US20190049107A1 - High output porous tile burner - Google Patents
High output porous tile burner Download PDFInfo
- Publication number
- US20190049107A1 US20190049107A1 US16/160,145 US201816160145A US2019049107A1 US 20190049107 A1 US20190049107 A1 US 20190049107A1 US 201816160145 A US201816160145 A US 201816160145A US 2019049107 A1 US2019049107 A1 US 2019049107A1
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- United States
- Prior art keywords
- flame holder
- perforated flame
- fuel
- combustion
- fuel stream
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D11/00—Burners using a direct spraying action of liquid droplets or vaporised liquid into the combustion space
- F23D11/36—Details, e.g. burner cooling means, noise reduction means
- F23D11/40—Mixing tubes or chambers; Burner heads
- F23D11/406—Flame stabilising means, e.g. flame holders
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN A CARRIER GAS OR AIR
- F23C9/00—Combustion apparatus characterised by arrangements for returning combustion products or flue gases to the combustion chamber
- F23C9/06—Combustion apparatus characterised by arrangements for returning combustion products or flue gases to the combustion chamber for completing combustion
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN A CARRIER GAS OR AIR
- F23C99/00—Subject-matter not provided for in other groups of this subclass
- F23C99/001—Applying electric means or magnetism to combustion
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D11/00—Burners using a direct spraying action of liquid droplets or vaporised liquid into the combustion space
- F23D11/36—Details, e.g. burner cooling means, noise reduction means
- F23D11/38—Nozzles; Cleaning devices therefor
- F23D11/383—Nozzles; Cleaning devices therefor with swirl means
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
- F23D14/02—Premix gas burners, i.e. in which gaseous fuel is mixed with combustion air upstream of the combustion zone
- F23D14/04—Premix gas burners, i.e. in which gaseous fuel is mixed with combustion air upstream of the combustion zone induction type, e.g. Bunsen burner
- F23D14/10—Premix gas burners, i.e. in which gaseous fuel is mixed with combustion air upstream of the combustion zone induction type, e.g. Bunsen burner with elongated tubular burner head
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
- F23D14/12—Radiant burners
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
- F23D14/12—Radiant burners
- F23D14/14—Radiant burners using screens or perforated plates
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
- F23D14/46—Details, e.g. noise reduction means
- F23D14/70—Baffles or like flow-disturbing devices
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D2212/00—Burner material specifications
- F23D2212/10—Burner material specifications ceramic
- F23D2212/103—Fibres
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23N—REGULATING OR CONTROLLING COMBUSTION
- F23N2229/00—Flame sensors
- F23N2229/20—Camera viewing
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23N—REGULATING OR CONTROLLING COMBUSTION
- F23N5/00—Systems for controlling combustion
- F23N5/02—Systems for controlling combustion using devices responsive to thermal changes or to thermal expansion of a medium
- F23N5/022—Systems for controlling combustion using devices responsive to thermal changes or to thermal expansion of a medium using electronic means
Definitions
- 15/235,517 is also a Continuation-in-Part application of co-pending U.S. patent application Ser. No. 15/215,401, entitled “LOW NO x FIRE TUBE BOILER,” filed Jul. 20, 2016 (docket number 2651-205-03).
- Co-pending U.S. patent application Ser. No. 15/215,401 claims priority benefit to International Patent Application No. PCT/US2015/012843, entitled “LOW NO x FIRE TUBE BOILER,” filed Jan. 26, 2015 (docket number 2651-205-04), now expired.
- International Patent Application No. PCT/US2015/012843 claims priority benefit to U.S. Provisional Patent Application No.
- Ceramic tile burners having some degree of porosity may be used as flame holders and radiant heat sources in a variety of applications.
- a fuel stream including a fuel component and an oxidant component is introduced at an input face of a ceramic tile burner, where the fuel stream passes into channels or pores of the ceramic tile.
- the fuel stream may begin combusting while inside the porous tile, or may combust as it passes out of an output face of the porous tile.
- U.S. Pat. No. 4,919,605 to Sarkisian, explains that “at low surface heat loads, ceramic tiles act as radiant burners. Combustion of gaseous reactants . . . takes place within the ceramic tile, and the tile becomes radiant. Ignition of the incoming reactants is caused by the high temperature of the ceramic [tile].”
- Sarkisian proposes a tile burner with a wire mesh positioned over the output face to act as a flame holder. Using this arrangement with a tile burner having a porosity of 70%, Sarkisian reports surface loading rates as high as 6500 BTU/H/in 2 (0.94 MBTU/H/ft 2 ).
- FIG. 1 is a flow chart showing a method for operating a burner including a perforated flame holder, according to an embodiment.
- FIG. 2 is a simplified perspective view of a burner system including a perforated flame holder, according to an embodiment.
- FIG. 3 is a side sectional diagram of a portion of the perforated flame holder of FIG. 2 , according to an embodiment.
- FIG. 4 is a flow chart showing a method for operating a burner system including the perforated flame holder of FIGS. 2 and 3 , according to an embodiment.
- FIG. 5 is a simplified side sectional view of the burner system of FIG. 2 , according to an embodiment.
- FIG. 6 shows a detail of the burner system of FIG. 5 , as indicated at 3 in FIG. 5 , according to an embodiment.
- FIGS. 7 and 8 are diagrammatic views of a burner system during respective modes of operation, according to an embodiment.
- FIGS. 9-12 are flowcharts of methods of operating a burner system, according to respective embodiments.
- FIG. 13A is a simplified perspective view of a combustion system, including a reticulated ceramic perforated flame holder, according to an embodiment.
- FIG. 13B is a simplified side sectional diagram of a portion of the reticulated ceramic perforated flame holder of FIG. 13A , according to an embodiment.
- BTU/H indicates a value in British thermal units per hour.
- BTU/H/ft 2 indicates a value of British thermal units per hour, per square foot.
- FIG. 1 is a flow chart showing a method 100 for operating a burner including a perforated flame holder (e.g., see FIGS. 2-3, 102 ), according to an embodiment.
- a perforated flame holder is supported in a combustion volume away from a fuel nozzle at a dilution distance (D D ), described below.
- the perforated flame holder is preheated to an operating temperature.
- a fuel and oxidant mixture is provided to the perforated flame holder, as shown in step 108 .
- the fuel and oxidant combusts and may further heat the perforated flame holder.
- the initial combustion rate may optionally be low-to-moderate but not high.
- the rate of flow of the fuel and oxidant mixture is increased to a desired heat output level.
- the perforated flame holder may support a combustion reaction having a heat output of at least 216 thousand BTU per hour per square foot.
- the perforated flame holder 102 may have an input face 212 and an output face 214 .
- the area of the output face 214 (and/or the input face 212 ) is the area referred to in the heat output rates described herein.
- the inventors have discovered that during a start-up procedure, the fuel flow rate may be increased, and the perforated flame holder 102 may reliably support combustion at a high fuel and oxidant mixture flow rate with combustion heat output rates of equal to or greater than 1 million BTU per hour per square foot of output face 214 area of the perforated flame holder 102 .
- FIG. 2 is a simplified diagram of a burner system 200 including a perforated flame holder 102 configured to hold a combustion reaction, according to an embodiment.
- a perforated flame holder 102 configured to hold a combustion reaction
- the terms perforated flame holder, perforated reaction holder, porous flame holder, porous reaction holder, duplex, and duplex tile shall be considered synonymous unless further definition is provided.
- perforated flame holders 102 described herein can support very clean combustion. Specifically, in experimental use of systems 200 ranging from pilot scale to full scale, output of oxides of nitrogen (NOx) was measured to range from low single digit parts per million (ppm) down to undetectable (less than 1 ppm) concentration of NOx at the stack. These remarkable results were measured at 3% (dry) oxygen (O 2 ) concentration with undetectable carbon monoxide (CO) at stack temperatures typical of industrial furnace applications (1400-1600° F.).
- NOx oxides of nitrogen
- the burner system 200 includes a fuel and oxidant source 202 disposed to output fuel and oxidant into a combustion volume 204 to form a fuel and oxidant mixture 206 .
- fuel and oxidant mixture and fuel stream may be used interchangeably and considered synonymous depending on the context, unless further definition is provided.
- combustion volume, combustion chamber, furnace volume, and the like shall be considered synonymous unless further definition is provided.
- the perforated flame holder 102 is disposed in the combustion volume 204 and positioned to receive the fuel and oxidant mixture 206 .
- FIG. 3 is a side sectional diagram 300 of a portion of the perforated flame holder 102 of FIGS. 1 and 2 , according to an embodiment.
- the perforated flame holder 102 includes a perforated flame holder body 208 defining a plurality of perforations 210 aligned to receive the fuel and oxidant mixture 206 from the fuel and oxidant source 202 .
- the terms perforation, pore, aperture, elongated aperture, and the like, in the context of the perforated flame holder 102 shall be considered synonymous unless further definition is provided.
- the perforations 210 are configured to collectively hold a combustion reaction 302 supported by the fuel and oxidant mixture 206 .
- the fuel can include hydrogen, a hydrocarbon gas, a vaporized hydrocarbon liquid, an atomized hydrocarbon liquid, or a powdered or pulverized solid.
- the fuel can be a single species or can include a mixture of gas(es), vapor(s), atomized liquid(s), and/or pulverized solid(s).
- the fuel in a process heater application the fuel can include fuel gas or byproducts from the process that include carbon monoxide (CO), hydrogen (H 2 ), and methane (CH 4 ).
- the fuel can include natural gas (mostly CH 4 ) or propane (C 3 H 8 ).
- the fuel can include #2 fuel oil or #6 fuel oil. Dual fuel applications and flexible fuel applications are similarly contemplated by the inventors.
- the oxidant can include oxygen carried by air, flue gas, and/or can include another oxidant, either pure or carried by a carrier gas.
- the terms oxidant and oxidizer shall be considered synonymous herein.
- the perforated flame holder body 208 can be bounded by an input face 212 disposed to receive the fuel and oxidant mixture 206 , an output face 214 facing away from the fuel and oxidant source 202 , and a peripheral surface 216 defining a lateral extent of the perforated flame holder 102 .
- the plurality of perforations 210 which are defined by the perforated flame holder body 208 extend from the input face 212 to the output face 214 .
- the plurality of perforations 210 can receive the fuel and oxidant mixture 206 at the input face 212 .
- the fuel and oxidant mixture 206 can then combust in or near the plurality of perforations 210 and combustion products can exit the plurality of perforations 210 at or near the output face 214 .
- the perforated flame holder 102 is configured to hold a majority of the combustion reaction 302 within the perforations 210 .
- more than half the molecules of fuel output into the combustion volume 204 by the fuel and oxidant source 202 may be converted to combustion products between the input face 212 and the output face 214 of the perforated flame holder 102 .
- more than half of the heat or thermal energy output by the combustion reaction 302 may be output between the input face 212 and the output face 214 of the perforated flame holder 102 .
- the terms heat, heat energy, and thermal energy shall be considered synonymous unless further definition is provided.
- heat energy and thermal energy refer generally to the released chemical energy initially held by reactants during the combustion reaction 302 .
- heat, heat energy and thermal energy correspond to a detectable temperature rise undergone by real bodies characterized by heat capacities.
- the perforations 210 can be configured to collectively hold at least 80% of the combustion reaction 302 between the input face 212 and the output face 214 of the perforated flame holder 102 .
- the inventors produced a combustion reaction 302 that was apparently wholly contained in the perforations 210 between the input face 212 and the output face 214 of the perforated flame holder 102 .
- the perforated flame holder 102 can support combustion between the input face 212 and output face 214 when combustion is “time-averaged.” For example, during transients, such as before the perforated flame holder 102 is fully heated, or if too high a (cooling) load is placed on the system, the combustion may travel somewhat downstream from the output face 214 of the perforated flame holder 102 . Alternatively, if the cooling load is relatively low and/or the furnace temperature reaches a high level, the combustion may travel somewhat upstream of the input face 212 of the perforated flame holder 102 .
- Such transient huffing or flashback is generally short in duration such that, on a time-averaged basis, a majority of combustion occurs within the perforations 210 of the perforated flame holder 102 , between the input face 212 and the output face 214 .
- the inventors have noted apparent combustion occurring downstream from the output face 214 of the perforated flame holder 102 , but still a majority of combustion occurred within the perforated flame holder 102 as evidenced by continued visible glow from the perforated flame holder 102 that was observed.
- the perforated flame holder 102 can be configured to receive heat from the combustion reaction 302 and output a portion of the received heat as thermal radiation 304 to heat-receiving structures (e.g., furnace walls and/or radiant section working fluid tubes) in or adjacent to the combustion volume 204 .
- heat-receiving structures e.g., furnace walls and/or radiant section working fluid tubes
- terms such as radiation, thermal radiation, radiant heat, heat radiation, etc. are to be construed as being substantially synonymous, unless further definition is provided. Specifically, such terms refer to blackbody-type radiation of electromagnetic energy, primarily at infrared wavelengths, but also at visible wavelengths owing to elevated temperature of the perforated flame holder body 208 .
- the perforated flame holder 102 outputs another portion of the received heat to the fuel and oxidant mixture 206 received at the input face 212 of the perforated flame holder 102 .
- the perforated flame holder body 208 may receive heat from the combustion reaction 302 at least in heat receiving regions 306 of perforation walls 308 .
- Experimental evidence has suggested to the inventors that the position of the heat receiving regions 306 , or at least the position corresponding to a maximum rate of receipt of heat, can vary along the length of the perforation walls 308 .
- the location of maximum receipt of heat was apparently between 1 ⁇ 3 and 1 ⁇ 2 of the distance from the input face 212 to the output face 214 (i.e., somewhat nearer to the input face 212 than to the output face 214 ).
- the perforated flame holder body 208 can be characterized by a heat capacity.
- the perforated flame holder body 208 may hold thermal energy from the combustion reaction 302 in an amount corresponding to the heat capacity multiplied by temperature rise, and transfer the thermal energy from the heat receiving regions 306 to heat output regions 310 of the perforation walls 308 .
- the heat output regions 310 are nearer to the input face 212 than are the heat receiving regions 306 .
- the perforated flame holder body 208 can transfer heat from the heat receiving regions 306 to the heat output regions 310 via thermal radiation, depicted graphically as 304 .
- the perforated flame holder body 208 can transfer heat from the heat receiving regions 306 to the heat output regions 310 via heat conduction along heat conduction paths 312 .
- the inventors contemplate that multiple heat transfer mechanisms including conduction, radiation, and possibly convection may be operative in transferring heat from the heat receiving regions 306 to the heat output regions 310 .
- the perforated flame holder 102 may act as a heat source to maintain the combustion reaction 302 , even under conditions where a combustion reaction 302 would not be stable when supported from a conventional flame holder.
- the perforated flame holder 102 causes the combustion reaction 302 to begin within thermal boundary layers 314 formed adjacent to walls 308 of the perforations 210 .
- combustion is generally understood to include a large number of individual reactions, and since a large portion of combustion energy is released within the perforated flame holder 102 , it is apparent that at least a majority of the individual reactions occur within the perforated flame holder 102 .
- the flow is split into portions that respectively travel through individual perforations 210 .
- the hot perforated flame holder body 208 transfers heat to the fluid, notably within thermal boundary layers 314 that progressively thicken as more and more heat is transferred to the incoming fuel and oxidant mixture 206 .
- a combustion temperature e.g., the auto-ignition temperature of the fuel
- the reactants continue to flow while a chemical ignition delay time elapses, over which time the combustion reaction 302 occurs. Accordingly, the combustion reaction 302 is shown as occurring within the thermal boundary layers 314 .
- the thermal boundary layers 314 merge at a merger point 316 .
- the merger point 316 lies between the input face 212 and output face 214 that define the ends of the perforations 210 .
- the combustion reaction 302 outputs more heat to the perforated flame holder body 208 than it receives from the perforated flame holder body 208 .
- the heat is received at the heat receiving region 306 , is held by the perforated flame holder body 208 , and is transported to the heat output region 310 nearer to the input face 212 , where the heat is transferred into the cool reactants (and any included diluent) to bring the reactants to the ignition temperature.
- each of the perforations 210 is characterized by a length L defined as a reaction fluid propagation path length between the input face 212 and the output face 214 of the perforated flame holder 102 .
- the term reaction fluid refers to matter that travels through a perforation 210 .
- the reaction fluid includes the fuel and oxidant mixture 206 (optionally including nitrogen, flue gas, and/or other “non-reactive” species).
- the reaction fluid may include plasma associated with the combustion reaction 302 , molecules of reactants and their constituent parts, any non-reactive species, reaction intermediates (including transition states), and reaction products.
- the reaction fluid may include reaction products and byproducts, non-reactive gas, and excess oxidant.
