The invention relates to fuel combustion systems, components, and methods.
Liquid fuel burners can be classified into two categories: atomizing burners and vaporizing burners. In an atomizing burner, combinations of high pressures and high velocity air are used to flow liquid fuel through an orifice and to break up the fuel into small droplets. The small droplets of fuel mix with air, vaporize and burn, usually more readily than larger droplets of fuel, due to surface-to-volume ratio effects. In a vaporizing burner, fuel is heated and vaporized without the aid of atomization. The vaporized fuel then mixes with air and burns. In some cases, electric heaters are used to help vaporize the fuel; in other cases, heat from the combustion process is sufficient to vaporize the fuel. Pre-heated air can also help vaporize fuel from a wick.
Gaseous fuel burners need not vaporize fuel since the fuel starts in the vapor phase. Many gaseous fuel burners pre-mix or partially pre-mix fuel and air prior to combustion. A flame can be stabilized using recirculation of hot exhaust products, or by the use of a bluff body, or by the use of a foam or a fibrous material to pre-heat the fuel-air mixture and then to stabilize the flame on the metal fiber or foam, or by the use of a swirling flow-field which can re-circulate exhaust products and stabilize the flame over large variations in supply velocity.
The invention relates to fuel combustion systems, components, and methods.
The invention provides components, systems and methods to vaporize liquid fuels and to burn them with very low emissions in a burner that can also cleanly burn gaseous fuels. The burner and a controller for the burner can be used, for example, in external combustion engines, chemical processors, or heaters. In some embodiments, the burner is a swirl-stabilized burner that can stabilize combustion over a wide range of fuel types, including liquid or gaseous fuels, firing rates, and air/fuel ratios. Fuel flexibility of a burner or external combustion system can be very useful in emergency situations when choices of fuel can be limited.
The burner incorporates a mechanism for vaporizing liquid fuels without interrupting the swirl-stabilization and with limited tendency for coke formation. Gaseous fuels can operate on the same burner and pass through the vaporizing mechanism before mixing with air and combusting. The controller allows one system to operate with gaseous or liquid fuels without changes to any hardware; that is, a single burner can operate with gaseous fuels as well as liquid fuels.
In one aspect, the invention features a system, including a first source containing a liquid fuel; a second source containing a gaseous fuel; and a combustion burner connected to the first and second sources and selectively in fluid communication with the liquid fuel and the gaseous fuel to receive the fuels, wherein the burner is capable of switching between combustion of the liquid fuel and combustion of the gaseous fuel without modification to the burner or the system.
Embodiments may include one or more of the following features. The system further includes a controller configured to control flow of fuel from the first source or the second source to the burner. The system further includes a controller configured to control flow of fuel from the first source or the second source to the burner based on a measurement of an output of the burner. The system further includes a sensor configured to sense a temperature or a stoichiometry of a fuel/gas mixture. The burner includes a fuel inlet, a fuel outlet, and an air inlet overlapping at least a portion of the fuel outlet along a longitudinal axis of the burner. The air inlet has at least one dimension greater than at least one dimension of the fuel outlet. The burner includes a plurality of air inlets located about a periphery of the burner, the air inlets configured to direct air at a non-perpendicular angle to the periphery. The burner includes a thermally conductive porous material configured to vaporize the liquid fuel. The burner includes a space surrounding the porous material. The burner includes an air inlet and projections downstream of the air inlet, the projections configured to direct air and vaporized fuel in curved direction. The burner includes a burner outlet defined by a portion of a cone. The cone has an angle between approximately 0° and approximately 120°. The burner includes a fuel inlet, a vaporizer cavity in fluid communication with the fuel inlet, a fuel outlet in fluid communication with the vaporizer cavity, an air inlet in fluid communication with the fuel outlet, and a burner outlet in fluid communication with the air inlet. The burner further includes a thermally conductive porous material in the vaporizer cavity. The porous material is in fluid communication with the burner outlet only through the fuel outlet. The burner further includes a heater configured to heat the porous material. The burner further includes a space located downstream of the air inlet and surrounding the vaporizer cavity. The burner further includes projections in the space and configured to direct air and gaseous fuel in curved direction. The air inlet overlaps with at least a portion of the fuel outlet along a longitudinal axis of the burner.
In another aspect, the invention features a method of combustion, including introducing a first fuel in a first phase through a fuel inlet of a burner of a combustion system; and introducing a second fuel through the fuel inlet, the second fuel being in a second phase different from the first phase, wherein introduction of the second fuel to the burner is performed without modifying the burner or the combustion system.
