless flare burner mounted on a trailer in accordance with one embodiment of the present invention;

FIG. 2 is a diagram of a smokeless flare burner in accordance with one embodiment of the present invention;

FIG. 3 is a diagram of a smokeless flare burner mounted on a fixed stack in accordance with one embodiment of the present invention; and

FIG. 4 is a diagram of a dual flare burner in accordance with another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention. The discussion herein relates primarily to flare burners, but it will be understood that the concepts of the present invention are applicable to any type of burner.
Now referring to FIG. 1, a diagram of a smokeless flare burner 100 mounted on a trailer 104 in accordance with one embodiment of the present invention is shown. The smokeless flare burner 100 is attached to a stack 102 that is attached to a trailer 104. The stack 102 pivots around point 106 so that the stack 102 rests on support 108 for transport. The trailer 104 also includes a set of extendable supports 110 to prevent the trailer 104 from moving during use. The stack 102 also locks into place during use and includes one or more connections 112 that allow the stack 102 to be connected to a gas source (not shown). Note that the burner 100 is not limited to use on a trailer as shown in FIG. 3. The burner 100 can be part of a permanent installation. Moreover, the burner 100 can be disposed within a chimney or vented enclosure.
Referring now to FIG. 2, a diagram of a smokeless flare burner 100 in accordance with one embodiment of the present invention is shown. The smokeless flare burner 100 includes a housing 210, an orificed gas nozzle 212, a conical diffuser 214, two or more support members 216, and a retention cap 218. The housing 210 has a longitudinal axis 220, a first cylindrical portion 222, a first tapered portion 224 connected to the first cylindrical portion 222, a second cylindrical portion 226 connected to the first tapered portion 224, a second tapered portion 228 connected to the second cylindrical portion 226. The first tapered portion 224, the second cylindrical portion 226 and the second tapered portion 228 form a venturi. The orificed gas nozzle 212 is aligned with the longitudinal axis 220 and disposed within the housing 210 proximate to the first cylindrical portion 222 and the first tapered portion 224 of the housing 210. The conical diffuser 214 is aligned with the longitudinal axis 220 and has a vertex 230 disposed within the second tapered portion 228 of the housing 210 and a base 232 substantially perpendicular to the longitudinal axis 220. The two or more support members 216 are attached to the second tapered portion 228 of the housing 210 and the conical diffuser 214 to create a gap 234 between the second tapered portion 228 of the housing 210 and the conical diffuser 214. The retention cap 218 is attached to the base 232 of the conical diffuser 214 and extends beyond a perimeter 236 of the base 232 of the conical diffuser 214. The housing 210 and other components will typically be made of a heat resistant material, such as 310 stainless steel or other suitable material.
A gas exiting the orificed gas nozzle 212 provides a motive force that induces a flow of air 238 into the first cylindrical portion 222 of the housing 210. The flow of air 238 into the first cylindrical portion 222 of the housing 210 mixes with the gas within the housing 212 and an air outside the gap 234 completes a combustion of the gas. To provide proper operation, a flow rate of a gas exiting the orificed gas nozzle 212 should be no less than approximately 30% of a maximum flow rate of the gas. The retention cap 218 deflects the air-gas mixture to ensure a substantially complete burn of the gas.
The burner 100 may include two or more air intake openings 240 within the first cylindrical portion 222 of the housing 212. The air intake openings 240 can be slots, holes or types of openings as long as they provide a sufficient flow of air 238. Similarly, the gap 234 and/or the two or more support members 216 can be a tapered cylinder having two or more openings (e.g., slots, holes, etc.). A lower cap 242 may also be attached to the first cylindrical portion 222 substantially perpendicular to the longitudinal axis 220.
The retention cap 218 may have a diameter greater than or equal to a maximum diameter of the second tapered portion 228 of the housing 212. Moreover, the shape of the conical diffuser 214 can be substantially parallel to a shape of the second tapered portion 228 of the housing 210. In one embodiment, the burner 100 has a height to diameter ratio of between 2.0 and 2.2 to 1. In another embodiment, the burner 100 has a height to diameter ratio of approximately 2.1 to 1. The burner 100 may also have an effective cross-sectional area of the gap 234 of approximately 250 times a cross-sectional area of the orificed gas nozzle 212. In addition, the effective cross-sectional area of the gap 234 may be greater than a cross-sectional area of the second cylindrical portion 226 of the housing 212. A cross-sectional area of the second cylindrical portion 226 of the housing 210 can be approximately 35 to 40% of a cross-sectional area of the first cylindrical portion 222 of the housing 210.
The following table shows data for various burner 100 sizes in accordance with the present invention:


			BURNER	PIPE	HEIGHT	DIAMETER

FLOWS

RANGE

PRESSURE

SIZE

ESTIMATED

STOCK #	SCFD	MMBTU/h	PSI	RETROFIT	IN INCHES	IN INCHES

SBT1	100M-300M	5 to 15	30	3″ OR 4″	19	9
SBT3	300M-1 MM	15 to 50	30	3″ OR 4″	34	16
SBT1-2	1-2 MM	50 to 100	30	4″	46	22
SBT2-4	2-4 MM	100 to 200	30	6″	68	32
SBT4-6	4-6 MM	200 to 300	30	6″	83	39
SBT6-8	6-8 MM	300 to 400	30	6″	95	45
SBT8-10	8-10 MM	400 to 500	30	6″	108	51
SBT10-12	10-12 MM	500 to 600	30	8″	114	54

Now referring to FIG. 3, a diagram of a smokeless flare burner 100 mounted on a fixed stack 302 in accordance with one embodiment of the present invention is shown. The fixed stack 302 includes several sets of four guy eyelets 304. A pilot or igniter 306 is disposed proximate to the gap of the flare burner 100 and is attached to a channel (e.g., 2″) 308. In this example, the total height of the fixed stack 302 and burner 100 is 44′-3″ with a gas inlet 310 located 4′ above ground level.
Referring now to FIG. 4, a diagram of a dual pressure flare burning 400 in accordance with another embodiment of the present invention is shown. The dual pressure flare burner 400 has a similar configuration as shown in FIG. 1, but includes a low pressure gas nozzle 402, expansion chamber 404 and exit 406. The low pressure gas and high pressure gas are not manifolded together. Instead, the low pressure gas is fed into the expansion chamber 404 having a small exit 406 proximate to the high pressure gas exit (gap 234). The flare burner 400 has numerous operating advantages. For example, complete combustion will occur when high pressure gas or low pressure gas are provided to the burner 400 at different times, as well as when high pressure gas and low pressure gas streams are provided to the burner 400 at the same time. The size of the burner 400 is scalable.
The smokeless flare burner 400 includes a housing 210, an orificed high pressure gas nozzle 212, a conical diffuser 214, two or more support members 216, a retention cap 218, a low pressure gas nozzle 402, an expansion chamber 404 and an exit 406. The housing 210 has a longitudinal axis 220, a first cylindrical portion 222, a first tapered portion 224 connected to the first cylindrical portion 222, a second cylindrical portion 226 connected to the first tapered portion 224, a second tapered portion 228 connected to the second cylindrical portion 226. The first tapered portion 224, the second cylindrical portion 226 and the second tapered portion 228 form a venturi. The orificed gas nozzle 212 is aligned with the longitudinal axis 220 and disposed within the housing 210 proximate to the first cylindrical portion 222 and the first tapered portion 224 of the housing 210. The conical diffuser 214 is aligned with the longitudinal axis 220 and has a vertex 230 disposed within the second tapered portion 228 of the housing 210 and a base 232 substantially perpendicular to the longitudinal axis 220. The two or more support members 216 are attached to the second tapered portion 228 of the housing 210 and the conical diffuser 214 to create a gap 234 between the second tapered portion 228 of the housing 210 and the conical diffuser 214. The retention cap 218 is attached to the base 232 of the conical diffuser 214 and extends beyond a perimeter 236 of the base 232 of the conical diffuser 214. The expansion chamber 404 is disposed around the exterior second cylindrical portion 226. The low pressure gas nozzle 402 is connected to the expansion chamber 404 using tubing 408. The tubing 408 may include a flared portion 410 proximate to the low pressure gas nozzle 402 and an opening 412 that creates a venturi effect to mix the low pressure gas with outside air 414. The exit 406 is proximate to the gap 234 between the second tapered portion 228 of the housing 210 and the conical diffuser 214, such the a compete combustion of both the low pressure gas and the high pressure gas is provided. The low pressure nozzle 402 is fed from a low pressure supply 416 proximate to or attached to the stack 102. The housing 210 and other components will typically be made of a heat resistant material, such as 310 stainless steel or other suitable material.
A gas exiting the orificed gas nozzle 212 provides a motive force that induces a flow of air 238 into the first cylindrical portion 222 of the housing 210. The flow of air 238 into the first cylindrical portion 222 of the housing 210 mixes with the gas within the housing 212 and an air outside the gap 234 completes a combustion of the gas. To provide proper operation, a flow rate of a gas exiting the orificed gas nozzle 212 should be no less than approximately 30% of a maximum flow rate of the gas. The retention cap 218 deflects the air-gas mixture to ensure a substantially complete burn of the gas.
The burner 400 may include two or more air intake openings 240 within the first cylindrical portion 222 of the housing 212. The air intake openings 240 can be slots, holes or types of openings as long as they provide a sufficient flow of air 238. Similarly, the gap 234 and/or the two or more support members 216 can be a tapered cylinder having two or more openings (e.g., slots, holes, etc.). A lower cap 242 may also be attached to the first cylindrical portion 222 substantially perpendicular to the longitudinal axis 220.
The retention cap 218 may have a diameter greater than or equal to a maximum diameter of the second tapered portion 228 of the housing 212. Moreover, the shape of the conical diffuser 214 can be substantially parallel to a shape of the second tapered portion 228 of the housing 210. In one embodiment, the burner 400 has a height to diameter ratio of between 2.0 and 2.2 to 1. In another embodiment, the burner 400 has a height to diameter ratio of approximately 2.1 to 1. The burner 400 may also have an effective cross-sectional area of the gap 234 of approximately 250 times a cross-sectional area of the orificed gas nozzle 212. In addition, the effective cross-sectional area of the gap 234 may be greater than a cross-sectional area of the second cylindrical portion 226 of the housing 212. A cross-sectional area of the second cylindrical portion 226 of the housing 210 can be approximately 35 to 40% of a cross-sectional area of the first cylindrical portion 222 of the housing 210.
It will be understood by those of skill in the art that information and signals may be represented using any of a variety of different technologies and techniques (e.g., data, instructions, commands, information, signals, bits, symbols, and chips may be represented by voltages, currents, electromagnetic waves, magnetic fields or particles, optical fields or particles, or any combination thereof). Likewise, the various illustrative logical blocks, modules, circuits, and algorithm steps described herein may be implemented as electronic hardware, computer software, or combinations of both, depending on the application and functionality. Moreover, the various logical blocks, modules, and circuits described herein may be implemented or performed with a general purpose processor (e.g., microprocessor, conventional processor, controller, microcontroller, state machine or combination of computing devices), a digital signal processor (“DSP”), an application specific integrated circuit (“ASIC”), a field programmable gate array (“FPGA”) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. Similarly, steps of a method or process described herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art. Although preferred embodiments of the present invention have been described in detail, it will be understood by those skilled in the art that various modifications can be made therein without departing from the spirit and scope of the invention as set forth in the appended claims.