- the plurality of perforations 210 can be each characterized by a transverse dimension D between opposing perforation walls 308 .
- the inventors have found that stable combustion can be maintained in the perforated flame holder 102 if the length L of each perforation 210 is at least four times the transverse dimension D of the perforation. In other embodiments, the length L can be greater than six times the transverse dimension D. For example, experiments have been run where L is at least eight, at least twelve, at least sixteen, and at least twenty-four times the transverse dimension D.
- the length L is sufficiently long for thermal boundary layers 314 to form adjacent to the perforation walls 308 in a reaction fluid flowing through the perforations 210 to converge at merger points 316 within the perforations 210 between the input face 212 and the output face 214 of the perforated flame holder 102 .
- L/D ratios between 12 and 48 to work well (i.e., produce low NOx, produce low CO, and maintain stable combustion).
- the perforated flame holder body 208 can be configured to convey heat between adjacent perforations 210 .
- the heat conveyed between adjacent perforations 210 can be selected to cause heat output from the combustion reaction portion 302 in a first perforation 210 to supply heat to stabilize a combustion reaction portion 302 in an adjacent perforation 210 .
- the fuel and oxidant source 202 can further include a fuel nozzle 218 , configured to output fuel, and an oxidant source 220 configured to output a fluid including the oxidant.
- the fuel nozzle 218 can be configured to output pure fuel.
- the oxidant source 220 can be configured to output combustion air carrying oxygen, and optionally, flue gas.
- the perforated flame holder 102 can be held by a perforated flame holder support structure 222 configured to hold the perforated flame holder 102 at a dilution distance D D away from the fuel nozzle 218 .
- the fuel nozzle 218 can be configured to emit a fuel jet selected to entrain the oxidant to form the fuel and oxidant mixture 206 as the fuel jet and oxidant travel along a path to the perforated flame holder 102 through the dilution distance D D between the fuel nozzle 218 and the perforated flame holder 102 .
- the oxidant or combustion air source can be configured to entrain the fuel and the fuel and oxidant travel through the dilution distance D D .
- a flue gas recirculation path 224 can be provided.
- the fuel nozzle 218 can be configured to emit a fuel jet selected to entrain the oxidant and to entrain flue gas as the fuel jet travels through the dilution distance D D between the fuel nozzle 218 and the input face 212 of the perforated flame holder 102 .
- the fuel nozzle 218 can be configured to emit the fuel through one or more fuel orifices 226 having an inside diameter dimension that is referred to as “nozzle diameter.”
- the perforated flame holder support structure 222 can support the perforated flame holder 102 to receive the fuel and oxidant mixture 206 at the distance D D away from the fuel nozzle 218 greater than 20 times the nozzle diameter.
- the perforated flame holder 102 is disposed to receive the fuel and oxidant mixture 206 at the distance D D away from the fuel nozzle 218 between 100 times and 1100 times the nozzle diameter.
- the perforated flame holder support structure 222 is configured to hold the perforated flame holder 102 at a distance about 200 times or more of the nozzle diameter away from the fuel nozzle 218 .
- the fuel and oxidant mixture 206 travels about 200 times the nozzle diameter or more, the mixture is sufficiently homogenized to cause the combustion reaction 302 to produce minimal NOx.
- the fuel and oxidant source 202 can alternatively include a premix fuel and oxidant source, according to an embodiment.
- a premix fuel and oxidant source can include a premix chamber (not shown), a fuel nozzle configured to output fuel into the premix chamber, and an oxidant (e.g., combustion air) channel configured to output the oxidant into the premix chamber.
- a flame arrestor can be disposed between the premix fuel and oxidant source and the perforated flame holder 102 and be configured to prevent flame flashback into the premix fuel and oxidant source.
- the oxidant source 220 can include a blower configured to force the oxidant through the fuel and oxidant source 202 .
- the support structure 222 can be configured to support the perforated flame holder 102 from a floor or wall (not shown) of the combustion volume 204 , for example. In another embodiment, the support structure 222 supports the perforated flame holder 102 from the fuel and oxidant source 202 . Alternatively, the support structure 222 can suspend the perforated flame holder 102 from an overhead structure (such as a flue, in the case of an up-fired system). The support structure 222 can support the perforated flame holder 102 in various orientations and directions.
- the perforated flame holder 102 can include a single perforated flame holder body 208 .
- the perforated flame holder 102 can include a plurality of adjacent perforated flame holder sections that collectively provide a tiled perforated flame holder 102 .
- the perforated flame holder support structure 222 can be configured to support the plurality of perforated flame holder sections.
- the perforated flame holder support structure 222 can include a metal superalloy, a cementatious, and/or ceramic refractory material.
- the plurality of adjacent perforated flame holder sections can be joined with a fiber reinforced refractory cement.
- the perforated flame holder 102 can have a width dimension W between opposite sides of the peripheral surface 216 at least twice a thickness dimension T between the input face 212 and the output face 214 . In another embodiment, the perforated flame holder 102 can have a width dimension W between opposite sides of the peripheral surface 216 at least three times, at least six times, or at least nine times the thickness dimension T between the input face 212 and the output face 214 of the perforated flame holder 102 .
- the perforated flame holder 102 can have a width dimension W less than a width of the combustion volume 204 . This can allow the flue gas circulation path 224 from above to below the perforated flame holder 102 to lie between the peripheral surface 216 of the perforated flame holder 102 and the combustion volume wall (not shown).
- the perforations 210 can be of various shapes.
- the perforations 210 can include elongated squares, each having a transverse dimension D between opposing sides of the squares.
- the perforations 210 can include elongated hexagons, each having a transverse dimension D between opposing sides of the hexagons.
- the perforations 210 can include hollow cylinders, each having a transverse dimension D corresponding to a diameter of the cylinder.
- the perforations 210 can include truncated cones or truncated pyramids (e.g., frustums), each having a transverse dimension D radially symmetric relative to a length axis that extends from the input face 212 to the output face 214 .
- the perforations 210 can each have a lateral dimension D equal to or greater than a quenching distance of the flame based on standard reference conditions.
- the perforations 210 may have lateral dimension D less then than a standard reference quenching distance.
- each of the plurality of perforations 210 has a lateral dimension D between 0.05 inch and 1.0 inch.
- each of the plurality of perforations 210 has a lateral dimension D between 0.1 inch and 0.5 inch.
- the plurality of perforations 210 can each have a lateral dimension D of about 0.2 to 0.4 inch.
- the void fraction of a perforated flame holder 102 is defined as the total volume of all perforations 210 in a section of the perforated flame holder 102 divided by a total volume of the perforated flame holder 102 including body 208 and perforations 210 .
- the perforated flame holder 102 should have a void fraction between 0.10 and 0.90.
- the perforated flame holder 102 can have a void fraction between 0.30 and 0.80.
- the perforated flame holder 102 can have a void fraction of about 0.70. Using a void fraction of about 0.70 was found to be especially effective for producing very low NOx.
- the perforated flame holder 102 can be formed from a fiber reinforced cast refractory material and/or a refractory material such as an aluminum silicate material.
- the perforated flame holder 102 can be formed to include mullite or cordierite.
- the perforated flame holder body 208 can include a metal superalloy such as Inconel or Hastelloy.
- the perforated flame holder body 208 can define a honeycomb. Honeycomb is an industrial term of art that need not strictly refer to a hexagonal cross section and most usually includes cells of square cross section. Honeycombs of other cross sectional areas are also known.
- the perforated flame holder 102 can be formed from VERSAGRID® ceramic honeycomb, available from Applied Ceramics, Inc. of Doraville, S.C.
- the perforations 210 can be parallel to one another and normal to the input and output faces 212 , 214 . In another embodiment, the perforations 210 can be parallel to one another and formed at an angle relative to the input and output faces 212 , 214 . In another embodiment, the perforations 210 can be non-parallel to one another. In another embodiment, the perforations 210 can be non-parallel to one another and non-intersecting. In another embodiment, the perforations 210 can be intersecting.
- the body 308 can be one piece or can be formed from a plurality of sections.
- the perforated flame holder 102 may be formed from reticulated ceramic material.
- reticulated refers to a netlike structure. Reticulated ceramic material is often made by dissolving a slurry into a sponge of specified porosity, allowing the slurry to harden, and burning away the sponge and curing the ceramic.
- the perforated flame holder 102 may be formed from a ceramic material that has been punched, bored or cast to create channels.
- the perforated flame holder 102 can include a plurality of tubes or pipes bundled together.
- the plurality of perforations 210 can include hollow cylinders and can optionally also include interstitial spaces between the bundled tubes.
- the plurality of tubes can include ceramic tubes. Refractory cement can be included between the tubes and configured to adhere the tubes together.
- the plurality of tubes can include metal (e.g., superalloy) tubes.
- the plurality of tubes can be held together by a metal tension member circumferential to the plurality of tubes and arranged to hold the plurality of tubes together.
- the metal tension member can include stainless steel, a superalloy metal wire, and/or a superalloy metal band.
- the perforated flame holder body 208 can alternatively include stacked perforated sheets of material, each sheet having openings that connect with openings of subjacent and superjacent sheets.
- the perforated sheets can include perforated metal sheets, ceramic sheets and/or expanded sheets.
- the perforated flame holder body 208 can include discontinuous packing bodies such that the perforations 210 are formed in the interstitial spaces between the discontinuous packing bodies.
- the discontinuous packing bodies include structured packing shapes.
- the discontinuous packing bodies include random packing shapes.
- the discontinuous packing bodies can include ceramic Raschig ring, ceramic Berl saddles, ceramic Intalox saddles, and/or metal rings or other shapes (e.g. Super Raschig Rings) that may be held together by a metal cage.
- burner systems including the perforated flame holder 102 provide such clean combustion.
- the perforated flame holder 102 may act as a heat source to maintain a combustion reaction even under conditions where a combustion reaction would not be stable when supported by a conventional flame holder. This capability can be leveraged to support combustion using a leaner fuel-to-oxidant mixture than is typically feasible.
- an average fuel-to-oxidant ratio of the fuel stream 206 is below a (conventional) lower combustion limit of the fuel component of the fuel stream 206 —lower combustion limit defines the lowest concentration of fuel at which a fuel and oxidant mixture 206 will burn when exposed to a momentary ignition source under normal atmospheric pressure and an ambient temperature of 25° C. (77° F.).
- the perforated flame holder 102 and systems including the perforated flame holder 102 described herein were found to provide substantially complete combustion of CO (single digit ppm down to undetectable, depending on experimental conditions), while supporting low NOx. According to one interpretation, such a performance can be achieved due to a sufficient mixing used to lower peak flame temperatures (among other strategies). Flame temperatures tend to peak under slightly rich conditions, which can be evident in any diffusion flame that is insufficiently mixed. By sufficiently mixing, a homogenous and slightly lean mixture can be achieved prior to combustion. This combination can result in reduced flame temperatures, and thus reduced NOx formation.
- “slightly lean” may refer to 3% O 2 , i.e. an equivalence ratio of ⁇ 0.87. Use of even leaner mixtures is possible, but may result in elevated levels of O 2 .
- perforation walls 308 may act as a heat sink for the combustion fluid. This effect may alternatively or additionally reduce combustion temperatures and lower NOx.
- production of NOx can be reduced if the combustion reaction 302 occurs over a very short duration of time.
- Rapid combustion causes the reactants (including oxygen and entrained nitrogen) to be exposed to NOx-formation temperature for a time too short for NOx formation kinetics to cause significant production of NOx.
- the time required for the reactants to pass through the perforated flame holder 102 is very short compared to a conventional flame.
- the low NOx production associated with perforated flame holder combustion may thus be related to the short duration of time required for the reactants (and entrained nitrogen) to pass through the perforated flame holder 102 .
- FIG. 4 is a flow chart showing a method 400 for operating a burner system including the perforated flame holder shown and described herein.
- the perforated flame holder is first heated to a temperature sufficient to maintain combustion of the fuel and oxidant mixture.
- the method 400 begins with step 106 , wherein the perforated flame holder is preheated to a start-up temperature, T S . After the perforated flame holder is raised to the start-up temperature, the method proceeds to step 404 , wherein fuel and oxidant are provided to the perforated flame holder and combustion is held by the perforated flame holder.
- step 106 begins with step 406 , wherein start-up energy is provided at the perforated flame holder. Simultaneously or following providing start-up energy, a decision step 408 determines whether the temperature T of the perforated flame holder is at or above the start-up temperature, T S . As long as the temperature of the perforated flame holder is below its start-up temperature, the method loops between steps 406 and 408 within the preheat step 106 .
- step 408 if the temperature T of at least a predetermined portion of the perforated flame holder is greater than or equal to the start-up temperature, the method 400 proceeds to overall step 404 , wherein fuel and oxidant is supplied to and combustion is held by the perforated flame holder.
- Step 404 may be broken down into several discrete steps, at least some of which may occur simultaneously.
- a fuel and oxidant mixture is provided to the perforated flame holder, as shown in step 108 .
- the fuel and oxidant may be provided by a fuel and oxidant source that includes a separate fuel nozzle and combustion air source, for example.
- the fuel and combustion air are output in one or more directions selected to cause the fuel and combustion air mixture to be received by an input face of the perforated flame holder.
- the fuel may entrain the combustion air (or alternatively, the combustion air may dilute the fuel) to provide a fuel and oxidant mixture at the input face of the perforated flame holder at a fuel dilution selected for a stable combustion reaction that can be held within the perforations of the perforated flame holder.
- step 412 the combustion reaction is held by the perforated flame holder.
- heat may be output from the perforated flame holder.
- the heat output from the perforated flame holder may be used to power an industrial process, heat a working fluid, generate electricity, or provide motive power, for example.
- step 416 the presence of combustion may be sensed.
- Various sensing approaches have been used and are contemplated by the inventors.
- combustion held by the perforated flame holder is very stable and no unusual sensing requirement is placed on the system.
- Combustion sensing may be performed using an infrared sensor, a video sensor, an ultraviolet sensor, a charged species sensor, thermocouple, thermopile, and/or other known combustion sensing apparatuses.
- a pilot flame or other ignition source may be provided to cause ignition of the fuel and oxidant mixture in the event combustion is lost at the perforated flame holder.
- step 418 if combustion is sensed not to be stable, the method 400 may exit to step 424 , wherein an error procedure is executed.
- the error procedure may include turning off fuel flow, re-executing the preheating step 106 , outputting an alarm signal, igniting a stand-by combustion system, or other steps.
- step 418 combustion in the perforated flame holder is determined to be stable
- the method 400 proceeds to decision step 420 , wherein it is determined if combustion parameters should be changed. If no combustion parameters are to be changed, the method loops (within step 404 ) back to step 108 , and the combustion process continues. If a change in combustion parameters is indicated, the method 400 proceeds to step 422 , wherein the combustion parameter change is executed. After changing the combustion parameter(s), the method loops (within step 404 ) back to step 108 , and combustion continues.
- Combustion parameters may be scheduled to be changed, for example, if a change in heat demand is encountered. For example, if less heat is required (e.g., due to decreased electricity demand, decreased motive power requirement, or lower industrial process throughput), the fuel and oxidant flow rate may be decreased in step 422 . Conversely, if heat demand is increased, then fuel and oxidant flow may be increased. Additionally or alternatively, if the combustion system is in a start-up mode, then fuel and oxidant flow may be gradually increased to the perforated flame holder over one or more iterations of the loop within step 404 .
- the burner system 200 includes a heater 228 operatively coupled to the perforated flame holder 102 .
- the perforated flame holder 102 operates by outputting heat to the incoming fuel and oxidant mixture 206 . After combustion is established, this heat is provided by the combustion reaction 302 ; but before combustion is established, the heat is provided by the heater 228 .
- the heater 228 can include a flame holder configured to support a flame disposed to heat the perforated flame holder 102 .
- the fuel and oxidant source 202 can include a fuel nozzle 218 configured to emit a fuel stream 206 and an oxidant source 220 configured to output oxidant (e.g., combustion air) adjacent to the fuel stream 206 .
- the fuel nozzle 218 and oxidant source 220 can be configured to output the fuel stream 206 to be progressively diluted by the oxidant (e.g., combustion air).
- the perforated flame holder 102 can be disposed to receive a diluted fuel and oxidant mixture 206 that supports a combustion reaction 302 that is stabilized by the perforated flame holder 102 when the perforated flame holder 102 is at an operating temperature.
- a start-up flame holder in contrast, can be configured to support a start-up flame at a location corresponding to a relatively unmixed fuel and oxidant mixture that is stable without stabilization provided by the heated perforated flame holder 102 .
- the burner system 200 can further include a controller 230 operatively coupled to the heater 228 and to a data interface 232 .