Embodiments may include one or more of the following features. The method further includes controlling flow of the first fuel or the second fuel to the burner based on a measurement of an output of the burner. The method further includes measuring a temperature or an indication of stoichiometry of fuel air mixture of an output of the burner. The burner includes a fuel outlet and an air inlet overlapping at least a portion of the fuel outlet in a radial direction. The air inlet has at least one dimension greater than at least one dimension of the fuel outlet. The method further includes directing air at a non-perpendicular angle to a periphery of the burner. The method further includes vaporizing liquid fuel with a thermally conductive porous material. The method further includes mixing fuel and air in a space surrounding a porous material. The method further includes directing air and fuel in a curved direction. The burner includes a burner outlet defined by a portion of a cone. The cone has an angle from approximately 0° to approximately 120°. The burner includes a fuel inlet, a vaporizer cavity in fluid communication with the fuel inlet, a fuel outlet in fluid communication with the vaporizer cavity, an air inlet in fluid communication with the fuel outlet, and a burner outlet in fluid communication with the air inlet. The burner further includes a thermally conductive porous material in the vaporizer cavity. The porous material is in fluid communication with the burner outlet only through the fuel outlet. The burner further includes a heater configured to heat the porous material. The burner further includes a space located downstream of the air inlet and surrounding the vaporizer cavity. The burner further includes projections in the space and configured to direct air and gaseous fuel in curved direction. The air inlet overlaps with at least a portion of the fuel outlet along a radial direction of the burner. The burner includes a plurality of air inlets located about a periphery of the burner, the air inlets configured to direct air at a non-perpendicular angle to the periphery. The burner outlet is defined by a portion of a cone. The cone has an angle from approximately 0° to approximately 120°.
In another aspect, the invention features a burner, including a fuel inlet; a vaporizer cavity in fluid communication with the fuel inlet; a fuel outlet in fluid communication with the vaporizer cavity; and an air inlet in fluid communication with the fuel outlet, wherein the air inlet overlaps with at least a portion of the fuel outlet along a radial direction of the burner.
Embodiments may include one or more of the following features. The burner further includes a thermally conductive porous material in the vaporizer cavity. The porous material is in fluid communication with a burner outlet only through the fuel outlet. The burner further includes a heater configured to heat the porous material. The burner further includes a space located downstream of the air inlet and surrounding the vaporizer cavity. The burner further includes projections in the space and configured to direct air and gaseous fuel in curved direction. The air inlet overlaps with at least a portion of the fuel outlet along a longitudinal axis of the burner. The burner includes a plurality of air inlets located about a periphery of the burner, the air inlets configured to direct air at a non-perpendicular angle to the periphery. The burner further includes a burner outlet defined by a portion of a cone. The cone has an angle from approximately 0° to approximately 120°.
In another aspect, the invention features a burner, including a fuel inlet; a vaporizer cavity in fluid communication with the fuel inlet; a fuel outlet in fluid communication with the vaporizer cavity; an air inlet in fluid communication with the fuel outlet; and a space located downstream of the air inlet and surrounding the vaporizer cavity.
Embodiments may include one or more of the following features. The burner further includes a thermally conductive porous material in the vaporizer cavity. The porous material is in fluid communication with a burner outlet only through the fuel outlet. The burner further includes a heater configured to heat the porous material. The burner further includes projections in the space and configured to direct air and gaseous fuel in curved direction. The burner includes a plurality of air inlets located about a periphery of the burner, the air inlets configured to direct air at a non-perpendicular angle to the periphery. The burner further includes a burner outlet defined by a portion of a cone. The cone has an angle between approximately 0° and approximately 120°.
A combustion process using the burners described herein can produce a swirl-stabilized flame with a Swirl. Number of from approximately 0.2 to approximately 1.5 (such as from approximately 0.5 to approximately 0.7).
In some embodiments, air can be introduced through an opening or a passageway located at an end portion of a burner.
Embodiments may include one or more of the following advantages.
Having a swirling flame around a vaporizer can allow stabilization of a flame for multiple fuels. In some applications, liquid and gaseous fuels can not be used in the same burner because their flame lengths and flame speeds are significantly different. Having an intense swirling flame can compensate for the different flame characteristics. The swirling flame also allows a vaporizing surface to be placed in the center of the flame with minimal effect on the flame flow field.