Claims

What is claimed is:

1. A burner comprising:

a housing having a longitudinal axis, a first cylindrical portion, a first tapered portion connected to the first cylindrical portion, a second cylindrical portion connected to the first tapered portion, a second tapered portion connected to the second cylindrical portion, and the first tapered portion, the second cylindrical portion and the second tapered portion form a venturi;

an orificed gas nozzle aligned with the longitudinal axis and disposed within the housing proximate to the first cylindrical portion and the first tapered portion of the housing;

a conical diffuser aligned with the longitudinal axis and having a vertex disposed within the second tapered portion of the housing and a base substantially perpendicular to the longitudinal axis;

two or more support members attached to the second tapered portion of the housing and the conical diffuser that create a gap between the second tapered portion of the housing and the conical diffuser; and

a retention cap attached to the base of the conical diffuser and extending beyond a perimeter of the base of the conical diffuser.

2. The burner as recited in claim 1, further comprising two or more air intake openings within the first cylindrical portion of the housing.

3. The burner as recited in claim 2, further comprising a lower cap attached to the first cylindrical portion substantially perpendicular to the longitudinal axis.

4. The burner as recited in claim 1, the retention cap having a diameter greater than or equal to a maximum diameter of the second tapered portion of the housing.

5. The burner as recited in claim 1, a shape of the conical diffuser is substantially parallel to a shape of the second tapered portion of the housing.

6. The burner as recited in claim 1, the two or more support members comprising a tapered cylinder having two or more exhaust openings.

7. The burner as recited in claim 1, further comprising a stack connected to the orificed gas nozzle.

8. The burner as recited in claim 1, the burner having a height to diameter ratio of between 2.0 and 2.2 to 1.

9. The burner as recited in claim 1, the burner having a height to diameter ratio of approximately 2.1 to 1.

10. The burner as recited in claim 1, an effective cross-sectional area of the gap is approximately 250 times a cross-sectional area of the orificed gas nozzle.

11. The burner as recited in claim 1, an effective cross-sectional area of the gap is greater than a cross-sectional area of the second cylindrical portion of the housing.

12. The burner as recited in claim 1, a cross-sectional area of the second cylindrical portion of the housing is approximately 35 to 40% of a cross-sectional area of the first cylindrical portion of the housing.