- the controller 230 can be configured to control a start-up flame holder actuator configured to cause the start-up flame holder to hold the start-up flame when the perforated flame holder 102 needs to be pre-heated and to not hold the start-up flame when the perforated flame holder 102 is at an operating temperature (e.g., when T ⁇ T S ).
- the start-up flame holder includes a mechanically-actuated bluff body configured to be actuated to intercept the fuel and oxidant mixture 206 to cause heat-recycling and/or stabilizing vortices and thereby hold a start-up flame; or to be actuated to not intercept the fuel and oxidant mixture 206 to cause the fuel and oxidant mixture 206 to proceed to the perforated flame holder 102 .
- a fuel control valve, blower, and/or damper may be used to select a fuel and oxidant mixture flow rate that is sufficiently low for a start-up flame to be jet-stabilized; and upon reaching a perforated flame holder 102 operating temperature, the flow rate may be increased to “blow out” the start-up flame.
- the heater 228 may include an electrical power supply operatively coupled to the controller 230 and configured to apply an electrical charge or voltage to the fuel and oxidant mixture 206 .
- An electrically conductive start-up flame holder may be selectively coupled to a voltage ground or other voltage selected to attract the electrical charge in the fuel and oxidant mixture 206 . The attraction of the electrical charge was found by the inventors to cause a start-up flame to be held by the electrically conductive start-up flame holder.
- the heater 228 may include an electrical resistance heater configured to output heat to the perforated flame holder 102 and/or to the fuel and oxidant mixture 206 .
- the electrical resistance heater can be configured to heat up the perforated flame holder 102 to an operating temperature.
- the heater 228 can further include a power supply and a switch operable, under control of the controller 230 , to selectively couple the power supply to the electrical resistance heater.
- An electrical resistance heater 228 can be formed in various ways.
- the electrical resistance heater 228 can be formed from KANTHAL® wire (available from Sandvik Materials Technology division of Sandvik AB of Hallstahammar, Sweden) threaded through at least a portion of the perforations 210 defined by the perforated flame holder body 208 .
- the heater 228 can include an inductive heater, a high-energy beam heater (e.g. microwave or laser), a frictional heater, electro-resistive ceramic coatings, or other types of heating technologies.
- the heater 228 can include an electrical discharge igniter or hot surface igniter configured to output a pulsed ignition to the oxidant and fuel.
- a start-up apparatus can include a pilot flame apparatus disposed to ignite the fuel and oxidant mixture 206 that would otherwise enter the perforated flame holder 102 .
- the electrical discharge igniter, hot surface igniter, and/or pilot flame apparatus can be operatively coupled to the controller 230 , which can cause the electrical discharge igniter or pilot flame apparatus to maintain combustion of the fuel and oxidant mixture 206 in or upstream from the perforated flame holder 102 before the perforated flame holder 102 is heated sufficiently to maintain combustion.
- the burner system 200 can further include a sensor 234 operatively coupled to the control circuit 230 .
- the sensor 234 can include a heat sensor configured to detect infrared radiation or a temperature of the perforated flame holder 102 .
- the control circuit 230 can be configured to control the heating apparatus 228 responsive to input from the sensor 234 .
- a fuel control valve 236 can be operatively coupled to the controller 230 and configured to control a flow of fuel to the fuel and oxidant source 202 .
- an oxidant blower or damper 238 can be operatively coupled to the controller 230 and configured to control flow of the oxidant (or combustion air).
- the sensor 234 can further include a combustion sensor operatively coupled to the control circuit 230 , the combustion sensor being configured to detect a temperature, video image, and/or spectral characteristic of a combustion reaction held by the perforated flame holder 102 .
- the fuel control valve 236 can be configured to control a flow of fuel from a fuel source to the fuel and oxidant source 202 .
- the controller 230 can be configured to control the fuel control valve 236 responsive to input from the combustion sensor 234 .
- the controller 230 can be configured to control the fuel control valve 236 and/or oxidant blower or damper to control a preheat flame type of heater 228 to heat the perforated flame holder 102 to an operating temperature.
- the controller 230 can similarly control the fuel control valve 236 and/or the oxidant blower or damper to change the fuel and oxidant mixture 206 flow responsive to a heat demand change received as data via the data interface 232 .
- FIG. 5 is a simplified side sectional view of the burner system 500 of FIGS. 2-3 , according to an embodiment.
- the combustion volume 204 is defined by a base surface 502 and inner surfaces 504 of sidewalls substantially enclosing the combustion volume 204 laterally.
- fuel stream is to be construed broadly, as reading on a stream of fuel; fuel and oxidant; and/or fuel, oxidant, and diluent. Some or all of the non-fuel components of a fuel stream may be premixed with the fuel or entrained, such as by a stream of fuel as it exits a nozzle 218 .
- flue gas is vented to the atmosphere through an exhaust flue 506 .
- the vented flue gas may pass through convective heat transfer tubes and/or an economizer that pre-heats the combustion air, the fuel, and/or feed water.
- the perforated flame holder 102 is shown in FIG. 2 as being rectangular and as having apertures 210 that are substantially square, as viewed from above. According to other embodiments, the perforated flame holder 102 may have any appropriate shape, including square, round, hexagonal, etc. Likewise, the apertures 210 may have any appropriate shape, including round, square, rectangular, hexagonal, etc., and may be arranged according to any configuration that meets the requirements of the particular application. According to an embodiment, the apertures 210 are arranged in an X-Y grid, as shown in FIG. 2 , at a pitch of between 0.1′′ and 0.5′′.
- the walls defining and separating the apertures 210 may have a thickness that corresponds to an overall “porosity” of the perforated flame holder 102 of between about 30% and 80%.
- each aperture 210 has a width of about 0.206′′, separated by walls having a thickness of about 0.041′′, yielding a porosity of about 70%.
- FIG. 6 shows a detail of the burner system 500 of FIG. 5 , as indicated at 3 in FIG. 5 , according to an embodiment.
- the upper boundary 302 b and the lower boundary 302 a of the flame may extend only a small distance above and below the perforated flame holder 102 , respectively.
- the majority of the fuel within the fuel stream 206 may be combusted within the apertures 210 of the perforated flame holder 102 .
- Such transient huffing is generally short in duration such that, on a time-averaged basis, a majority of combustion may occur within the apertures 210 of the perforated flame holder 102 , between the input face 212 and the output face 214 of the perforated flame holder 102 .
- the inventors have noted apparent combustion occurring above the output face 214 of the perforated flame holder 102 , but still a majority of combustion occurred within the perforated flame holder as evidenced by the continued visible glow (a visible wavelength tail of blackbody radiation) from the perforated flame holder 102 .
- heat output of the perforated burner system 500 is controlled by regulation of the flow rate of fuel in the fuel stream.
- Heat output may be determined by direct measurement at the perforated flame holder 102 , or may be inferred indirectly, based on measurements taken at other locations within the burner system, such as at a flue outlet or at an outlet of a working fluid, etc.
- a table may be prepared from which a heat output value may be derived, given a flow rate, based on an input temperature and an output temperature of a working fluid.
- moderate heat output is heat output at values exceeding about 215 kBTU/H/ft 2 (1.5 kBTU/H/in 2 ), and high heat output is heat output at values exceeding about 430 kBTU/H/ft 2 (3 kBTU/H/in 2 ).
- heat output of the burner system 500 is greater than 500 kBTU/H/ft 2 , or about 3.5 kBTU/H/in 2 (158 W/cm 2 ).
- perforated flame holders 102 like the one described above were routinely operated at heat outputs of about 1 MBTU/H/ft 2 (7 kBTU/H/in 2 ) or more, and in some tests, reached or exceeded levels of about 5 MBTU/H/ft 2 (35 kBTU/H/in 2 ).
- heat output of the burner system 500 is greater than 1 MBTU/H/ft 2 (about 7 kBTU/H/in 2 ), 3 MBTU/H/ft 2 (about 21 kBTU/H/in 2 ), and 5 MBTU/H/ft 2 (about 35 kBTU/H/in 2 ).
- the entire body of the perforated flame holder 102 may be held at a temperature at or above the auto-ignition temperature of the fuel component of the fuel stream 206 .
- the fuel stream 206 may be nominally ignited as it travels through the apertures 210 of the perforated flame holder 102 and the combustion process is complete, or nearly so, by the time the reactants have traversed the length of the apertures 210 (e.g., the thickness of the perforated flame holder 102 ).
- the output side of a ceramic burner tile is heated to a point where it radiates energy in infrared wavelengths, but the input side is cooled by the incoming fuel stream, and remains much cooler, particularly at moderate and high heat output, so that combustion begins only as the fuel stream 206 nears the output face 214 of the burner, or even beyond the output face 214 .
- many prior art systems rely on the cooling effect of the fuel stream. As the Sarkisian reference explains, “the ceramic tile, which is cooled by the reactants, effectively insulates the upstream reactants from the hot downstream combustion products, preventing flashback.”
- the perforated flame holder 102 is preheated during a start-up procedure (or held indefinitely at an elevated temperature) such that at least a portion of the perforated flame holder 102 is at a temperature that exceeds the auto-ignition temperature of the fuel component of the fuel stream 206 .
- any appropriate method of preheating the perforated flame holder 102 may be employed.
- a number of structures and methods for preheating a perforated flame holder are disclosed, for example, in International Patent Application No. PCT/US2014/016632, entitled “FUEL COMBUSTION SYSTEM WITH A PERFORATED REACTION HOLDER,” filed Feb. 14, 2014 (docket number 2651-188-04); which, to the extent not inconsistent with the disclosure herein, is incorporated by reference.
- FIGS. 7 and 8 are diagrammatic views of a burner system 700 during respective modes of operation, according to an embodiment.
- the burner system 700 includes a perforated flame holder 102 and a nozzle 218 as described above with reference to the burner system 100 .
- the burner system 700 includes a controller 706 , and first and second electrodes 702 , 704 .
- the first electrode 702 is configured as a flame holder electrode
- the second electrode 704 is configured as a charge electrode.
- the controller 706 is operatively coupled to the first electrode 702 and the second electrode 704 via connectors 708 , and is configured to apply an electrical potential across the first and second electrodes 702 , 704 .
- the first electrode 702 has an annular shape, such as, for example, the shape of a toroid, and is positioned a distance D N from the nozzle 218 , with a center axis aligned with a longitudinal axis of the nozzle 218 .
- a fuel stream 206 emitted from the nozzle 218 will preferably have a conical shape, with a diameter that increases as a function of the distanced from the nozzle 218 , according to an embodiment.
- the angle of dispersion of the fuel stream 206 is about 15 degrees, relative to the longitudinal axis of the nozzle 218 .
- an inside diameter of the first electrode 702 is selected to be greater than a diameter of the fuel stream 206 at the distance D N . According to another embodiment, the inside diameter of the first electrode 702 is selected to be equal to, or slightly less than the diameter of the fuel stream 206 at the distance D N .
- the nozzle 218 is configured to receive a flow of fuel via a fuel line 710 .
- a valve 712 is coupled to the fuel line 710 , and is configured to regulate a flow of fuel to the nozzle 218 .
- the controller 706 is operatively coupled to the valve 712 via a connector 714 , and is configured to provide a signal on the connector 714 by which operation of the valve 712 is controlled.
- the burner system 700 is shown in a preheat mode of operation. While operating in the preheat mode, the controller 706 controls the valve 712 to admit a flow of fuel to the nozzle 218 while simultaneously applying a voltage across the first and second electrodes 702 , 704 , and a preheat flame 716 is ignited in the fuel stream 206 by any of a number of well-known methods.
- the second electrode 704 applies a charge of a first polarity to the preheat flame 716 , while a voltage of an opposite polarity (or a ground potential) present at the first electrode 702 attracts charged species within the preheat flame 716 .
- a flame front 718 of the preheat flame 716 is held in a region near the first electrode 702 , which holds a substantial portion of the preheat flame 716 between the nozzle 218 and the perforated flame holder 102 .
- the perforated flame holder 102 is heated by the flame 716 .
- the controller 706 is configured to apply an electrical potential that varies over time, such as, for example, an AC voltage, or an AC voltage with a DC offset.
- the electrical potential applied by the controller 706 has a peak-to-peak value that exceeds 10 kV.
- the electrical potential applied by the controller 706 has a peak-to-peak value that exceeds 20 kV.
- the electrical potential applied by the controller 706 has a peak-to-peak value that exceeds 40 kV.
- one or more amplifiers are provided, configured to receive a time-varying signal from the controller 706 , to amplify the signal, and to provide the amplified signal to the first and second electrodes 702 , 704 .
- the inside diameter of the first electrode 702 is greater than the diameter of the fuel stream 206 at the distance D N .
- the burner system 700 transitions from the preheat mode to a heating mode (i.e., normal operation), as shown in FIG. 8 . While transitioning to the heating mode of operation, the controller 706 terminates the application of the electrical potential across the first and second electrodes 702 , 704 , while continuing to control the valve 712 to admit fuel to the nozzle 218 .
- a heating mode i.e., normal operation
- the preheat flame 716 is blown off the holding first electrode 702 .
- the minimum start-up temperature of the perforated flame holder 102 is selected to be greater than the auto-ignition temperature of the fuel in the fuel stream 206 .
- the optional controller 706 can regulate the heat output of the burner system 700 by controlling the volume of fuel admitted by the valve 712 and/or a volume of oxidant provided by a combustion air source. Combustion continue substantially as described with reference to FIGS. 2 and 5 .
- FIGS. 9-12 flowcharts illustrating various methods of operation of burner systems are shown, according to respective embodiments. It should be noted that in the methods disclosed hereafter, many of the steps disclosed are not mandatory or essential. Additionally, many steps disclosed with respect to one method can be combined with other methods, as appropriate, and according to the particular circumstances. For example, while only included as an element of the process of FIG. 9 , the preheat step described with reference to step 106 can be incorporated into any of the disclosed methods, as appropriate.
- FIG. 9 is a flowchart of a method 900 of operating a burner system, according to an embodiment.
- This method begins with the assumption that the burner is not initially in a heating operation or mode.
- a perforated flame holder is preheated to a selected start-up temperature. This step may involve preheating only a portion of the perforated flame holder, or alternatively, the entire perforated flame holder can be preheated to the selected start-up temperature.
- the selected start-up temperature is a temperature that exceeds the auto-ignition temperature of the fuel component of the fuel stream.
- the selected start-up temperature can also be a temperature that exceeds the auto-ignition temperature of the fuel component of the fuel stream plus an incremental additional temperature selected such that the perforated flame holder can hold sufficient heat energy to sustain the combustion reaction for a period after start-up.
- the temperature of the perforated flame holder may tend to dip upon introduction of a cool fuel and oxidant mixture to the perforated flame holder.
- the incremental additional temperature is selected to maintain at least the auto-ignition temperature through this temperature dip of the perforated flame holder.
- step 108 a fuel stream that includes a fuel component and an oxidant component is introduced to an input face of the perforated flame holder.
- emission of the fuel stream from a nozzle can begin as part of step 106 , or can be started at the end of step 106 .
- the fuel stream initially supports the preheat flame, which is used during startup to preheat the perforated flame holder.
- the fuel stream per se, does not reach the perforated flame holder until the electrodes are de-energized.
- emission of the fuel stream does not begin until the perforated flame holder is at its minimum start-up temperature.
- the perforated flame holder is preheated using other means, such as by an electrical heating element, laser bombardment, etc.
- step 412 the fuel stream is combusted, in majority, between the input face and an output face of the perforated flame holder.
- combustion of the fuel stream refers to the combustion process in which the fuel component is converted to combustion products. That is, a majority of the combustion process occurs between the input and output faces of the perforated flame holder.
- Determination of the degree to which the combustion process is complete can be on any reasonable basis, including, for example, the percentage of fuel—i.e., the fuel component of the fuel stream—that is converted to combustion products between the input and output faces of the perforated flame holder relative to the total amount of fuel that is converted within the burner system, or the percentage of thermal energy that is released by the process of combustion between the input and output faces of the perforated flame holder relative to the total amount of thermal energy released within the burner system.
- At least 80% of the combustion process occurs between the input and output faces of the perforated flame holder.
- combustion of the fuel stream is used to produce at least a minimum heat output of the burner system, of about 216 kBTU/H/ft 2 (1.5 kBTU/H/in 2 ).
- the minimum heat output is about 432 kBTU/H/ft 2 (3 kBTU/H/in 2 ).
- the minimum heat output is about 7 kBTU/H/in 2 , about 21 kBTU/H/in 2 , and about 35 kBTU/H/in 2 .
- 7 kBTU/H/in 2 corresponds to about 1 MBTU/H/ft 2 (i.e., one million BTUH per square foot, or about 15.4 million watts per square meter).
- 21 kBTU/H/in 2 , and 35 kBTU/H/in 2 correspond, respectively, to about 3 MBTU/H/ft 2 and about 5 MBTU/H/ft 2 .
