US-12618557-B2 - Burner apparatus

US12618557B2US 12618557 B2US12618557 B2US 12618557B2US-12618557-B2

Abstract

A burner apparatus is disclosed. The burner apparatus comprising a tube having a proximal portion, a middle portion, and a distal portion, a fuel inlet port adapted to receive fuel inside the tube. The fuel inlet port splits into a first conduit and a second conduit, an air inlet port receives air inside the tube, at least one air swirler unit positioned at the middle portion of the tube, generates a swirling air flow and an axial air flow from the air received, a block having a plurality of staged fuel tips, receives fuel from the second conduit. The block discharges a primary flame by containing the fuel received from the first conduit and the swirling air flow, and provide for a secondary flame by directing the fuel received from the plurality of staged fuel tips into the primary flame downstream of the primary flame attachment point.

Inventors

Joshua Weaver
Edward Lovett
Bradley Wright
Timothy Moore
Christopher Eldridge

Assignees

HONEYWELL INTERNATIONAL INC.

Dates

Publication Date: 20260505
Application Date: 20240923

Claims (13)

1 . A burner apparatus, comprising: a tube having a proximal portion, a middle portion, and a distal portion, wherein the middle portion of the tube comprises at least a reduction unit; a fuel inlet port at the proximal portion of the tube, wherein the fuel inlet port is split into a first conduit and a second conduit, wherein the first conduit is positioned coaxially within the tube and adapted to receive fuel inside the tube, wherein the second conduit bypasses a portion of the tube; an air inlet port at the proximal portion of the tube, and positioned perpendicular to the fuel inlet port, wherein the air inlet port is adapted to receive air inside the tube; at least one air swirler unit positioned at the middle portion of the tube and mounted around the first conduit, wherein the at least one air swirler unit is configured to generate a swirling air flow and an axial air flow from the air received through the air inlet port; the reduction unit positioned downstream of the at least one air swirler unit along a flow of the air, wherein the reduction unit has a tapered shape along the flow of the air, wherein the reduction unit increases a speed of the air received from the at least one air swirler unit; at least one fuel nozzle coupled to the first conduit at the distal portion of the tube, wherein the at least one fuel nozzle defines a plurality of nozzle tips, wherein the plurality of nozzle tips discharge the fuel from the first conduit into the tube to mix with the air received from the reduction unit, wherein the air received from the reduction unit have increased speed in comparison to the air received by the reduction unit from the at least one air swirler unit; and a block positioned at the distal portion of the tube and downstream of the at least one fuel nozzle, along the flow of the air, wherein the block comprising a plurality of staged fuel tips arranged around a periphery of the block, wherein each of the plurality of staged fuel tips are configured to receive fuel from the second conduit, wherein the block is configured to discharge a primary flame by containing the fuel received from the first conduit and the swirling air flow, and provide for a secondary flame by directing the fuel received from the plurality of staged fuel tips into the primary flame downstream of a primary flame attachment point.
2 . The burner apparatus of claim 1 , wherein the first conduit is positioned along the proximal portion and the middle portion of the tube and the second conduit bypasses the middle portion and merges at the distal portion of the tube.
3 . The burner apparatus of claim 1 , further comprising an air body positioned at the middle portion of the tube, wherein the air body receives the air from the air inlet port and directs the air towards the at least one air swirler unit.
4 . The burner apparatus of claim 1 , wherein the at least one air swirler unit comprises a swirler base and a plurality of swirl vanes attached along a periphery of the swirler base, wherein the swirler base and the plurality of swirl vanes are configured to divide the air into the swirling air flow and the axial air flow respectively, wherein the swirling air flow comprises an axial component and a tangential component, generated by each of the plurality of swirl vanes.
5 . The burner apparatus of claim 1 , further comprising a throat of the tube positioned around a periphery of the at least one fuel nozzle, wherein the axial air flow discharged from the at least one air swirler unit mixes with the fuel discharged from the at least one fuel nozzle at the throat of the tube.
6 . The burner apparatus of claim 5 , wherein the reduction unit positioned between the at least one air swirler unit and the throat of the tube.
7 . The burner apparatus of claim 1 , further comprising a stabilization disc attached at the distal portion of the tube, wherein the stabilization disc is configured to reduce velocity of the mixture of the air and the fuel to a flame velocity that stabilizes the primary flame.
8 . The burner apparatus of claim 1 , further comprising a fuel manifold coupled to the second conduit at the distal portion of the tube, wherein the fuel manifold is fluidly connected to each of the plurality of staged fuel tips, wherein the fuel manifold is configured to transfer the fuel from the second conduit to each of the plurality of staged fuel tips.
9 . The burner apparatus of claim 1 , wherein the plurality of staged fuel tips is fabricated at a predefined angle with respect to the first conduit, wherein each of the plurality of staged fuel tips are configured to discharge the fuel into a plurality of flow paths, wherein the plurality of flow paths is created around an outer circumference of a discharge section of the block.
10 . The burner apparatus of claim 9 , wherein the discharge section of the block is further configured to provide a shelter to the primary flame from an environment to resist the primary flame from changing temperature and cross-velocities.
11 . The burner apparatus of claim 9 , wherein the swirling air flow generated from the at least one air swirler unit exists from an outer periphery of the discharge section to create a recirculation zone in proximity to the plurality of flow paths, wherein the recirculation zone is configured to draw reduced oxygen flue gases and the fuel received from the plurality of staged fuel tips into the primary flame.
12 . The burner apparatus of claim 9 , wherein the predefined angle varies in a range between 30 degrees to 45 degrees.
13 . The burner apparatus of claim 1 , wherein the at least one air swirler unit is configured to rotate based on a force generated by the air received through the air inlet port.