Using high speed air around vapor holes can extract fuel vapor and promote pre-mixing of fuel and air, regardless of the type of fuel. Embodiments can operate using liquid or gaseous fuels without modification to the burner.
Vaporization with a foam allows heat transfer to feed fuel even if coke has formed inside the foam. If and when coking occurs, it may not be catastrophic because the foam can distribute heat away from its hottest section so the coke does not prevent further vaporization by its insulating qualities.
The structure of the foam can be mostly voids, which can provide large vaporization surfaces. Having mostly voids and no small orifices can reduce the occurrence of clogging.
In some embodiments, the burners are not readily poisoned by sulfur and/or do not readily decompose at high temperatures, which can occur with other multi-fuel burners such as catalytic burners.
The control system can operate on various fuels without changes to hardware.
As used herein, “without modification to a burner” means that no physical component is added to or removed from the burner. However, operational parameters of the burner, such as fuel flow rates, air flow rates, and temperatures, can change.
As used herein, “without modification to a system” means that no physical component is added to or removed from the system. However, operational parameters of the system, such as flow rates, temperatures, and state of switches, can change.
The details of one or more embodiments are set forth in the accompanying description below. Other aspects, features, and advantages of the invention will be apparent from the following drawings, detailed description of embodiments, and also from the appending claims.
Referring also to
During operation, a liquid fuel (such as diesel fuel) or a gaseous fuel (such as propane) is introduced through fuel inlet 34 for combustion at burner outlet 28. More specifically, in a “liquid mode” to combust a liquid fuel, glow plug 46 is energized at start-up to heat porous material 44, which is used to provide vaporization heat to vaporize the liquid fuel. In some embodiments, glow plug 46 is energized for up to five minutes prior to fuel introduction and up to five minutes after ignition to ensure complete vaporization at start-up, but as combustion of the liquid fuel proceeds, vaporization heat can increasingly come from radiation from the combustion and convection from the hot gases near burner 20. When glow plug 46 and porous material 44 are sufficiently heated to vaporize the liquid fuel, the liquid fuel is introduced into burner 20 through fuel inlet 34. The liquid fuel then flows to and into porous material 44 where the liquid fuel is vaporized to a gaseous fuel, which then flows through fuel outlets 42. At the same time, air flows through air inlets 38 (e.g., forced by a fan, a blower, or a compressor), and this air mixes with the gaseous fuel exiting fuel outlets 42 in mixing zone 50 prior to combustion near burner outlet 28. The flame is initially ignited with an ignition source, with, for example, a spark plug, a glow plug, or a hot surface igniter, near outlet 28. Once burner 20 is lit, the ignition source is no longer required to maintain combustion. Glow plug 46 can be de-energized, for example, approximately five minutes after ignition.
In a “gas mode” to combust a gaseous fuel, the gaseous fuel is flowed through substantially the same flow path as the flow path of the liquid fuel described above. More specifically, the gaseous fuel is introduced into burner 20 through fuel inlet 34. The gaseous fuel can contact porous material 44 and absorb small quantities of heat, but the fuel does not undergo a phase change as with the liquid fuel. The gaseous fuel then flows through fuel outlets 42. Air introduced through air inlets 38 then mixes with the gaseous fuel exiting the fuel outlets 42 in mixing zone 50, and this air and fuel mixture is combusted near burner outlet 28, initially ignited with an ignition source, as described for the “liquid mode” of operation.
Referring again to
Porous material 44 can be formed of any high-temperature tolerant, thermally conductive material having high surface area. For example, computational fluid dynamics analysis of a burner indicates a maximum temperature of a metal foam porous material approaching 600° C. when the burner is operating with kerosene fuel.
As a result, in some embodiments, porous material 44 can withstand temperatures of at least approximately 600° C., such as at least approximately 800° C. without any negative effect, such as oxidation or degradation. Porous material 44 can have a porosity between approximately 60% and approximately 95%. The cell size of porous material 44 can be between approximately 10 ppi (pores per inch) and 100 ppi to gain the advantage of high surface area without negatively affecting flow resistance into the porous material. The structure of porous material 44 provides vaporizing surfaces that remain to provide the heat required to vaporize liquid fuel, for example, if part of the porous material starts to fill with coke. Examples of porous material 44 include metal foams, such as those that include (e.g., is formed entirely) stainless steel or an iron-chromium (FeCr) alloy.