- FIG. 10 is a flowchart of a method 1000 of operating a burner system, according to another embodiment.
- step 108 a fuel stream that includes a fuel component and an oxidant component is introduced to an input face of a perforated flame holder, substantially as described above with reference to step 108 .
- step 1004 the fuel stream is combusted at the perforated flame holder.
- step 1006 combustion of the fuel stream is used to produce a heat output of the burner system of at least about 7 kBTU/H/in 2 .
- combustion of the fuel stream is used to produce a heat output of at least about 21 kBTU/H/in 2 , and at least about 35 kBTU/H/in 2 .
- a majority of the combustion is performed between the input face and an output face of the perforated flame holder, substantially as described with reference to step 412 .
- FIG. 11 is a flowchart of a method 1100 of operating a burner system, according to another embodiment.
- a fuel stream is introduced to an input face of a perforated flame holder, substantially as previously described.
- the fuel stream is combusted at the perforated flame holder, and in step 1106 , combustion of the fuel stream is used to produce at least a minimum heat output, of about 216 kBTU/H/ft 2 (1.5 kBTU/H/in 2 ).
- the minimum heat output is about 1 MBTU/H/ft 2 .
- step 1108 while producing at least the minimum heat output, the input face of the perforated flame holder is maintained at a temperature that exceeds an auto-ignition temperature of a fuel component of the fuel stream.
- the input face of the perforated flame holder is maintained at a temperature of at least 1100 degrees F. (about 593 degrees C.).
- combustion of the fuel stream is initiated as the fuel stream enters the input face of the perforated flame holder.
- a majority of the combustion is performed between the input face and an output face of the perforated flame holder.
- FIG. 12 is a flowchart of a method 1200 of operating a burner system, according to a further embodiment.
- a fuel stream is introduced to an input face of a perforated flame holder.
- the fuel stream of step 1202 has an average fuel-to-oxidant ratio that is below a lower combustion limit of a fuel component of the fuel stream.
- the fuel stream is combusted at the perforated flame holder.
- a majority of the combustion is performed between the input face and an output face of the perforated flame holder.
- At least a portion of the perforated flame holder is maintained at a temperature that exceeds an auto-ignition temperature of a fuel component of the fuel stream.
- combustion of the fuel stream is used to produce at least a minimum heat output, of about 216 kBTU/H/ft 2 (1.5 kBTU/H/in 2 ).
- FIG. 13A is a simplified perspective view of a combustion system 1300 , including another alternative perforated flame holder 102 , according to an embodiment.
- the perforated flame holder 102 is a reticulated ceramic perforated flame holder, according to an embodiment.
- FIG. 13B is a simplified side sectional diagram of a portion of the reticulated ceramic perforated flame holder 102 of FIG. 13A , according to an embodiment.
- the perforated flame holder 102 of FIGS. 13A, 13B can be implemented in the various combustion systems described herein, according to an embodiment.
- the perforated flame holder 102 is configured to support a combustion reaction (e.g., combustion reaction 302 of FIG.
- the perforated flame holder 102 can be configured to support a combustion reaction of the fuel and oxidant mixture 206 upstream, downstream, within, and adjacent to the reticulated ceramic perforated flame holder 102 .
- the perforated flame holder body 208 can include reticulated fibers 1339 .
- the reticulated fibers 1339 can define branching perforations 210 that weave around and through the reticulated fibers 1339 .
- the perforations 210 are formed as passages between the reticulated fibers 1339 .
- the reticulated fibers 1339 are formed as a reticulated ceramic foam. According to an embodiment, the reticulated fibers 1339 are formed using a reticulated polymer foam as a template. According to an embodiment, the reticulated fibers 1339 can include alumina silicate. According to an embodiment, the reticulated fibers 1339 can be formed from extruded mullite or cordierite. According to an embodiment, the reticulated fibers 1339 can include Zirconia. According to an embodiment, the reticulated fibers 1339 can include silicon carbide.
- reticulated fibers refers to a netlike structure.
- the reticulated fibers 1339 are formed from an extruded ceramic material.
- the interaction between the fuel and oxidant mixture 206 , the combustion reaction, and heat transfer to and from the perforated flame holder body 208 can function similarly to the embodiment shown and described above with respect to FIGS. 2-4 .
- One difference in activity is a mixing between perforations 210 , because the reticulated fibers 1339 form a discontinuous perforated flame holder body 208 that allows flow back and forth between neighboring perforations 210 , according to an embodiment.
- the network of reticulated fibers 1339 is sufficiently open for downstream reticulated fibers 1339 to emit radiation for receipt by upstream reticulated fibers 1339 for the purpose of heating the upstream reticulated fibers 1339 sufficiently to maintain combustion of a fuel and oxidant mixture 206 .
- heat conduction paths (such as heat conduction paths 312 in FIG. 3 ) between reticulated fibers 1339 are reduced due to separation of the reticulated fibers 1339 . This may cause relatively more heat to be transferred from a heat-receiving region or area (such as heat receiving region 306 in FIG. 3 ) to a heat-output region or area (such as heat-output region 310 of FIG. 3 ) of the reticulated fibers 1339 via thermal radiation (shown as element 304 in FIG. 3 ).
- individual perforations 210 may extend between an input face 212 to an output face 214 of the perforated flame holder 102 .
- Perforations 210 may have varying lengths L. According to an embodiment, because the perforations 210 branch into and out of each other, individual perforations 210 are not clearly defined by a length L.
- the perforated flame holder 102 is configured to support or hold a combustion reaction (see element 302 of FIG. 3 ) or a flame at least partially between the input face 212 and the output face 214 .
- the input face 212 corresponds to a surface of the perforated flame holder 102 proximal to the fuel nozzle 218 or to a surface that first receives fuel.
- the input face 212 corresponds to an extent of the reticulated fibers 1339 proximal to the fuel nozzle 218 .
- the output face 214 corresponds to a surface distal to the fuel nozzle 218 or opposite the input face 212 .
- the input face 212 corresponds to an extent of the reticulated fibers 1339 distal to the fuel nozzle 218 or opposite to the input face 212 .
- the formation of thermal boundary layers 314 , transfer of heat between the perforated flame holder body 208 and the gases flowing through the perforations 210 , a characteristic perforation width dimension D, and the length L can each be regarded as related to an average or overall path through the perforated reaction holder 102 .
- the dimension D can be determined as a root-mean-square of individual Dn values determined at each point along a flow path.
- the length L can be a length that includes length contributed by tortuosity of the flow path, which may be somewhat longer than a straight line distance T RH from the input face 212 to the output face 214 through the perforated reaction holder 102 .
- the void fraction (expressed as (total perforated reaction holder 102 volume ⁇ reticulated fiber 1339 volume)/total volume)) is about 70%.
- the reticulated ceramic perforated flame holder 102 is a tile about 1′′ ⁇ 4′′ ⁇ 4′′. According to an embodiment, the reticulated ceramic perforated flame holder 102 includes about 100 pores per square inch of surface area. Other materials and dimensions can also be used for a reticulated ceramic perforated flame holder 102 in accordance with principles of the present disclosure.
- the reticulated ceramic perforated flame holder 102 can include shapes and dimensions other than those described herein.
- the perforated flame holder 102 can include reticulated ceramic tiles that are larger or smaller than the dimensions set forth above.
- the reticulated ceramic perforated flame holder 102 can include shapes other than generally cuboid shapes.
- the reticulated ceramic perforated flame holder 102 can include multiple reticulated ceramic tiles.
- the multiple reticulated ceramic tiles can be joined together such that each ceramic tile is in direct contact with one or more adjacent reticulated ceramic tiles.
- the multiple reticulated ceramic tiles can collectively form a single perforated flame holder 102 .
- each reticulated ceramic tile can be considered a distinct perforated flame holder 102 .
Abstract
A method of operation of a burner system includes introducing a fuel stream into a perforated flame holder, combusting the fuel stream, with a majority of the combustion occurring between an input face and an output face of the flame holder, and producing a heat output from the combustion of at least 1.5 kBTU/H/in2.
Description
- The present application is a U.S. Continuation-in-Part application of co-pending U.S. patent application Ser. No. 15/235,517, entitled “HIGH OUTPUT POROUS TILE BURNER,” filed Aug. 12, 2016. Co-pending U.S. patent application Ser. No. 15/235,517 is a Continuation-in-Part application which claims priority benefit under 35 U.S.C. § 120 (pre-AIA) of International Patent Application No. PCT/US2015/016152, entitled “HIGH OUTPUT POROUS TILE BURNER,” filed Feb. 17, 2015 (docket number 2651-251-04), now expired. International Patent Application No. PCT/US2015/016152 claims priority to International Patent Application No. PCT/US2014/016632, entitled “FUEL COMBUSTION SYSTEM WITH A PERFORATED REACTION HOLDER,” filed Feb. 14, 2014 (docket number 2651-188-04), now expired. Co-pending U.S. patent application Ser. No. 15/235,517 is also a Continuation-in-Part application of U.S. patent application Ser. No. 14/763,271, entitled “PERFORATED FLAME HOLDER AND BURNER INCLUDING A PERFORATED FLAME HOLDER,” filed Jul. 24, 2015 (docket number 2651-172-03), now issued as U.S. Pat. No. 9,857,076, issued Jan. 2, 2018. U.S. patent application Ser. No. 14/763,271 is a U.S. National Stage Application under 35 U.S.C. § 371 of International Patent Application No. PCT/US2014/016628, entitled “PERFORATED FLAME HOLDER AND BURNER INCLUDING A PERFORATED FLAME HOLDER,” filed Feb. 14, 2014 (docket number 2651-172-04), now expired. International Patent Application No. PCT/US2014/016628 claims priority benefit to U.S. Provisional Patent Application No. 61/765,022, entitled “PERFORATED FLAME HOLDER AND BURNER INCLUDING A PERFORATED FLAME HOLDER,” filed Feb. 14, 2013 (docket number 2651-172-02), now expired. Co-pending U.S. patent application Ser. No. 15/235,517 is also a Continuation-in-Part application of co-pending U.S. patent application Ser. No. 15/215,401, entitled “LOW NOx FIRE TUBE BOILER,” filed Jul. 20, 2016 (docket number 2651-205-03). Co-pending U.S. patent application Ser. No. 15/215,401 claims priority benefit to International Patent Application No. PCT/US2015/012843, entitled “LOW NOx FIRE TUBE BOILER,” filed Jan. 26, 2015 (docket number 2651-205-04), now expired. International Patent Application No. PCT/US2015/012843 claims priority benefit to U.S. Provisional Patent Application No. 61/931,407, entitled “LOW NOx FIRE TUBE BOILER,” filed Jan. 24, 2014 (docket number 2651-205-02), now expired. Each of the international patent applications, U.S. patent applications, and U.S. provisional patent applications listed in this paragraph are, to the extent not inconsistent with the disclosure herein, incorporated by reference.
- Ceramic tile burners having some degree of porosity may be used as flame holders and radiant heat sources in a variety of applications. Typically, a fuel stream including a fuel component and an oxidant component is introduced at an input face of a ceramic tile burner, where the fuel stream passes into channels or pores of the ceramic tile.
- The prior art teaches that, depending upon the surface heat loading of the ceramic tile burner, the fuel stream may begin combusting while inside the porous tile, or may combust as it passes out of an output face of the porous tile. For example, U.S. Pat. No. 4,919,605, to Sarkisian, explains that “at low surface heat loads, ceramic tiles act as radiant burners. Combustion of gaseous reactants . . . takes place within the ceramic tile, and the tile becomes radiant. Ignition of the incoming reactants is caused by the high temperature of the ceramic [tile].”
- Increasing the surface heat loading results in increased velocity of the fuel stream. According to Sarkisian, “at moderate surface heat loading rates, combustion takes place at or above the ceramic tile and the tile is cooled by the incoming reactants. In this regime, the ceramic tile acts as a . . . thermal barrier, and flame holder. Segments between the pores of the tiles cause turbulent recirculation zones to form, and this recirculation of hot gases ignites the combustion reactants as they exit the tile . . . . Increasing the surface heat loading . . . of a ceramic tile burner . . . produces very high velocity reactant flow when low porosity tiles are used . . . . With high porosity ceramic tiles, channel wall thicknesses are small. This has a detrimental effect on the formation of downstream recirculation zones. For this reason, the flame holding capabilities of the tiles are poor, resulting in unstable combustion.”
- Thus, Sarkisian proposes a tile burner with a wire mesh positioned over the output face to act as a flame holder. Using this arrangement with a tile burner having a porosity of 70%, Sarkisian reports surface loading rates as high as 6500 BTU/H/in2 (0.94 MBTU/H/ft2).
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FIG. 1 is a flow chart showing a method for operating a burner including a perforated flame holder, according to an embodiment. -
FIG. 2 is a simplified perspective view of a burner system including a perforated flame holder, according to an embodiment. -
FIG. 3 is a side sectional diagram of a portion of the perforated flame holder ofFIG. 2 , according to an embodiment. -
FIG. 4 is a flow chart showing a method for operating a burner system including the perforated flame holder ofFIGS. 2 and 3 , according to an embodiment. -
FIG. 5 is a simplified side sectional view of the burner system ofFIG. 2 , according to an embodiment. -
FIG. 6 shows a detail of the burner system ofFIG. 5 , as indicated at 3 inFIG. 5 , according to an embodiment. -
FIGS. 7 and 8 are diagrammatic views of a burner system during respective modes of operation, according to an embodiment. -
FIGS. 9-12 are flowcharts of methods of operating a burner system, according to respective embodiments. -
FIG. 13A is a simplified perspective view of a combustion system, including a reticulated ceramic perforated flame holder, according to an embodiment. -
FIG. 13B is a simplified side sectional diagram of a portion of the reticulated ceramic perforated flame holder ofFIG. 13A , according to an embodiment. - In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here.
- Various units and unit symbols are used herein in accordance with accepted convention to refer to corresponding values. The double-prime symbol (″) is used to denote a length or distance, in inches. Inches and feet may also be abbreviated as “in” and “ft,” respectively. “BTU/H” indicates a value in British thermal units per hour. Thus, “BTU/H/ft2” indicates a value of British thermal units per hour, per square foot. “W/cm2” indicates watts per square centimeter. (BTU/H≈W×3.412, in =cm×2.54). 1 W/cm2 is approximately equal to 22 BTU/H/in2. Any value for which the unit symbol is preceded by “k” (kilo) or “M” (mega) is to be multiplied by 1×103 or 1×106, respectively. The letters “C” and “F” are used to denote temperature in, respectively, degrees Celsius and degrees Fahrenheit (F=C×9/5+32).