Description

TECHNOLOGICAL FIELD Example embodiments of the present disclosure relate generally to an industrial burner, and more particularly, to a burner apparatus and a method thereof. BACKGROUND Industrial burners play a crucial role in reducing emissions in thermal processes, particularly with the use of low NOx burners, which are among the most cost-effective solutions for minimizing NOx emissions. However, achieving low CO emissions is also essential due to CO's toxicity and combustibility. Various strategies are employed to reduce NOx and CO emissions, such as using high excess air, premixing fuel and air, or flue gas recycling. These strategies, while effective, come with trade-offs, including decreased thermal efficiency, limited operational windows, and potential corrosion or CO issues. Fuel staging is another technique often applied to reduce NOx, especially in applications above auto-ignition temperatures. However, it can be less effective below auto-ignition without the aid of flue gas recycling or other compromises. A new approach allows fuel staging to be used effectively across a wider range of temperatures, both above and below auto-ignition, without relying on flue gas recycling, while maintaining a wide thermal turndown. Such approach offers a more versatile and cost-effective solution for reducing emissions in various industrial thermal applications. The inventors identified numerous deficiencies and problems in in existing technologies and processes, which are the subjects of embodiments described herein. Through applied effort, ingenuity, and innovation, many of these deficiencies and problems have been solved by developing solutions that are included in embodiments of the present disclosure, many examples of which are described in detail herein. BRIEF SUMMARY The following presents a summary of some example embodiments to provide a basic understanding of some aspects of the present disclosure. This summary is not an extensive overview and is intended to neither identify key or critical elements nor delineate the scope of such elements. It will also be appreciated that the scope of the disclosure encompasses many potential embodiments in addition to those here summarized, some of which will be further described in the detailed description that is presented later. In an example embodiment, a burner apparatus is disclosed. The burner apparatus comprising a tube having a proximal portion, a middle portion, and a distal portion, a fuel inlet port at the proximal portion of the tube, positioned coaxially within the tube and adapted to receive fuel inside the tube. Further, the fuel inlet port further splits into a first conduit and a second conduit, an air inlet port at the proximal portion of the tube, and positioned perpendicular to the fuel inlet port. Further, the air inlet port is adapted to receive air inside the tube, at least one air swirler unit positioned at the middle portion of the tube and mounted around the first conduit. Further, the at least one air swirler unit is configured to generate a swirling air flow and an axial air flow from the air received through the air inlet port, a block positioned at the distal portion of the tube and having a plurality of staged fuel tips arranged around a periphery of the block. Further, each of the plurality of staged fuel tips are configured to receive fuel from the second conduit. Further, the block is configured to discharge a primary flame by containing the fuel received from the first conduit and the swirling air flow, and provide for a secondary flame by directing the fuel received from the plurality of staged fuel tips into the primary flame downstream of the primary flame attachment point. In some embodiments, the first conduit is positioned along the proximal portion and the middle portion of the tube and the second conduit bypasses the middle portion and merges at the distal portion of the tube. In some embodiments, an air body positioned at the middle portion of the tube. Further, the air body receives the air from the air inlet port and directs the air towards the at least one air swirler unit. In some embodiments, the at least one air swirler unit comprises a swirler base and a plurality of swirl vanes attached along a periphery of the swirler base. Further, the swirler base and the plurality of swirl vanes are configured to divide the air into the swirling air flow and the axial air flow, respectively. Further, the swirling air flow comprises an axial component and a tangential component, generated by each of the plurality of swirl vanes. In some embodiments, at least one fuel nozzle coupled to the first conduit at the distal portion of the tube and fabricated with a plurality of nozzle tips. Further, each of the plurality of nozzles tips is configured to discharge the fuel to the distal portion of the tube to mix with the axial air flow. In some embodiments, a throat positioned around a periphery of the at least one fuel nozzle. Further