13. The burner as recited in claim 1, wherein a gas exiting the orificed gas nozzle provides a motive force that induces a flow of air into the first cylindrical portion of the housing.

14. The burner as recited in claim 13, wherein the flow of air into the first cylindrical portion of the housing mixes with the gas within the housing and an air outside the gap completes a combustion of the gas.

15. The burner as recited in claim 1, further comprising a pilot or igniter disposed proximate to the gap.

16. The burner as recited in claim 1, a flow rate of a gas exiting the orificed gas nozzle is no less than approximately 30% of a maximum flow rate of the gas.

17. The burner as recited in claim 1, the housing disposed within a chimney or vented enclosure.

18. The burner as recited in claim 1, further comprising:

an expansion chamber disposed around an exterior of the second cylindrical portion and having an exit proximate to the gap between the second tapered portion of the housing and the conical diffuser; and

a low pressure gas nozzle connected to the expansion chamber using a tubing.

19. The burner as recited in claim 18, the tubing includes a flared portion proximate to the low pressure gas nozzle and an opening that creates a venturi effect to mix a low pressure gas with an outside air.

20. The burner as recited in claim 18, the burner operates using a high pressure gas only, a low pressure gas only, or both the high pressure gas and the low pressure gas.

21. A burner comprising:

two or more support members attached to the second tapered portion of the housing and the conical diffuser that create a gap between the second tapered portion of the housing and the conical diffuser;

a retention cap attached to the base of the conical diffuser and extending beyond a perimeter of the base of the conical diffuser;

a low pressure gas nozzle connected to the expansion chamber using a tubing.

22. The burner as recited in claim 21, the tubing includes a flared portion proximate to the low pressure gas nozzle and an opening that creates a venturi effect to mix a low pressure gas with an outside air.

23. The burner as recited in claim 21, the burner operates using a high pressure gas only, a low pressure gas only, or both the high pressure gas and the low pressure gas.

24. A burner comprising:

two or more air intake openings within the first cylindrical portion of the housing;

a conical diffuser aligned with the longitudinal axis, having a vertex disposed within the second tapered portion of the housing, a base substantially perpendicular to the longitudinal axis, and a shape of the conical diffuser is substantially parallel to a shape of the second tapered portion of the housing;

a retention cap attached to the base of the conical diffuser, extending beyond a perimeter of the base of the conical diffuser the retention cap, and having a diameter greater than or equal to a maximum diameter of the second tapered portion of the housing.

25. The burner as recited in claim 24, further comprising a lower cap attached to the first cylindrical portion substantially perpendicular to the longitudinal axis.

26. The burner as recited in claim 24, the two or more support members comprising a tapered cylinder having two or more exhaust openings.

27. The burner as recited in claim 24, further comprising a stack connected to the orificed gas nozzle.

28. The burner as recited in claim 24, the burner having a height to diameter ratio of between 2.0 and 2.2 to 1.

29. The burner as recited in claim 24, the burner having a height to diameter ratio of approximately 2.1 to 1.

30. The burner as recited in claim 24, an effective cross-sectional area of the gap is approximately 250 times a cross-sectional area of the orificed gas nozzle.

31. The burner as recited in claim 24, an effective cross-sectional area of the gap is greater than a cross-sectional area of the second cylindrical portion of the housing.

32. The burner as recited in claim 24, a cross-sectional area of the second cylindrical portion of the housing is approximately 35 to 40% of a cross-sectional area of the first cylindrical portion of the housing.

33. The burner as recited in claim 24, wherein a gas exiting the orificed gas nozzle provides a motive force that induces a flow of air into the first cylindrical portion of the housing.

34. The burner as recited in claim 33, wherein the flow of air into the first cylindrical portion of the housing mixes with the gas within the housing and an air outside the gap completes a combustion of the gas.

35. The burner as recited in claim 24, further comprising a pilot or igniter disposed proximate to the gap.

36. The burner as recited in claim 24, a flow rate of a gas exiting the orificed gas nozzle is no less than approximately 30% of a maximum flow rate of the gas.

37. The burner as recited in claim 24, the housing disposed within a chimney or vented enclosure.

38. The burner as recited in claim 24, further comprising:

a low pressure gas nozzle connected to the expansion chamber using a tubing.

39. The burner as recited in claim 38, wherein the tubing includes a flared portion proximate to the low pressure gas nozzle and an opening that creates a venturi effect to mix a low pressure gas with an outside air.

40. The burner as recited in claim 38, wherein the burner operates using a high pressure gas only, a low pressure gas only, or both the high pressure gas and the low pressure gas.