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FIG. 1 is a flow chart showing amethod 100 for operating a burner including a perforated flame holder (e.g., seeFIGS. 2-3, 102 ), according to an embodiment. Beginning withstep 104, a perforated flame holder is supported in a combustion volume away from a fuel nozzle at a dilution distance (DD), described below. Instep 106, the perforated flame holder is preheated to an operating temperature. After the perforated flame holder is preheated, a fuel and oxidant mixture is provided to the perforated flame holder, as shown instep 108. The fuel and oxidant combusts and may further heat the perforated flame holder. The initial combustion rate may optionally be low-to-moderate but not high. - According to an embodiment, proceeding to step 110, the rate of flow of the fuel and oxidant mixture is increased to a desired heat output level. As shown in
step 112, the perforated flame holder may support a combustion reaction having a heat output of at least 216 thousand BTU per hour per square foot. As shown inFIG. 2 below, theperforated flame holder 102 may have aninput face 212 and anoutput face 214. The area of the output face 214 (and/or the input face 212) is the area referred to in the heat output rates described herein. While the fuel flow initially provided to theperforated flame holder 102 instep 108 may be relatively low, the inventors have discovered that during a start-up procedure, the fuel flow rate may be increased, and theperforated flame holder 102 may reliably support combustion at a high fuel and oxidant mixture flow rate with combustion heat output rates of equal to or greater than 1 million BTU per hour per square foot ofoutput face 214 area of theperforated flame holder 102. -
FIG. 2 is a simplified diagram of aburner system 200 including aperforated flame holder 102 configured to hold a combustion reaction, according to an embodiment. As used herein, the terms perforated flame holder, perforated reaction holder, porous flame holder, porous reaction holder, duplex, and duplex tile shall be considered synonymous unless further definition is provided. - Experiments performed by the inventors have shown that
perforated flame holders 102 described herein can support very clean combustion. Specifically, in experimental use ofsystems 200 ranging from pilot scale to full scale, output of oxides of nitrogen (NOx) was measured to range from low single digit parts per million (ppm) down to undetectable (less than 1 ppm) concentration of NOx at the stack. These remarkable results were measured at 3% (dry) oxygen (O2) concentration with undetectable carbon monoxide (CO) at stack temperatures typical of industrial furnace applications (1400-1600° F.). Moreover, these results did not require any extraordinary measures such as selective catalytic reduction (SCR), selective non-catalytic reduction (SNCR), water/steam injection, external flue gas recirculation (FGR), or other heroic extremes that may be required for conventional burners to even approach such clean combustion. - According to embodiments, the
burner system 200 includes a fuel andoxidant source 202 disposed to output fuel and oxidant into acombustion volume 204 to form a fuel andoxidant mixture 206. As used herein, the terms fuel and oxidant mixture and fuel stream may be used interchangeably and considered synonymous depending on the context, unless further definition is provided. As used herein, the terms combustion volume, combustion chamber, furnace volume, and the like shall be considered synonymous unless further definition is provided. Theperforated flame holder 102 is disposed in thecombustion volume 204 and positioned to receive the fuel andoxidant mixture 206. -
FIG. 3 is a side sectional diagram 300 of a portion of theperforated flame holder 102 ofFIGS. 1 and 2 , according to an embodiment. Referring toFIGS. 2 and 3 , theperforated flame holder 102 includes a perforatedflame holder body 208 defining a plurality ofperforations 210 aligned to receive the fuel andoxidant mixture 206 from the fuel andoxidant source 202. As used herein, the terms perforation, pore, aperture, elongated aperture, and the like, in the context of theperforated flame holder 102, shall be considered synonymous unless further definition is provided. Theperforations 210 are configured to collectively hold acombustion reaction 302 supported by the fuel andoxidant mixture 206. - The fuel can include hydrogen, a hydrocarbon gas, a vaporized hydrocarbon liquid, an atomized hydrocarbon liquid, or a powdered or pulverized solid. The fuel can be a single species or can include a mixture of gas(es), vapor(s), atomized liquid(s), and/or pulverized solid(s). For example, in a process heater application the fuel can include fuel gas or byproducts from the process that include carbon monoxide (CO), hydrogen (H2), and methane (CH4). In another application the fuel can include natural gas (mostly CH4) or propane (C3H8). In another application, the fuel can include #2 fuel oil or #6 fuel oil. Dual fuel applications and flexible fuel applications are similarly contemplated by the inventors. The oxidant can include oxygen carried by air, flue gas, and/or can include another oxidant, either pure or carried by a carrier gas. The terms oxidant and oxidizer shall be considered synonymous herein.
- According to an embodiment, the perforated
flame holder body 208 can be bounded by aninput face 212 disposed to receive the fuel andoxidant mixture 206, anoutput face 214 facing away from the fuel andoxidant source 202, and aperipheral surface 216 defining a lateral extent of theperforated flame holder 102. The plurality ofperforations 210 which are defined by the perforatedflame holder body 208 extend from theinput face 212 to theoutput face 214. The plurality ofperforations 210 can receive the fuel andoxidant mixture 206 at theinput face 212. The fuel andoxidant mixture 206 can then combust in or near the plurality ofperforations 210 and combustion products can exit the plurality ofperforations 210 at or near theoutput face 214. - According to an embodiment, the
perforated flame holder 102 is configured to hold a majority of thecombustion reaction 302 within theperforations 210. For example, on a steady-state basis, more than half the molecules of fuel output into thecombustion volume 204 by the fuel andoxidant source 202 may be converted to combustion products between theinput face 212 and theoutput face 214 of theperforated flame holder 102. According to an alternative interpretation, more than half of the heat or thermal energy output by thecombustion reaction 302 may be output between theinput face 212 and theoutput face 214 of theperforated flame holder 102. As used herein, the terms heat, heat energy, and thermal energy shall be considered synonymous unless further definition is provided. As used above, heat energy and thermal energy refer generally to the released chemical energy initially held by reactants during thecombustion reaction 302. As used elsewhere herein, heat, heat energy and thermal energy correspond to a detectable temperature rise undergone by real bodies characterized by heat capacities. Under nominal operating conditions, theperforations 210 can be configured to collectively hold at least 80% of thecombustion reaction 302 between theinput face 212 and theoutput face 214 of theperforated flame holder 102. In some experiments, the inventors produced acombustion reaction 302 that was apparently wholly contained in theperforations 210 between theinput face 212 and theoutput face 214 of theperforated flame holder 102. According to an alternative interpretation, theperforated flame holder 102 can support combustion between theinput face 212 andoutput face 214 when combustion is “time-averaged.” For example, during transients, such as before theperforated flame holder 102 is fully heated, or if too high a (cooling) load is placed on the system, the combustion may travel somewhat downstream from theoutput face 214 of theperforated flame holder 102. Alternatively, if the cooling load is relatively low and/or the furnace temperature reaches a high level, the combustion may travel somewhat upstream of theinput face 212 of theperforated flame holder 102. - While a “flame” is described in a manner intended for ease of description, it should be understood that in some instances, no visible flame is present. Combustion occurs primarily within the
perforations 210, but the “glow” of combustion heat is dominated by a visible glow of theperforated flame holder 102 itself. In other instances, the inventors have noted transient “huffing” or “flashback” wherein a visible flame momentarily ignites in a region lying between theinput face 212 of theperforated flame holder 102 and thefuel nozzle 218, within the dilution region DD. Such transient huffing or flashback is generally short in duration such that, on a time-averaged basis, a majority of combustion occurs within theperforations 210 of theperforated flame holder 102, between theinput face 212 and theoutput face 214. In still other instances, the inventors have noted apparent combustion occurring downstream from theoutput face 214 of theperforated flame holder 102, but still a majority of combustion occurred within theperforated flame holder 102 as evidenced by continued visible glow from theperforated flame holder 102 that was observed. - The
perforated flame holder 102 can be configured to receive heat from thecombustion reaction 302 and output a portion of the received heat asthermal radiation 304 to heat-receiving structures (e.g., furnace walls and/or radiant section working fluid tubes) in or adjacent to thecombustion volume 204. As used herein, terms such as radiation, thermal radiation, radiant heat, heat radiation, etc. are to be construed as being substantially synonymous, unless further definition is provided. Specifically, such terms refer to blackbody-type radiation of electromagnetic energy, primarily at infrared wavelengths, but also at visible wavelengths owing to elevated temperature of the perforatedflame holder body 208. - Referring especially to
FIG. 3 , theperforated flame holder 102 outputs another portion of the received heat to the fuel andoxidant mixture 206 received at theinput face 212 of theperforated flame holder 102. The perforatedflame holder body 208 may receive heat from thecombustion reaction 302 at least inheat receiving regions 306 ofperforation walls 308. Experimental evidence has suggested to the inventors that the position of theheat receiving regions 306, or at least the position corresponding to a maximum rate of receipt of heat, can vary along the length of theperforation walls 308. In some experiments, the location of maximum receipt of heat was apparently between ⅓ and ½ of the distance from theinput face 212 to the output face 214 (i.e., somewhat nearer to theinput face 212 than to the output face 214). The inventors contemplate that theheat receiving regions 306 may lie nearer to theoutput face 214 of theperforated flame holder 102 under other conditions. Most probably, there is no clearly defined edge of the heat receiving regions 306 (or for that matter, theheat output regions 310, described below). For ease of understanding, theheat receiving regions 306 and theheat output regions 310 will be described asparticular regions - The perforated
flame holder body 208 can be characterized by a heat capacity. The perforatedflame holder body 208 may hold thermal energy from thecombustion reaction 302 in an amount corresponding to the heat capacity multiplied by temperature rise, and transfer the thermal energy from theheat receiving regions 306 to heatoutput regions 310 of theperforation walls 308. Generally, theheat output regions 310 are nearer to theinput face 212 than are theheat receiving regions 306. According to one interpretation, the perforatedflame holder body 208 can transfer heat from theheat receiving regions 306 to theheat output regions 310 via thermal radiation, depicted graphically as 304. According to another interpretation, the perforatedflame holder body 208 can transfer heat from theheat receiving regions 306 to theheat output regions 310 via heat conduction alongheat conduction paths 312. The inventors contemplate that multiple heat transfer mechanisms including conduction, radiation, and possibly convection may be operative in transferring heat from theheat receiving regions 306 to theheat output regions 310. In this way, theperforated flame holder 102 may act as a heat source to maintain thecombustion reaction 302, even under conditions where acombustion reaction 302 would not be stable when supported from a conventional flame holder. - The inventors believe that the
perforated flame holder 102 causes thecombustion reaction 302 to begin withinthermal boundary layers 314 formed adjacent towalls 308 of theperforations 210. Insofar as combustion is generally understood to include a large number of individual reactions, and since a large portion of combustion energy is released within theperforated flame holder 102, it is apparent that at least a majority of the individual reactions occur within theperforated flame holder 102. As the relatively cool fuel andoxidant mixture 206 approaches theinput face 212, the flow is split into portions that respectively travel throughindividual perforations 210. The hot perforatedflame holder body 208 transfers heat to the fluid, notably withinthermal boundary layers 314 that progressively thicken as more and more heat is transferred to the incoming fuel andoxidant mixture 206. After reaching a combustion temperature (e.g., the auto-ignition temperature of the fuel), the reactants continue to flow while a chemical ignition delay time elapses, over which time thecombustion reaction 302 occurs. Accordingly, thecombustion reaction 302 is shown as occurring within the thermal boundary layers 314. As flow progresses, thethermal boundary layers 314 merge at amerger point 316. Ideally, themerger point 316 lies between theinput face 212 and output face 214 that define the ends of theperforations 210. At some position along the length of aperforation 210, thecombustion reaction 302 outputs more heat to the perforatedflame holder body 208 than it receives from the perforatedflame holder body 208. The heat is received at theheat receiving region 306, is held by the perforatedflame holder body 208, and is transported to theheat output region 310 nearer to theinput face 212, where the heat is transferred into the cool reactants (and any included diluent) to bring the reactants to the ignition temperature. - In an embodiment, each of the
perforations 210 is characterized by a length L defined as a reaction fluid propagation path length between theinput face 212 and theoutput face 214 of theperforated flame holder 102. As used herein, the term reaction fluid refers to matter that travels through aperforation 210. Near theinput face 212, the reaction fluid includes the fuel and oxidant mixture 206 (optionally including nitrogen, flue gas, and/or other “non-reactive” species). Within the combustion reaction region, the reaction fluid may include plasma associated with thecombustion reaction 302, molecules of reactants and their constituent parts, any non-reactive species, reaction intermediates (including transition states), and reaction products. Near theoutput face 214, the reaction fluid may include reaction products and byproducts, non-reactive gas, and excess oxidant. - The plurality of
perforations 210 can be each characterized by a transverse dimension D between opposingperforation walls 308. The inventors have found that stable combustion can be maintained in theperforated flame holder 102 if the length L of eachperforation 210 is at least four times the transverse dimension D of the perforation. In other embodiments, the length L can be greater than six times the transverse dimension D. For example, experiments have been run where L is at least eight, at least twelve, at least sixteen, and at least twenty-four times the transverse dimension D. Preferably, the length L is sufficiently long forthermal boundary layers 314 to form adjacent to theperforation walls 308 in a reaction fluid flowing through theperforations 210 to converge at merger points 316 within theperforations 210 between theinput face 212 and theoutput face 214 of theperforated flame holder 102. In experiments, the inventors have found L/D ratios between 12 and 48 to work well (i.e., produce low NOx, produce low CO, and maintain stable combustion). - The perforated
flame holder body 208 can be configured to convey heat betweenadjacent perforations 210. The heat conveyed betweenadjacent perforations 210 can be selected to cause heat output from thecombustion reaction portion 302 in afirst perforation 210 to supply heat to stabilize acombustion reaction portion 302 in anadjacent perforation 210. - Referring especially to
FIG. 2 , the fuel andoxidant source 202 can further include afuel nozzle 218, configured to output fuel, and anoxidant source 220 configured to output a fluid including the oxidant. For example, thefuel nozzle 218 can be configured to output pure fuel. Theoxidant source 220 can be configured to output combustion air carrying oxygen, and optionally, flue gas. - The
perforated flame holder 102 can be held by a perforated flameholder support structure 222 configured to hold theperforated flame holder 102 at a dilution distance DD away from thefuel nozzle 218. Thefuel nozzle 218 can be configured to emit a fuel jet selected to entrain the oxidant to form the fuel andoxidant mixture 206 as the fuel jet and oxidant travel along a path to theperforated flame holder 102 through the dilution distance DD between thefuel nozzle 218 and theperforated flame holder 102. Additionally or alternatively (particularly when a blower is used to deliver oxidant contained in combustion air), the oxidant or combustion air source can be configured to entrain the fuel and the fuel and oxidant travel through the dilution distance DD. In some embodiments, a fluegas recirculation path 224 can be provided. Additionally or alternatively, thefuel nozzle 218 can be configured to emit a fuel jet selected to entrain the oxidant and to entrain flue gas as the fuel jet travels through the dilution distance DD between thefuel nozzle 218 and theinput face 212 of theperforated flame holder 102. - The
fuel nozzle 218 can be configured to emit the fuel through one ormore fuel orifices 226 having an inside diameter dimension that is referred to as “nozzle diameter.” The perforated flameholder support structure 222 can support theperforated flame holder 102 to receive the fuel andoxidant mixture 206 at the distance DD away from thefuel nozzle 218 greater than 20 times the nozzle diameter. In another embodiment, theperforated flame holder 102 is disposed to receive the fuel andoxidant mixture 206 at the distance DD away from thefuel nozzle 218 between 100 times and 1100 times the nozzle diameter. Preferably, the perforated flameholder support structure 222 is configured to hold theperforated flame holder 102 at a distance about 200 times or more of the nozzle diameter away from thefuel nozzle 218. When the fuel andoxidant mixture 206 travels about 200 times the nozzle diameter or more, the mixture is sufficiently homogenized to cause thecombustion reaction 302 to produce minimal NOx. - The fuel and
oxidant source 202 can alternatively include a premix fuel and oxidant source, according to an embodiment. A premix fuel and oxidant source can include a premix chamber (not shown), a fuel nozzle configured to output fuel into the premix chamber, and an oxidant (e.g., combustion air) channel configured to output the oxidant into the premix chamber. A flame arrestor can be disposed between the premix fuel and oxidant source and theperforated flame holder 102 and be configured to prevent flame flashback into the premix fuel and oxidant source. - The
oxidant source 220, whether configured for entrainment in thecombustion volume 204 or for premixing, can include a blower configured to force the oxidant through the fuel andoxidant source 202. - The
support structure 222 can be configured to support theperforated flame holder 102 from a floor or wall (not shown) of thecombustion volume 204, for example. In another embodiment, thesupport structure 222 supports theperforated flame holder 102 from the fuel andoxidant source 202. Alternatively, thesupport structure 222 can suspend theperforated flame holder 102 from an overhead structure (such as a flue, in the case of an up-fired system). Thesupport structure 222 can support theperforated flame holder 102 in various orientations and directions. - The
perforated flame holder 102 can include a single perforatedflame holder body 208. In another embodiment, theperforated flame holder 102 can include a plurality of adjacent perforated flame holder sections that collectively provide a tiledperforated flame holder 102. - The perforated flame
holder support structure 222 can be configured to support the plurality of perforated flame holder sections. The perforated flameholder support structure 222 can include a metal superalloy, a cementatious, and/or ceramic refractory material. In an embodiment, the plurality of adjacent perforated flame holder sections can be joined with a fiber reinforced refractory cement. - The
perforated flame holder 102 can have a width dimension W between opposite sides of theperipheral surface 216 at least twice a thickness dimension T between theinput face 212 and theoutput face 214. In another embodiment, theperforated flame holder 102 can have a width dimension W between opposite sides of theperipheral surface 216 at least three times, at least six times, or at least nine times the thickness dimension T between theinput face 212 and theoutput face 214 of theperforated flame holder 102. - In an embodiment, the
perforated flame holder 102 can have a width dimension W less than a width of thecombustion volume 204. This can allow the fluegas circulation path 224 from above to below theperforated flame holder 102 to lie between theperipheral surface 216 of theperforated flame holder 102 and the combustion volume wall (not shown). - Referring again to both
FIGS. 2 and 3 , theperforations 210 can be of various shapes. In an embodiment, theperforations 210 can include elongated squares, each having a transverse dimension D between opposing sides of the squares. In another embodiment, theperforations 210 can include elongated hexagons, each having a transverse dimension D between opposing sides of the hexagons. In yet another embodiment, theperforations 210 can include hollow cylinders, each having a transverse dimension D corresponding to a diameter of the cylinder. In another embodiment, theperforations 210 can include truncated cones or truncated pyramids (e.g., frustums), each having a transverse dimension D radially symmetric relative to a length axis that extends from theinput face 212 to theoutput face 214. In some embodiments, theperforations 210 can each have a lateral dimension D equal to or greater than a quenching distance of the flame based on standard reference conditions. Alternatively, theperforations 210 may have lateral dimension D less then than a standard reference quenching distance. - In one range of embodiments, each of the plurality of
