Combination Combustor and Burner

A system for combusting reactants. The system includes a low pressure combustor coupled to a low pressure line. Coupled to, and sitting atop the low pressure combustor is a high pressure combustor coupled to a high pressure line. The high pressure line is coupled to a flame arrester and an ignition source. The flame arrester is located a sub-sonic distance from the ignition source such that a flame arrester can be used as opposed to a flame detonator arrester. Further, the ignition source is retractable such that it can be removed, altered, repaired, etc., from the safety of the ground.

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Description
PRIORITY

This application claims priority to provisional application 62/074,034 filed Nov. 2, 2014, the entirety of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to a system and method for an adjustable burner.

2. Description of Related Art

Burners are used to combust reactants such as fuel and an air mixture. Burners have many different applications. Thus, there is a need for an adjustable burner. Further, burners are often housed within a combustor. There is a need for an efficient, safe, and affordable combustor.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:

FIG. 1 is a view of a burner in one embodiment with FIG. 1a being the side view and FIG. 1b being the top view;

FIG. 2 is a top perspective view of a burner in one embodiment;

FIG. 3 is a perspective view of the bottom of a burner in one embodiment;

FIG. 4 is a flow chart of a series of burners used with tanks in one embodiment;

FIG. 5 is a flow chart of a combination combustor in one embodiment.

 DETAILED DESCRIPTION

Several embodiments of Applicants' invention will now be described with reference to the drawings. Unless otherwise noted, like elements will be identified by identical numbers throughout all figures. The invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.

Several embodiments of Applicants' invention will now be described with reference to the drawings. Unless otherwise noted, like elements will be identified by identical numbers throughout all figures. The invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.

FIG. 1 is a view of a burner in one embodiment with FIG. 1a being the side view and FIG. 1b being the top view. FIG. 2 is a top perspective view of a burner in one embodiment. FIG. 3 is a perspective view of the bottom of a burner in one embodiment. Referring to FIG. 1, FIG. 1 depicts a burner shroud 110 coupled to a mixing tube 103 via a shroud connector 103. Virtually any type of suitable material can be used for these items. In one embodiment the burner tip and swirlers 102 comprise 304 Stainless steel with a melting temperature of about 2600° F. In one embodiment the Venturi and air damper, discussed below comprise aluminum with a melting temperature of about 1200° F. FIG. 2 shows a perspective view of the burner. Referring now to FIG. 2, as depicted, the burner 100 comprises one or more swirlers 102. A swirler 102, as used herein, refers to a flap which controls the amount and direction of air flow. As depicted, the swirl 102 comprises a planar shape. In operation, air is pulled upward through gaps between adjacent swirlers 102. In one embodiment, the burner 100 comprises a low-swirl burner, but in other embodiments the burner 100 comprises a high-swirl burner. Low-swirl combustion is an aerodynamic flame stabilization method which results in low emissions of nitrogen. The swirl is created by the swirlers 102.

The number and pitch of the swirlers 102 can vary. As depicted the burner 100 comprises nine swirlers 102 but this is for illustrative purposes and should not be deemed limiting. The swirlers 102, in one embodiment, are angled from about 0 to about 30 degrees relative to the horizontal. A steeper angle results in more aggressive mixing of the reactants with the air introduced through the swirlers 102. In operation, as the reactants within the mixing tube 103 exit the mixing tube 103, this creates a pressure drop causing air to be pulled upward through the swirlers 102.

The swirlers 102 are positioned between the centrally located mixing tube 103 and the larger burner shroud 110. The shroud 110 comprises an inner diameter and an outer diameter, and the mixing tube 103 has an inner and outer diameter. In one embodiment, and as depicted, the inner diameter of the shroud 110 is greater than the outer diameter of the mixing tube 103 resulting in a void. The swirlers 102 are located at the void. Thus, as depicted, the mixing tube 103 is fully encompassed and surrounded by the shroud 110. In one embodiment, the width of the swirler 102 is approximately equal to the length of the void. The length of the void, as measured as the distance between the outer diameter of the mixing tube 103 and the inner diameter of the shroud 102 ranges from about 0.4 to about 0.65 inches.

In one embodiment, the swirlers 102 are coupled to both the mixing tube 103 and the burner shroud 110. The swirlers 102 can be coupled via any method or device known in the art including welding, soldering, screws, etc. In one embodiment the swirlers 102 are fixed meaning they cannot be moved. In other embodiments, however, the swirlers 102 are coupled so as to be adjustable. In this sense, the pitch of the swirlers 102 can be adjusted.