Still referring to
To further enhance mixing, air inlets 38 are angled to direct incoming air at a non-perpendicular angle to the periphery of burner 20. For example, the wall of lower body 32 that defines air inlets 38 can be angled so that incoming air is directed tangentially to the periphery of burner 20, thereby helping to swirl air and the air/gaseous fuel mixture in mixing zone 50.
In some embodiments, referring to
The angled direction of incoming air through air inlets 38 and/or the structural features in mixing zone 50 can help generate an air/gaseous fuel swirl in burner 20. The swirl can provide shear layers and an intense mixing stream, which can be particularly important for large fuel molecules with low diffusivity, such as kerosene or DF-2 diesel fuel. The swirl can also offer a flame stability mechanism that can work over a wide range of flame speeds or equivalence ratios. For example, kerosene can be burned with equivalence ratios of between approximately 0.6 and approximately 0.9. The same burner can operate with propane, with equivalence ratios of between approximately 0.6 and approximately 0.9, even though the flame speeds of the two fuels are not the same. In some embodiments, once the gaseous fuel and air mix, the combustion process is stabilized in a swirl-stabilized flame, with Swirl Number (SN) of from approximately 0.2 to approximately 1.5 (such as from approximately 0.5 to approximately 0.7) at burner outlet 28, where SN is defined as the ratio of the axial flux of the angular momentum to the axial flux of the axial momentum.
Referring now to
In operation, a user-set switch can activate a “liquid mode” or a “gaseous mode” to control system 100. The mode of system 100 can activate controls of burner 20, including, for example, the feed system for the fuel and the air. Fuel flow can be set based on a temperature set-point and a feedback signal from a temperature measurement 116 of the burner 20. Air flow can be set based on fuel flow-based set-point and a feedback signal indicating the stoichiometry of the combustion mixture. This hybrid control system, with a “feedback” term from a sensor 114, combined with a “feed-forward” term based on a fuel rate, can improve stability, e.g., relative to control systems based only on “feedback” responses. A user can activate or select a desired mode of system 100, and since burner 20 can operate very similarly with liquid and gaseous fuels, the same sensors 114, 116 can be used for feedback with both modes.
The feedback systems for the fuel and the air can use the same hardware for both modes, but can have different set-points, depending on the mode. In the case of an external combustion engine, for example, one can control the fuel rate to maintain a temperature on a specified body of the engine. The temperature can be measured by a thermocouple or a resistance temperature detector (RTD), for example. The temperature can be different, depending on whether the mode is liquid or gaseous fuel. The amount of air can be controlled using feedback from a stoichiometry sensor, such as an automotive oxygen sensor, a carbon-monoxide sensor, or a flame rectification sensor, for example. In the case of an oxygen sensor, oxygen content in the exhaust can be pre-specified and be different for liquid fuels and gaseous fuels. A different setting for the feedback value can be specified, depending on the mode of system 100, in order to maintain clean emissions whether liquid or gaseous fuel is being burned. Because flame speeds are more similar within each mode of fuels (gaseous fuels, including natural gas, propane, or butane, and liquid fuels, such as gasoline, kerosene, or diesel), only one oxygen setting may be needed for each mode, and the mode for system 100 can be specified with one switch.
While a number of embodiments have been described, the invention is not so limited.
For example, pre-heated air can also aid in the vaporization process, e.g., if the burner air is recuperated. For example, the burner air can be recuperated by the exhaust gases and reach temperatures approaching 600° C., depending on the extent of recuperation. Air of this temperature can aid in the vaporization process of the fuel.
As another example, referring to
In some embodiments, a burner can be designed so porous material 44 and/or glow plug 46 can be easily replaced after a selected operational interval (like a filter). For example, glow plug 46 and porous material 44 can be manufactured as one pre-assembled package that can be removed together and replaced, such as by using threads of the glow plug to remove and to install the package.
Additionally or alternatively to introducing air into a burner via air inlets positioned at the side of the burner, air can be introduced from an end portion of the burner. For example, the burner can include an annular passageway that coaxially surrounds a glow plug and is in fluid communication with the vaporizer. In embodiments in which there is no glow plug, air can be introduced through passageway 36.
Terms that indicate position, such as “upper”, “lower”, and “bottom”, are used for convenience and with reference to the figures, and are not limiting.
Other embodiments are within the scope of the following claims.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US2008/064695 | 5/23/2008 | WO | 00 | 4/30/2010 |
Number | Date | Country | |
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60931919 | May 2007 | US |