perforations 210 has a lateral dimension D between 0.05 inch and 1.0 inch. Preferably, each of the plurality ofperforations 210 has a lateral dimension D between 0.1 inch and 0.5 inch. For example the plurality ofperforations 210 can each have a lateral dimension D of about 0.2 to 0.4 inch. - The void fraction of a
perforated flame holder 102 is defined as the total volume of allperforations 210 in a section of theperforated flame holder 102 divided by a total volume of theperforated flame holder 102 includingbody 208 andperforations 210. Theperforated flame holder 102 should have a void fraction between 0.10 and 0.90. In an embodiment, theperforated flame holder 102 can have a void fraction between 0.30 and 0.80. In another embodiment, theperforated flame holder 102 can have a void fraction of about 0.70. Using a void fraction of about 0.70 was found to be especially effective for producing very low NOx. - The
perforated flame holder 102 can be formed from a fiber reinforced cast refractory material and/or a refractory material such as an aluminum silicate material. For example, theperforated flame holder 102 can be formed to include mullite or cordierite. Additionally or alternatively, the perforatedflame holder body 208 can include a metal superalloy such as Inconel or Hastelloy. The perforatedflame holder body 208 can define a honeycomb. Honeycomb is an industrial term of art that need not strictly refer to a hexagonal cross section and most usually includes cells of square cross section. Honeycombs of other cross sectional areas are also known. - The inventors have found that the
perforated flame holder 102 can be formed from VERSAGRID® ceramic honeycomb, available from Applied Ceramics, Inc. of Doraville, S.C. - The
perforations 210 can be parallel to one another and normal to the input and output faces 212, 214. In another embodiment, theperforations 210 can be parallel to one another and formed at an angle relative to the input and output faces 212, 214. In another embodiment, theperforations 210 can be non-parallel to one another. In another embodiment, theperforations 210 can be non-parallel to one another and non-intersecting. In another embodiment, theperforations 210 can be intersecting. Thebody 308 can be one piece or can be formed from a plurality of sections. - In another embodiment, which is not necessarily preferred, the
perforated flame holder 102 may be formed from reticulated ceramic material. The term “reticulated” refers to a netlike structure. Reticulated ceramic material is often made by dissolving a slurry into a sponge of specified porosity, allowing the slurry to harden, and burning away the sponge and curing the ceramic. - In another embodiment, which is not necessarily preferred, the
perforated flame holder 102 may be formed from a ceramic material that has been punched, bored or cast to create channels. - In another embodiment, the
perforated flame holder 102 can include a plurality of tubes or pipes bundled together. The plurality ofperforations 210 can include hollow cylinders and can optionally also include interstitial spaces between the bundled tubes. In an embodiment, the plurality of tubes can include ceramic tubes. Refractory cement can be included between the tubes and configured to adhere the tubes together. In another embodiment, the plurality of tubes can include metal (e.g., superalloy) tubes. The plurality of tubes can be held together by a metal tension member circumferential to the plurality of tubes and arranged to hold the plurality of tubes together. The metal tension member can include stainless steel, a superalloy metal wire, and/or a superalloy metal band. - The perforated
flame holder body 208 can alternatively include stacked perforated sheets of material, each sheet having openings that connect with openings of subjacent and superjacent sheets. The perforated sheets can include perforated metal sheets, ceramic sheets and/or expanded sheets. In another embodiment, the perforatedflame holder body 208 can include discontinuous packing bodies such that theperforations 210 are formed in the interstitial spaces between the discontinuous packing bodies. In one example, the discontinuous packing bodies include structured packing shapes. In another example, the discontinuous packing bodies include random packing shapes. For example, the discontinuous packing bodies can include ceramic Raschig ring, ceramic Berl saddles, ceramic Intalox saddles, and/or metal rings or other shapes (e.g. Super Raschig Rings) that may be held together by a metal cage. - The inventors contemplate various explanations for why burner systems including the
perforated flame holder 102 provide such clean combustion. - According to an embodiment, the
perforated flame holder 102 may act as a heat source to maintain a combustion reaction even under conditions where a combustion reaction would not be stable when supported by a conventional flame holder. This capability can be leveraged to support combustion using a leaner fuel-to-oxidant mixture than is typically feasible. Thus, according to an embodiment, at the point where thefuel stream 206 contacts theinput face 212 of theperforated flame holder 102, an average fuel-to-oxidant ratio of thefuel stream 206 is below a (conventional) lower combustion limit of the fuel component of thefuel stream 206—lower combustion limit defines the lowest concentration of fuel at which a fuel andoxidant mixture 206 will burn when exposed to a momentary ignition source under normal atmospheric pressure and an ambient temperature of 25° C. (77° F.). - The
perforated flame holder 102 and systems including theperforated flame holder 102 described herein were found to provide substantially complete combustion of CO (single digit ppm down to undetectable, depending on experimental conditions), while supporting low NOx. According to one interpretation, such a performance can be achieved due to a sufficient mixing used to lower peak flame temperatures (among other strategies). Flame temperatures tend to peak under slightly rich conditions, which can be evident in any diffusion flame that is insufficiently mixed. By sufficiently mixing, a homogenous and slightly lean mixture can be achieved prior to combustion. This combination can result in reduced flame temperatures, and thus reduced NOx formation. In one embodiment, “slightly lean” may refer to 3% O2, i.e. an equivalence ratio of ˜0.87. Use of even leaner mixtures is possible, but may result in elevated levels of O2. Moreover, the inventors believeperforation walls 308 may act as a heat sink for the combustion fluid. This effect may alternatively or additionally reduce combustion temperatures and lower NOx. - According to another interpretation, production of NOx can be reduced if the
combustion reaction 302 occurs over a very short duration of time. Rapid combustion causes the reactants (including oxygen and entrained nitrogen) to be exposed to NOx-formation temperature for a time too short for NOx formation kinetics to cause significant production of NOx. The time required for the reactants to pass through theperforated flame holder 102 is very short compared to a conventional flame. The low NOx production associated with perforated flame holder combustion may thus be related to the short duration of time required for the reactants (and entrained nitrogen) to pass through theperforated flame holder 102. -
FIG. 4 is a flow chart showing amethod 400 for operating a burner system including the perforated flame holder shown and described herein. To operate a burner system including a perforated flame holder, the perforated flame holder is first heated to a temperature sufficient to maintain combustion of the fuel and oxidant mixture. - According to a simplified description, the
method 400 begins withstep 106, wherein the perforated flame holder is preheated to a start-up temperature, TS. After the perforated flame holder is raised to the start-up temperature, the method proceeds to step 404, wherein fuel and oxidant are provided to the perforated flame holder and combustion is held by the perforated flame holder. - According to a more detailed description,
step 106 begins withstep 406, wherein start-up energy is provided at the perforated flame holder. Simultaneously or following providing start-up energy, adecision step 408 determines whether the temperature T of the perforated flame holder is at or above the start-up temperature, TS. As long as the temperature of the perforated flame holder is below its start-up temperature, the method loops betweensteps preheat step 106. Instep 408, if the temperature T of at least a predetermined portion of the perforated flame holder is greater than or equal to the start-up temperature, themethod 400 proceeds tooverall step 404, wherein fuel and oxidant is supplied to and combustion is held by the perforated flame holder. - Step 404 may be broken down into several discrete steps, at least some of which may occur simultaneously.
- Proceeding from
step 408, a fuel and oxidant mixture is provided to the perforated flame holder, as shown instep 108. The fuel and oxidant may be provided by a fuel and oxidant source that includes a separate fuel nozzle and combustion air source, for example. In this approach, the fuel and combustion air are output in one or more directions selected to cause the fuel and combustion air mixture to be received by an input face of the perforated flame holder. The fuel may entrain the combustion air (or alternatively, the combustion air may dilute the fuel) to provide a fuel and oxidant mixture at the input face of the perforated flame holder at a fuel dilution selected for a stable combustion reaction that can be held within the perforations of the perforated flame holder. - Proceeding to step 412, the combustion reaction is held by the perforated flame holder.
- In
step 414, heat may be output from the perforated flame holder. The heat output from the perforated flame holder may be used to power an industrial process, heat a working fluid, generate electricity, or provide motive power, for example. - In
optional step 416, the presence of combustion may be sensed. Various sensing approaches have been used and are contemplated by the inventors. Generally, combustion held by the perforated flame holder is very stable and no unusual sensing requirement is placed on the system. Combustion sensing may be performed using an infrared sensor, a video sensor, an ultraviolet sensor, a charged species sensor, thermocouple, thermopile, and/or other known combustion sensing apparatuses. In an additional or alternative variant ofstep 416, a pilot flame or other ignition source may be provided to cause ignition of the fuel and oxidant mixture in the event combustion is lost at the perforated flame holder. - Proceeding to
decision step 418, if combustion is sensed not to be stable, themethod 400 may exit to step 424, wherein an error procedure is executed. For example, the error procedure may include turning off fuel flow, re-executing the preheatingstep 106, outputting an alarm signal, igniting a stand-by combustion system, or other steps. If, instep 418, combustion in the perforated flame holder is determined to be stable, themethod 400 proceeds todecision step 420, wherein it is determined if combustion parameters should be changed. If no combustion parameters are to be changed, the method loops (within step 404) back to step 108, and the combustion process continues. If a change in combustion parameters is indicated, themethod 400 proceeds to step 422, wherein the combustion parameter change is executed. After changing the combustion parameter(s), the method loops (within step 404) back to step 108, and combustion continues. - Combustion parameters may be scheduled to be changed, for example, if a change in heat demand is encountered. For example, if less heat is required (e.g., due to decreased electricity demand, decreased motive power requirement, or lower industrial process throughput), the fuel and oxidant flow rate may be decreased in
step 422. Conversely, if heat demand is increased, then fuel and oxidant flow may be increased. Additionally or alternatively, if the combustion system is in a start-up mode, then fuel and oxidant flow may be gradually increased to the perforated flame holder over one or more iterations of the loop withinstep 404. - Referring again to
FIG. 2 , theburner system 200 includes aheater 228 operatively coupled to theperforated flame holder 102. As described in conjunction withFIGS. 3 and 4 , theperforated flame holder 102 operates by outputting heat to the incoming fuel andoxidant mixture 206. After combustion is established, this heat is provided by thecombustion reaction 302; but before combustion is established, the heat is provided by theheater 228. - Various heating apparatuses have been used and are contemplated by the inventors. In some embodiments, the
heater 228 can include a flame holder configured to support a flame disposed to heat theperforated flame holder 102. The fuel andoxidant source 202 can include afuel nozzle 218 configured to emit afuel stream 206 and anoxidant source 220 configured to output oxidant (e.g., combustion air) adjacent to thefuel stream 206. Thefuel nozzle 218 andoxidant source 220 can be configured to output thefuel stream 206 to be progressively diluted by the oxidant (e.g., combustion air). Theperforated flame holder 102 can be disposed to receive a diluted fuel andoxidant mixture 206 that supports acombustion reaction 302 that is stabilized by theperforated flame holder 102 when theperforated flame holder 102 is at an operating temperature. A start-up flame holder, in contrast, can be configured to support a start-up flame at a location corresponding to a relatively unmixed fuel and oxidant mixture that is stable without stabilization provided by the heatedperforated flame holder 102. - The
burner system 200 can further include acontroller 230 operatively coupled to theheater 228 and to adata interface 232. For example, thecontroller 230 can be configured to control a start-up flame holder actuator configured to cause the start-up flame holder to hold the start-up flame when theperforated flame holder 102 needs to be pre-heated and to not hold the start-up flame when theperforated flame holder 102 is at an operating temperature (e.g., when T≥TS). - Various approaches for actuating a start-up flame are contemplated. In one embodiment, the start-up flame holder includes a mechanically-actuated bluff body configured to be actuated to intercept the fuel and
oxidant mixture 206 to cause heat-recycling and/or stabilizing vortices and thereby hold a start-up flame; or to be actuated to not intercept the fuel andoxidant mixture 206 to cause the fuel andoxidant mixture 206 to proceed to theperforated flame holder 102. In another embodiment, a fuel control valve, blower, and/or damper may be used to select a fuel and oxidant mixture flow rate that is sufficiently low for a start-up flame to be jet-stabilized; and upon reaching aperforated flame holder 102 operating temperature, the flow rate may be increased to “blow out” the start-up flame. In another embodiment, theheater 228 may include an electrical power supply operatively coupled to thecontroller 230 and configured to apply an electrical charge or voltage to the fuel andoxidant mixture 206. An electrically conductive start-up flame holder may be selectively coupled to a voltage ground or other voltage selected to attract the electrical charge in the fuel andoxidant mixture 206. The attraction of the electrical charge was found by the inventors to cause a start-up flame to be held by the electrically conductive start-up flame holder. - In another embodiment, the
heater 228 may include an electrical resistance heater configured to output heat to theperforated flame holder 102 and/or to the fuel andoxidant mixture 206. The electrical resistance heater can be configured to heat up theperforated flame holder 102 to an operating temperature. Theheater 228 can further include a power supply and a switch operable, under control of thecontroller 230, to selectively couple the power supply to the electrical resistance heater. - An
electrical resistance heater 228 can be formed in various ways. For example, theelectrical resistance heater 228 can be formed from KANTHAL® wire (available from Sandvik Materials Technology division of Sandvik AB of Hallstahammar, Sweden) threaded through at least a portion of theperforations 210 defined by the perforatedflame holder body 208. Alternatively, theheater 228 can include an inductive heater, a high-energy beam heater (e.g. microwave or laser), a frictional heater, electro-resistive ceramic coatings, or other types of heating technologies. - Other forms of start-up apparatuses are contemplated. For example, the
heater 228 can include an electrical discharge igniter or hot surface igniter configured to output a pulsed ignition to the oxidant and fuel. Additionally or alternatively, a start-up apparatus can include a pilot flame apparatus disposed to ignite the fuel andoxidant mixture 206 that would otherwise enter theperforated flame holder 102. The electrical discharge igniter, hot surface igniter, and/or pilot flame apparatus can be operatively coupled to thecontroller 230, which can cause the electrical discharge igniter or pilot flame apparatus to maintain combustion of the fuel andoxidant mixture 206 in or upstream from theperforated flame holder 102 before theperforated flame holder 102 is heated sufficiently to maintain combustion. - The
burner system 200 can further include asensor 234 operatively coupled to thecontrol circuit 230. Thesensor 234 can include a heat sensor configured to detect infrared radiation or a temperature of theperforated flame holder 102. Thecontrol circuit 230 can be configured to control theheating apparatus 228 responsive to input from thesensor 234. Optionally, afuel control valve 236 can be operatively coupled to thecontroller 230 and configured to control a flow of fuel to the fuel andoxidant source 202. Additionally or alternatively, an oxidant blower ordamper 238 can be operatively coupled to thecontroller 230 and configured to control flow of the oxidant (or combustion air). - The
sensor 234 can further include a combustion sensor operatively coupled to thecontrol circuit 230, the combustion sensor being configured to detect a temperature, video image, and/or spectral characteristic of a combustion reaction held by theperforated flame holder 102. Thefuel control valve 236 can be configured to control a flow of fuel from a fuel source to the fuel andoxidant source 202. Thecontroller 230 can be configured to control thefuel control valve 236 responsive to input from thecombustion sensor 234. Thecontroller 230 can be configured to control thefuel control valve 236 and/or oxidant blower or damper to control a preheat flame type ofheater 228 to heat theperforated flame holder 102 to an operating temperature. Thecontroller 230 can similarly control thefuel control valve 236 and/or the oxidant blower or damper to change the fuel andoxidant mixture 206 flow responsive to a heat demand change received as data via thedata interface 232. -
FIG. 5 is a simplified side sectional view of theburner system 500 ofFIGS. 2-3 , according to an embodiment. - According to an embodiment, the
combustion volume 204 is defined by abase surface 502 andinner surfaces 504 of sidewalls substantially enclosing thecombustion volume 204 laterally. - As used in the specification and claims, the term fuel stream is to be construed broadly, as reading on a stream of fuel; fuel and oxidant; and/or fuel, oxidant, and diluent. Some or all of the non-fuel components of a fuel stream may be premixed with the fuel or entrained, such as by a stream of fuel as it exits a
nozzle 218. - According to an embodiment, flue gas is vented to the atmosphere through an
exhaust flue 506. Optionally, the vented flue gas may pass through convective heat transfer tubes and/or an economizer that pre-heats the combustion air, the fuel, and/or feed water. - The
perforated flame holder 102 is shown inFIG. 2 as being rectangular and as havingapertures 210 that are substantially square, as viewed from above. According to other embodiments, theperforated flame holder 102 may have any appropriate shape, including square, round, hexagonal, etc. Likewise, theapertures 210 may have any appropriate shape, including round, square, rectangular, hexagonal, etc., and may be arranged according to any configuration that meets the requirements of the particular application. According to an embodiment, theapertures 210 are arranged in an X-Y grid, as shown inFIG. 2 , at a pitch of between 0.1″ and 0.5″. The walls defining and separating theapertures 210 may have a thickness that corresponds to an overall “porosity” of theperforated flame holder 102 of between about 30% and 80%. Thus, for example, according to an embodiment in which theapertures 210 have, in plan view, a square shape and a pitch of 0.25″, eachaperture 210 has a width of about 0.206″, separated by walls having a thickness of about 0.041″, yielding a porosity of about 70%. -
FIG. 6 shows a detail of theburner system 500 ofFIG. 5 , as indicated at 3 inFIG. 5 , according to an embodiment. As shown inFIG. 6 , during normal operation of theburner system 500, theupper boundary 302 b and thelower boundary 302 a of the flame may extend only a small distance above and below theperforated flame holder 102, respectively. Thus, the majority of the fuel within thefuel stream 206 may be combusted within theapertures 210 of theperforated flame holder 102. - While the depiction of the
flame boundaries elongated apertures 210, but the “glow” of combustion heat is dominated by a visible glow of theperforated flame holder 102 itself. In other instances, the inventors have noted transient “huffing” wherein a visible flame momentarily ignites in a region lying between theinput face 212 of theperforated flame holder 102 and the fuel source 218 (e.g., seeFIGS. 2 and 5 ), within the dilution region DD. Such transient huffing is generally short in duration such that, on a time-averaged basis, a majority of combustion may occur within theapertures 210 of theperforated flame holder 102, between theinput face 212 and theoutput face 214 of theperforated flame holder 102. In still other instances, the inventors have noted apparent combustion occurring above theoutput face 214 of theperforated flame holder 102, but still a majority of combustion occurred within the perforated flame holder as evidenced by the continued visible glow (a visible wavelength tail of blackbody radiation) from theperforated flame holder 102. - According to an embodiment, heat output of the
perforated burner system 500 is controlled by regulation of the flow rate of fuel in the fuel stream. Heat output may be determined by direct measurement at theperforated flame holder 102, or may be inferred indirectly, based on measurements taken at other locations within the burner system, such as at a flue outlet or at an outlet of a working fluid, etc. For example, on the basis of empirical data, a table may be prepared from which a heat output value may be derived, given a flow rate, based on an input temperature and an output temperature of a working fluid. - For the purposes of this disclosure, moderate heat output is heat output at values exceeding about 215 kBTU/H/ft2 (1.5 kBTU/H/in2), and high heat output is heat output at values exceeding about 430 kBTU/H/ft2 (3 kBTU/H/in2).