As depicted, the top end, the downstream end, of the mixing tube 103 comprises one or more channels 101. As used herein, downstream and upstream refer to relative locations throughout the process. A downstream process or part occurs after an upstream process or part. Thus, referring briefly to FIG. 1, the shroud 110 is downstream of the mixing tube 103 because reactants move through the mixing tube 103 and exit in the shroud 110. The channels 101 in one embodiment extend throughout the length of the mixing tube 103, whereas in other embodiments the channels 101 do not extend throughout the length of the feed line 103. In one embodiment the size and number of the channels 101 determine the desired flow rate of the burner. The channels 101 break the flow into smaller channels, increasing the available surface area of the flow compared to if a single channel were utilized. The efficiency of the burner is increased, due in part, to the increased surface area. Further, in one embodiment the channels provide a swirl which further increases mixing and efficiency. In some embodiments the channels are drilled at an angle to further increase swirl and increase dispersion.

Reactants, including fuel and air, are carried through the mixing tube 103. When properly mixed, the reactants combust in the presence of a flame. In one embodiment, the mixing tube provides turbulent flow. The flame can be provided with a pilot flame, a lighter, an igniter, etc. A mixing tube 103, as used herein, refers to any tube wherein reactants can be mixed. As depicted, the mixing tube 103 is upstream of the shroud 110 and downstream of the air intake adjuster 104. The mixing tube 103 can comprise virtually any length, but in one embodiment, the mixing tube 103 comprises a length of between about 10 inches to about 14.5 inches. The mixing tube 103 can comprise any diameter, but in one embodiment the diameter ranges from about ½ of an inch to about 5 inches. In one embodiment the mixing tube 103 comprises a diameter of about 1 and ¼ inch.

The reactants can comprise virtually any fuel. In one embodiment, and as will be discussed in more detail, the fuel comprises fumes collected from oil storage tanks. These fumes comprise volatile lights which collect in the headspace of storage tanks. In one embodiment the mixture comprises one or more of the following: hydrogen sulfide, nitrogen, oxygen, methane, carbon dioxide, ethane, propane, iso-butane, iso-pentane, N-butane, N-pentane, 2,2 dimethyl butane, cyclopentane, 2-methylpentane, 3-methylpentane, N-Hexane, methylcyclopentanes, benzene, cyclohexane, 2-methylhexane, 3-methylhexane, dimethylcyclopentanes, heptanes, N-heptanes, methylcyclohexane, toluene, octanes, N-octane, ethyl benzene, P-M-xylene, O-xylene, nonanes, N-nonane, decanes, N-decane, undecanes plus. In one embodiment, to alleviate the pressure from building on the tanks, the fuel in the headspace is removed and burned in a burner.

Returning back to FIG. 2, FIG. 2 depicts the burner shroud 110. The burner shroud 110 is the location at which the combustion occurs. Here, reactants from the mixing tube 103 are mixed with air which has been introduced through the swirlers 102 as discussed above. In one embodiment, for complete combustion of a 1,000 btu natural gas with a specific gravity of 0.65, the air to gas ratio of 10:1 is utilized. In this embodiment, this results in an oxygen to gas ratio of 2:1. This example is provided for illustrative purposes only and should not be deemed limiting. In one embodiment, a oxygen to reactant gas ratio of 2:1 allows for a more complete reaction and breakdown. Accordingly, this ratio allows for a complete and less partial combustion reaction. As an example, this ratio provides sufficient oxygen such that carbon dioxide, as opposed to carbon monoxide and NOx gas, is produced.

The burner shroud 110, in one embodiment, has a flared shape. This shape allows for a spreading of the air gas mixture. Further, this shape has a minimal impact on efficiency.

As depicted, the burner shroud 110 is coupled to the mixing tube 103 via a shroud connector 112. The shroud connector 112 can comprise any device which couples the shroud 110 to the mixing tube 103 and can comprise threads, screws, welding, soldering, etc. As depicted, the shroud connector 112 comprises an elongated connector piece which is coupled to both the shroud 110 and the mixing tube 103. As depicted, the shroud connector 112 couples the outside perimeter of the shroud 110 to the outside perimeter of the mixing tube 103. This allows the shroud 110 and mixing tube 103 to be connected in such a way as to leave a void between the two pieces for the swirlers 102.