- During normal operation, according to an embodiment, heat output of the
burner system 500 is greater than 500 kBTU/H/ft2, or about 3.5 kBTU/H/in2 (158 W/cm2). In experiments conducted by the inventors,perforated flame holders 102 like the one described above were routinely operated at heat outputs of about 1 MBTU/H/ft2 (7 kBTU/H/in2) or more, and in some tests, reached or exceeded levels of about 5 MBTU/H/ft2 (35 kBTU/H/in2). - According to respective embodiments, heat output of the
burner system 500 is greater than 1 MBTU/H/ft2 (about 7 kBTU/H/in2), 3 MBTU/H/ft2 (about 21 kBTU/H/in2), and 5 MBTU/H/ft2 (about 35 kBTU/H/in2). - One of the factors that enables operation at these high levels of heat output is that, according to an embodiment, active combustion occurs substantially along the entire length of the
apertures 210. As a result, the entire body of theperforated flame holder 102 may be held at a temperature at or above the auto-ignition temperature of the fuel component of thefuel stream 206. Thus, thefuel stream 206 may be nominally ignited as it travels through theapertures 210 of theperforated flame holder 102 and the combustion process is complete, or nearly so, by the time the reactants have traversed the length of the apertures 210 (e.g., the thickness of the perforated flame holder 102). In many prior art systems, the output side of a ceramic burner tile is heated to a point where it radiates energy in infrared wavelengths, but the input side is cooled by the incoming fuel stream, and remains much cooler, particularly at moderate and high heat output, so that combustion begins only as thefuel stream 206 nears theoutput face 214 of the burner, or even beyond theoutput face 214. In fact, many prior art systems rely on the cooling effect of the fuel stream. As the Sarkisian reference explains, “the ceramic tile, which is cooled by the reactants, effectively insulates the upstream reactants from the hot downstream combustion products, preventing flashback.” - In order to initiate operation of the
burner system 500 and enable the levels of heat output described with reference to various embodiments, theperforated flame holder 102 is preheated during a start-up procedure (or held indefinitely at an elevated temperature) such that at least a portion of theperforated flame holder 102 is at a temperature that exceeds the auto-ignition temperature of the fuel component of thefuel stream 206. - Any appropriate method of preheating the
perforated flame holder 102 may be employed. A number of structures and methods for preheating a perforated flame holder are disclosed, for example, in International Patent Application No. PCT/US2014/016632, entitled “FUEL COMBUSTION SYSTEM WITH A PERFORATED REACTION HOLDER,” filed Feb. 14, 2014 (docket number 2651-188-04); which, to the extent not inconsistent with the disclosure herein, is incorporated by reference. - One structure and corresponding method for preheating the
perforated flame holder 102 are described hereafter with reference toFIGS. 7 and 8 . -
FIGS. 7 and 8 are diagrammatic views of aburner system 700 during respective modes of operation, according to an embodiment. Theburner system 700 includes aperforated flame holder 102 and anozzle 218 as described above with reference to theburner system 100. Optionally, theburner system 700 includes acontroller 706, and first andsecond electrodes first electrode 702 is configured as a flame holder electrode, while thesecond electrode 704 is configured as a charge electrode. Thecontroller 706 is operatively coupled to thefirst electrode 702 and thesecond electrode 704 viaconnectors 708, and is configured to apply an electrical potential across the first andsecond electrodes - In the embodiment shown, the
first electrode 702 has an annular shape, such as, for example, the shape of a toroid, and is positioned a distance DN from thenozzle 218, with a center axis aligned with a longitudinal axis of thenozzle 218. During operation, afuel stream 206 emitted from thenozzle 218 will preferably have a conical shape, with a diameter that increases as a function of the distanced from thenozzle 218, according to an embodiment. Typically, the angle of dispersion of thefuel stream 206 is about 15 degrees, relative to the longitudinal axis of thenozzle 218. According to an embodiment, an inside diameter of thefirst electrode 702 is selected to be greater than a diameter of thefuel stream 206 at the distance DN. According to another embodiment, the inside diameter of thefirst electrode 702 is selected to be equal to, or slightly less than the diameter of thefuel stream 206 at the distance DN. - The
nozzle 218 is configured to receive a flow of fuel via afuel line 710. Avalve 712 is coupled to thefuel line 710, and is configured to regulate a flow of fuel to thenozzle 218. Thecontroller 706 is operatively coupled to thevalve 712 via aconnector 714, and is configured to provide a signal on theconnector 714 by which operation of thevalve 712 is controlled. - In
FIG. 7 , theburner system 700 is shown in a preheat mode of operation. While operating in the preheat mode, thecontroller 706 controls thevalve 712 to admit a flow of fuel to thenozzle 218 while simultaneously applying a voltage across the first andsecond electrodes preheat flame 716 is ignited in thefuel stream 206 by any of a number of well-known methods. According to an embodiment, thesecond electrode 704 applies a charge of a first polarity to thepreheat flame 716, while a voltage of an opposite polarity (or a ground potential) present at thefirst electrode 702 attracts charged species within thepreheat flame 716. As a result, aflame front 718 of thepreheat flame 716 is held in a region near thefirst electrode 702, which holds a substantial portion of thepreheat flame 716 between thenozzle 218 and theperforated flame holder 102. With thepreheat flame 716 in this position, theperforated flame holder 102 is heated by theflame 716. - According to an embodiment, the
controller 706 is configured to apply an electrical potential that varies over time, such as, for example, an AC voltage, or an AC voltage with a DC offset. According to an embodiment, the electrical potential applied by thecontroller 706 has a peak-to-peak value that exceeds 10 kV. According to another embodiment, the electrical potential applied by thecontroller 706 has a peak-to-peak value that exceeds 20 kV. According to a further embodiment, the electrical potential applied by thecontroller 706 has a peak-to-peak value that exceeds 40 kV. - According to an embodiment, one or more amplifiers are provided, configured to receive a time-varying signal from the
controller 706, to amplify the signal, and to provide the amplified signal to the first andsecond electrodes - In embodiments in which the inside diameter of the
first electrode 702 is greater than the diameter of thefuel stream 206 at the distance DN, there is no direct contact of thepreheat flame 716 with thefirst electrode 702. Thus, there is no direct electrical path between the first andsecond electrodes second electrodes - According to an embodiment, when at least a portion of the
perforated flame holder 102 has been heated to a selected minimum start-up temperature by thepreheat flame 716, theburner system 700 transitions from the preheat mode to a heating mode (i.e., normal operation), as shown inFIG. 8 . While transitioning to the heating mode of operation, thecontroller 706 terminates the application of the electrical potential across the first andsecond electrodes valve 712 to admit fuel to thenozzle 218. Because of the velocity thefuel stream 206, in the absence of the charge applied to theflame 302 via thesecond electrode 704 and the counter charge present at thefirst electrode 702, thepreheat flame 716 is blown off the holdingfirst electrode 702. However, the minimum start-up temperature of theperforated flame holder 102 is selected to be greater than the auto-ignition temperature of the fuel in thefuel stream 206. Thus, when thepreheat flame 716 is no longer held by a start-upflame holder 702, thefuel stream 206 is ignited within theapertures 210 of theperforated flame holder 102, and stable combustion commences at theperforated flame holder 102. - The
optional controller 706 can regulate the heat output of theburner system 700 by controlling the volume of fuel admitted by thevalve 712 and/or a volume of oxidant provided by a combustion air source. Combustion continue substantially as described with reference toFIGS. 2 and 5 . - Turning now to
FIGS. 9-12 , flowcharts illustrating various methods of operation of burner systems are shown, according to respective embodiments. It should be noted that in the methods disclosed hereafter, many of the steps disclosed are not mandatory or essential. Additionally, many steps disclosed with respect to one method can be combined with other methods, as appropriate, and according to the particular circumstances. For example, while only included as an element of the process ofFIG. 9 , the preheat step described with reference to step 106 can be incorporated into any of the disclosed methods, as appropriate. -
FIG. 9 is a flowchart of amethod 900 of operating a burner system, according to an embodiment. This method begins with the assumption that the burner is not initially in a heating operation or mode. Instep 106, a perforated flame holder is preheated to a selected start-up temperature. This step may involve preheating only a portion of the perforated flame holder, or alternatively, the entire perforated flame holder can be preheated to the selected start-up temperature. According to an embodiment, the selected start-up temperature is a temperature that exceeds the auto-ignition temperature of the fuel component of the fuel stream. The selected start-up temperature can also be a temperature that exceeds the auto-ignition temperature of the fuel component of the fuel stream plus an incremental additional temperature selected such that the perforated flame holder can hold sufficient heat energy to sustain the combustion reaction for a period after start-up. During start-up, the inventors have found that the temperature of the perforated flame holder may tend to dip upon introduction of a cool fuel and oxidant mixture to the perforated flame holder. The incremental additional temperature is selected to maintain at least the auto-ignition temperature through this temperature dip of the perforated flame holder. - Once the selected minimum start-up temperature of the perforated flame holder is achieved, the process advances to step 108, in which a fuel stream that includes a fuel component and an oxidant component is introduced to an input face of the perforated flame holder. It should be noted that emission of the fuel stream from a nozzle can begin as part of
step 106, or can be started at the end ofstep 106. For example, in the preheating process described above with reference toFIGS. 7 and 8 , the fuel stream initially supports the preheat flame, which is used during startup to preheat the perforated flame holder. However, because the flame is held between the nozzle and the flame holder during the preheat step, the fuel stream, per se, does not reach the perforated flame holder until the electrodes are de-energized. In other preheat processes, emission of the fuel stream does not begin until the perforated flame holder is at its minimum start-up temperature. In such processes, the perforated flame holder is preheated using other means, such as by an electrical heating element, laser bombardment, etc. - In
step 412, the fuel stream is combusted, in majority, between the input face and an output face of the perforated flame holder. In this context, combustion of the fuel stream refers to the combustion process in which the fuel component is converted to combustion products. That is, a majority of the combustion process occurs between the input and output faces of the perforated flame holder. Determination of the degree to which the combustion process is complete can be on any reasonable basis, including, for example, the percentage of fuel—i.e., the fuel component of the fuel stream—that is converted to combustion products between the input and output faces of the perforated flame holder relative to the total amount of fuel that is converted within the burner system, or the percentage of thermal energy that is released by the process of combustion between the input and output faces of the perforated flame holder relative to the total amount of thermal energy released within the burner system. - According to an embodiment, at least 80% of the combustion process occurs between the input and output faces of the perforated flame holder.
- Finally, in
step 908, combustion of the fuel stream is used to produce at least a minimum heat output of the burner system, of about 216 kBTU/H/ft2 (1.5 kBTU/H/in2). According to another embodiment, the minimum heat output is about 432 kBTU/H/ft2 (3 kBTU/H/in2). According to respective further embodiments, the minimum heat output is about 7 kBTU/H/in2, about 21 kBTU/H/in2, and about 35 kBTU/H/in2. 7 kBTU/H/in2 corresponds to about 1 MBTU/H/ft2 (i.e., one million BTUH per square foot, or about 15.4 million watts per square meter). Thus, 21 kBTU/H/in2, and 35 kBTU/H/in2 correspond, respectively, to about 3 MBTU/H/ft2 and about 5 MBTU/H/ft2. -
FIG. 10 is a flowchart of amethod 1000 of operating a burner system, according to another embodiment. Instep 108, a fuel stream that includes a fuel component and an oxidant component is introduced to an input face of a perforated flame holder, substantially as described above with reference to step 108. - In
step 1004, the fuel stream is combusted at the perforated flame holder. Instep 1006, combustion of the fuel stream is used to produce a heat output of the burner system of at least about 7 kBTU/H/in2. According to respective alternative embodiments, combustion of the fuel stream is used to produce a heat output of at least about 21 kBTU/H/in2, and at least about 35 kBTU/H/in2. - According to an embodiment, as set forth in step 1008, a majority of the combustion is performed between the input face and an output face of the perforated flame holder, substantially as described with reference to step 412.
-
FIG. 11 is a flowchart of amethod 1100 of operating a burner system, according to another embodiment. Instep 108, a fuel stream is introduced to an input face of a perforated flame holder, substantially as previously described. Instep 1104, the fuel stream is combusted at the perforated flame holder, and instep 1106, combustion of the fuel stream is used to produce at least a minimum heat output, of about 216 kBTU/H/ft2 (1.5 kBTU/H/in2). According to another embodiment, the minimum heat output is about 1 MBTU/H/ft2. - In
step 1108, while producing at least the minimum heat output, the input face of the perforated flame holder is maintained at a temperature that exceeds an auto-ignition temperature of a fuel component of the fuel stream. According to an embodiment, the input face of the perforated flame holder is maintained at a temperature of at least 1100 degrees F. (about 593 degrees C.). - According to an embodiment, combustion of the fuel stream is initiated as the fuel stream enters the input face of the perforated flame holder. According to another embodiment, a majority of the combustion is performed between the input face and an output face of the perforated flame holder.
-
FIG. 12 is a flowchart of amethod 1200 of operating a burner system, according to a further embodiment. Instep 1202, a fuel stream is introduced to an input face of a perforated flame holder. The fuel stream ofstep 1202 has an average fuel-to-oxidant ratio that is below a lower combustion limit of a fuel component of the fuel stream. Nevertheless, instep 1204, the fuel stream is combusted at the perforated flame holder. According to an embodiment, as set forth atstep 412, a majority of the combustion is performed between the input face and an output face of the perforated flame holder. - According to another embodiment, as set forth at
step 1208, at least a portion of the perforated flame holder is maintained at a temperature that exceeds an auto-ignition temperature of a fuel component of the fuel stream. According to an embodiment, as set forth atstep 1210, combustion of the fuel stream is used to produce at least a minimum heat output, of about 216 kBTU/H/ft2 (1.5 kBTU/H/in2). -
FIG. 13A is a simplified perspective view of acombustion system 1300, including another alternativeperforated flame holder 102, according to an embodiment. Theperforated flame holder 102 is a reticulated ceramic perforated flame holder, according to an embodiment.FIG. 13B is a simplified side sectional diagram of a portion of the reticulated ceramicperforated flame holder 102 ofFIG. 13A , according to an embodiment. Theperforated flame holder 102 ofFIGS. 13A, 13B can be implemented in the various combustion systems described herein, according to an embodiment. Theperforated flame holder 102 is configured to support a combustion reaction (e.g.,combustion reaction 302 ofFIG. 3 ) of the fuel andoxidant mixture 206 received from the fuel andoxidant source 202 at least partially within theperforated flame holder 102. According to an embodiment, theperforated flame holder 102 can be configured to support a combustion reaction of the fuel andoxidant mixture 206 upstream, downstream, within, and adjacent to the reticulated ceramicperforated flame holder 102. - According to an embodiment, the perforated
flame holder body 208 can includereticulated fibers 1339. Thereticulated fibers 1339 can define branchingperforations 210 that weave around and through thereticulated fibers 1339. According to an embodiment, theperforations 210 are formed as passages between thereticulated fibers 1339. - According to an embodiment, the
reticulated fibers 1339 are formed as a reticulated ceramic foam. According to an embodiment, thereticulated fibers 1339 are formed using a reticulated polymer foam as a template. According to an embodiment, thereticulated fibers 1339 can include alumina silicate. According to an embodiment, thereticulated fibers 1339 can be formed from extruded mullite or cordierite. According to an embodiment, thereticulated fibers 1339 can include Zirconia. According to an embodiment, thereticulated fibers 1339 can include silicon carbide. - The term “reticulated fibers” refers to a netlike structure. According to an embodiment, the
reticulated fibers 1339 are formed from an extruded ceramic material. In reticulated fiber embodiments, the interaction between the fuel andoxidant mixture 206, the combustion reaction, and heat transfer to and from the perforatedflame holder body 208 can function similarly to the embodiment shown and described above with respect toFIGS. 2-4 . One difference in activity is a mixing betweenperforations 210, because thereticulated fibers 1339 form a discontinuous perforatedflame holder body 208 that allows flow back and forth between neighboringperforations 210, according to an embodiment. - According to an embodiment, the network of
reticulated fibers 1339 is sufficiently open for downstreamreticulated fibers 1339 to emit radiation for receipt by upstreamreticulated fibers 1339 for the purpose of heating the upstreamreticulated fibers 1339 sufficiently to maintain combustion of a fuel andoxidant mixture 206. Compared to a continuous perforatedflame holder body 208, heat conduction paths (such asheat conduction paths 312 inFIG. 3 ) betweenreticulated fibers 1339 are reduced due to separation of thereticulated fibers 1339. This may cause relatively more heat to be transferred from a heat-receiving region or area (such asheat receiving region 306 inFIG. 3 ) to a heat-output region or area (such as heat-output region 310 ofFIG. 3 ) of thereticulated fibers 1339 via thermal radiation (shown aselement 304 inFIG. 3 ). - According to an embodiment,
individual perforations 210 may extend between aninput face 212 to anoutput face 214 of theperforated flame holder 102.Perforations 210 may have varying lengths L. According to an embodiment, because theperforations 210 branch into and out of each other,individual perforations 210 are not clearly defined by a length L. - According to an embodiment, the
perforated flame holder 102 is configured to support or hold a combustion reaction (seeelement 302 ofFIG. 3 ) or a flame at least partially between theinput face 212 and theoutput face 214. According to an embodiment, theinput face 212 corresponds to a surface of theperforated flame holder 102 proximal to thefuel nozzle 218 or to a surface that first receives fuel. According to an embodiment, theinput face 212 corresponds to an extent of thereticulated fibers 1339 proximal to thefuel nozzle 218. According to an embodiment, theoutput face 214 corresponds to a surface distal to thefuel nozzle 218 or opposite theinput face 212. According to an embodiment, theinput face 212 corresponds to an extent of thereticulated fibers 1339 distal to thefuel nozzle 218 or opposite to theinput face 212. - According to an embodiment, the formation of
thermal boundary layers 314, transfer of heat between the perforatedflame holder body 208 and the gases flowing through theperforations 210, a characteristic perforation width dimension D, and the length L can each be regarded as related to an average or overall path through theperforated reaction holder 102. In other words, the dimension D can be determined as a root-mean-square of individual Dn values determined at each point along a flow path. Similarly, the length L can be a length that includes length contributed by tortuosity of the flow path, which may be somewhat longer than a straight line distance TRH from theinput face 212 to theoutput face 214 through theperforated reaction holder 102. According to an embodiment, the void fraction (expressed as (totalperforated reaction holder 102 volume−reticulated fiber 1339 volume)/total volume)) is about 70%. - According to an embodiment, the reticulated ceramic
perforated flame holder 102 is a tile about 1″×4″×4″. According to an embodiment, the reticulated ceramicperforated flame holder 102 includes about 100 pores per square inch of surface area. Other materials and dimensions can also be used for a reticulated ceramicperforated flame holder 102 in accordance with principles of the present disclosure. - According to an embodiment, the reticulated ceramic
perforated flame holder 102 can include shapes and dimensions other than those described herein. For example, theperforated flame holder 102 can include reticulated ceramic tiles that are larger or smaller than the dimensions set forth above. Additionally, the reticulated ceramicperforated flame holder 102 can include shapes other than generally cuboid shapes. - According to an embodiment, the reticulated ceramic
perforated flame holder 102 can include multiple reticulated ceramic tiles. The multiple reticulated ceramic tiles can be joined together such that each ceramic tile is in direct contact with one or more adjacent reticulated ceramic tiles. The multiple reticulated ceramic tiles can collectively form a singleperforated flame holder 102. Alternatively, each reticulated ceramic tile can be considered a distinctperforated flame holder 102. - While various aspects and embodiments have been disclosed herein, other aspects and embodiments are contemplated. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
Claims (46)
1. A method, comprising:
passing a fuel stream into a perforated flame holder having an input face, an output face, and a plurality of perforations extending between the input face and the output face; and
combusting the fuel stream, with a majority of the combustion occurring between the input face and the output face of the perforated flame holder; and
producing a heat output from the combustion of at least 216 kBTU/H/ft2.
2. The method of claim 1 , comprising, prior to performing the combusting the fuel stream, preheating the perforated flame holder.
3. The method of claim 2 , wherein the preheating the perforated flame holder comprises preheating at least a portion of the perforated flame holder to a temperature that exceeds an auto-ignition temperature of a fuel component of the fuel stream.
4. The method of claim 1 , wherein the combusting the fuel stream comprises completing at least 80% of the combustion of the fuel stream between the input face and the output face of the perforated flame holder.
5. The method of claim 1 , wherein the producing a heat output from the combustion of at least 216 kBTU/H/ft2 includes producing a heat output from the combustion of at least 432 kBTU/H/ft2.
6. The method of claim 1 , wherein the producing a heat output from the combustion of at least 216 kBTU/H/ft2 includes producing a heat output from the combustion of at least 1 MBTU/H/ft2.
7. The method of claim 1 , wherein the producing a heat output from the combustion of at least 216 kBTU/H/ft2 includes producing a heat output from the combustion of at least 3 MBTU/H/ft2.
8. The method of claim 1 , wherein the producing a heat output from the combustion of at least 216 kBTU/H/ft2 includes producing a heat output from the combustion of at least 5 MBTU/H/ft2.
9. A method of operation, comprising:
passing a fuel stream into a perforated flame holder;
combusting the fuel stream at the perforated flame holder; and
producing a heat output from the combustion of at least 1 MBTU/H/ft2.
10. The method of operation of claim 9 , comprising, prior to performing the combusting the fuel stream at the perforated flame holder, preheating the perforated flame holder.
11. The method of operation of claim 10 , wherein the preheating the perforated flame holder comprises preheating at least a portion of the perforated flame holder to a temperature that exceeds an auto-ignition temperature of a fuel component of the fuel stream.
12. The method of operation of claim 9 , wherein the combusting the fuel stream at the perforated flame holder comprises combusting a majority of a fuel component of the fuel stream between an input face and an output face of the perforated flame holder.
13. The method of operation of claim 12 , wherein the combusting a majority of a fuel component of the fuel stream between an input face and an output face of the perforated flame holder comprises combusting at least 80 percent of the fuel component of the fuel stream between the input face and the output face of the flame holder.
14. The method of operation of claim 12 , wherein the combusting a majority of a fuel component of the fuel stream between an input face and an output face of the perforated flame holder comprises combusting a majority of the fuel component of the fuel stream within apertures extending between the input face and the output face of the perforated flame holder.
15. The method of operation of claim 9 , wherein the producing a heat output from the combustion of at least 1 MBTU/H/ft2 comprises producing a heat output from the combustion of at least 3 MBTU/H/ft2.
16. The method of operation of claim 9 , wherein the combusting the fuel stream at the perforated flame holder at a rate of at least 1 MBTU/H/ft2 comprises combusting the fuel stream at a rate of at least 5 MBTU/H/ft2.
17. A method, comprising:
passing a fuel stream into a reticulated ceramic perforated flame holder;
combusting the fuel stream at the reticulated ceramic perforated flame holder;
producing at least a minimum heat output from the combustion of 216 kBTU/H/ft2; and
maintaining, while producing at least the minimum heat output, a temperature in at least a portion of the reticulated ceramic perforated flame holder that exceeds an auto-ignition temperature of a fuel component of the fuel stream.
18. The method of claim 17 , wherein the passing a fuel stream into a reticulated ceramic perforated flame holder comprises passing the fuel stream into a plurality of apertures extending between an input face and an output face of the reticulated ceramic perforated flame holder.
19. The method of claim 17 , wherein the combusting the fuel stream at the reticulated ceramic perforated flame holder comprises combusting a majority of the fuel component of the fuel stream within apertures extending between the input face and the output face of the reticulated ceramic perforated flame holder.
20. The method of claim 17 , wherein the maintaining a temperature in at least a portion of the reticulated ceramic perforated flame holder that exceeds an auto-ignition temperature of a fuel component of the fuel stream comprises maintaining a temperature at the input face of the reticulated ceramic perforated flame holder of at least 1100 degrees F.
21. The method of claim 17 , wherein the producing a heat output from the combustion of at least 216 kBTU/H/ft2 comprises producing a heat output from the combustion of at least 1 MBTU/H/ft2.
22. The method of claim 17 , comprising initiating combustion of the fuel stream as the fuel stream enters the input face of the reticulated ceramic perforated flame holder.
23. The method of claim 17 , wherein the reticulated ceramic perforated flame holder includes a plurality of reticulated fibers.
24. The method of claim 23 , wherein the reticulated ceramic perforated flame holder includes zirconia.
25. The method of claim 23 , wherein the reticulated ceramic perforated flame holder includes alumina silicate.
26. The method of claim 23 , wherein the reticulated ceramic perforated flame holder includes silicon carbide.
27. The method of claim 23 , wherein the reticulated fibers are formed from extruded mullite.
28. The method of claim 23 , wherein the reticulated fibers are formed from cordierite.
29. The method of claim 23 , wherein the reticulated ceramic perforated flame holder is configured to support a combustion reaction of the fuel and oxidant upstream, downstream, and within the reticulated ceramic perforated flame holder.
30. The method of claim 23 , wherein the reticulated ceramic perforated flame holder includes about 100 pores per square inch of surface area.
31. The method of claim 23 , wherein the reticulated fibers are formed as a reticulated ceramic foam.
32. The method of claim 23 , wherein the reticulated fibers are formed using a reticulated polymer foam as a template.
33. The method of claim 23 , wherein the reticulated ceramic perforated flame holder includes:
an input face;
an output face; and
a plurality of perforations extending between the input face and the output face.
34. The method of claim 33 , wherein the perforations are formed as passages between the reticulated fibers.
35. The method of claim 34 , wherein the perforations are branching perforations.
36. The method of claim 35 , wherein the perforations extend between the input face and the output face.
37. The method of claim 33 , wherein the input face corresponds to an extent of the reticulated fibers proximal to a fuel nozzle outputting the fuel.
38. The method of claim 37 , wherein the output face corresponds to an extent of the reticulated fibers distal to the fuel nozzle.
39. The method of claim 33 , wherein the combusting the fuel stream at the reticulated ceramic perforated flame holder includes supporting at least a portion of the combustion reaction within the reticulated ceramic perforated flame holder between the input face and the output face.
40. A method, comprising:
passing, into an input face of a perforated flame holder, a fuel stream having an average fuel-to-oxidant ratio that is below a lower combustion limit of a fuel component of the fuel stream; and
combusting the fuel stream at the perforated flame holder.
41. The method of claim 40 , comprising maintaining a temperature at an input face of the perforated flame holder that exceeds an auto-ignition temperature of the fuel component of the fuel stream.
42. The method of claim 40 , wherein the combusting the fuel stream at the perforated flame holder comprises combusting a majority of the fuel component of the fuel stream between an input face and an output face of the perforated flame holder.
43. The method of claim 42 , wherein the combusting a majority of the fuel component of the fuel stream between an input face and an output face of the perforated flame holder comprises combusting a majority of the fuel component of the fuel stream within apertures extending in the perforated flame holder between the input face and the output face.
44. The method of claim 40 , wherein the combusting the fuel stream at the perforated flame holder comprises combusting at least 80 percent of the fuel component of the fuel stream between an input face and an output face of the perforated flame holder.
45. The method of claim 40 , wherein the combusting the fuel stream at the perforated flame holder comprises producing a heat output from the combustion of at least 1 MBTU/H/ft2.
46. The method of claim 40 , wherein the perforated flame holder is a reticulated ceramic perforated flame holder.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US16/160,145 US20190049107A1 (en) | 2013-02-14 | 2018-10-15 | High output porous tile burner |
Applications Claiming Priority (10)
Application Number | Priority Date | Filing Date | Title |
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US201361765022P | 2013-02-14 | 2013-02-14 | |
US201461931407P | 2014-01-24 | 2014-01-24 | |
PCT/US2014/016632 WO2014127311A1 (en) | 2013-02-14 | 2014-02-14 | Fuel combustion system with a perforated reaction holder |
PCT/US2014/016628 WO2014127307A1 (en) | 2013-02-14 | 2014-02-14 | Perforated flame holder and burner including a perforated flame holder |
PCT/US2015/012843 WO2015112950A1 (en) | 2014-01-24 | 2015-01-26 | LOW NOx FIRE TUBE BOILER |
PCT/US2015/016152 WO2015123670A1 (en) | 2013-02-14 | 2015-02-17 | High output porous tile burner |
US201514763271A | 2015-07-24 | 2015-07-24 | |
US15/215,401 US10359213B2 (en) | 2013-02-14 | 2016-07-20 | Method for low NOx fire tube boiler |
US15/235,517 US10125983B2 (en) | 2013-02-14 | 2016-08-12 | High output porous tile burner |
US16/160,145 US20190049107A1 (en) | 2013-02-14 | 2018-10-15 | High output porous tile burner |
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US15/235,517 Continuation-In-Part US10125983B2 (en) | 2013-02-14 | 2016-08-12 | High output porous tile burner |
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US20190049107A1 true US20190049107A1 (en) | 2019-02-14 |
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US16/160,145 Abandoned US20190049107A1 (en) | 2013-02-14 | 2018-10-15 | High output porous tile burner |
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Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11156356B2 (en) | 2013-02-14 | 2021-10-26 | Clearsign Technologies Corporation | Fuel combustion system with a perforated reaction holder |
US11221137B2 (en) | 2017-03-03 | 2022-01-11 | Clearsign Combustion Corporation | Field installed perforated flame holder and method of assembly and installation |
US11415316B2 (en) | 2017-03-02 | 2022-08-16 | ClearSign Technologies Cosporation | Combustion system with perforated flame holder and swirl stabilized preheating flame |
US11460188B2 (en) * | 2013-02-14 | 2022-10-04 | Clearsign Technologies Corporation | Ultra low emissions firetube boiler burner |
-
2018
- 2018-10-15 US US16/160,145 patent/US20190049107A1/en not_active Abandoned
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11156356B2 (en) | 2013-02-14 | 2021-10-26 | Clearsign Technologies Corporation | Fuel combustion system with a perforated reaction holder |
US11460188B2 (en) * | 2013-02-14 | 2022-10-04 | Clearsign Technologies Corporation | Ultra low emissions firetube boiler burner |
US11415316B2 (en) | 2017-03-02 | 2022-08-16 | ClearSign Technologies Cosporation | Combustion system with perforated flame holder and swirl stabilized preheating flame |
US11221137B2 (en) | 2017-03-03 | 2022-01-11 | Clearsign Combustion Corporation | Field installed perforated flame holder and method of assembly and installation |
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