Referring back to FIG. 1, coupled to, and upstream from the mixing tube 103, is a Venturi tube 114. A Venturi tube 114 is a reduced diameter pipe which results in a reduction in fluid pressure. The results in an increase of velocity with a corresponding decrease in pressure. The increase of velocity also results in increased mixing. As stated previously, the increased mixing results in increased burner efficiency.

As depicted in FIG. 1, upstream of the Venturi tube 114 is the gas supply 115. The gas supply 115 supplies gas and other reactants to the burner 100. In one embodiment the gas supply 115 is coupled to the headspace of tanks, which will be discussed in more detail below. The upstream gas supply 115 is coupled to the downstream gas coupler 106. The gas coupler 106 can comprise any pipe or tubing which connects the burner 100 to the gas supply 115. In one embodiment the gas supply ranges from about 10,000 to about 250,000 SCFD (thousand standard cubic feet per day). In one embodiment, each burner has a capacity of between about 10,000 to about 50,000 SCFD. These flow rates are for illustrative purposes only and should not be deemed limiting.

As depicted, the gas coupler 106 has at least one air inlet 105. An air inlet 205 is any opening on the body of the gas coupler 206 through which air can be entrained. Air that enters through the air inlet 105 is subsequently mixed with the other reactants in the mixing tube 103. As depicted the air inlet 205 is not located on the end of the gas coupler 106 but is instead located on the body of the gas coupler 106. The size of the air inlet 205 can vary.

FIG. 3 is a perspective view of the bottom of a burner in one embodiment. As depicted in FIG. 3, the air inlet 205 comprises two opposing air inlets 205, each on one side of the gas coupler 206. In one embodiment the air inlet 205 extends through the gas coupler 206 such that air can be pulled into the air inlet 205 and subsequently mixed with the reactants within the mixing tube 103. Put differently, in one embodiment the air inlet 205 is a void which extends from the outer diameter of the gas coupler 206 to the inner diameter of the gas coupler 206. The pressures, in one embodiment, range from about 0 to about 1 psi.

In one embodiment the size of the air inlet 205 can be controlled with an air intake adjuster 204. An air intake adjuster 204, as used herein, refers to any device which changes or alters the size of the air inlet 205. In one embodiment the air intake adjuster 204 comprises a sleeve which moves along the length of the gas coupler 106 to adjust the size of the air inlet 205. As depicted, the air intake adjuster 204 comprises a threaded sleeve which is coupled to external threading located on the gas coupler 206 and/or the Venturi 114. As can be seen, by rotating the air intake adjuster 204, the threaded sleeve advances along the length of the gas coupler 206, increasing or decreasing the size of the air inlet 205. While the air intake adjuster 104 is depicted as being threaded, this is for illustrative purposes only and should not be deemed limiting. In other embodiments, for example, the air intake adjuster 204 can be slidably adjusted and secured in place with a pin, screw, or the like. In other embodiments the air intake adjuster comprises a pivoting gate covering the air inlet 205 which can be manipulated to control the size of the air inlet 105. Virtually any air intake adjuster 204 which can be manipulated along the length of the gas coupler 106 can be utilized.

In one embodiment, the air intake adjuster 204 comprises a locking device 113, depicted in FIG. 1, which locks the air intake adjuster 204 in the desired location. A locking device 113 prevents the air intake adjuster 204 from undesirably moving and changing the size of the air inlet 205. The locking device 113 can comprise a set screw, a bolt, a nut, or other device which secures the air intake adjuster 204 in place.

By changing the size of the air inlet 205, the ratio of air to fuel mixture can be fine-tuned and controlled. If more air or oxygen is needed, the size of the air inlet 205 can be increased by adjusting the air intake adjuster 204. By better controlling the ratio of air to fuel, the efficiency of the burner can be increased and adjusted. In one embodiment the air intake adjuster 204 is manipulated by hand to control the size of the air inlet 105. In other embodiments, however, the air intake adjuster 204 is automated. In such an embodiment the air intake adjuster 204 can be coupled to a sensor such that the automated air intake adjuster 204 can be adjusted in real-time depending on the burner efficiency, the pressure on the tanks, etc.

There are several benefits with an adjustable air intake adjuster 204. First, as noted, is the ability to fine-tune and control the air to fuel ratio mixture. This provides the ability to adjust and control the burner to meet a desired burner efficiency, reduce emissions, etc.

Second, the air intake adjuster 204, in one embodiment, can be easily adjusted in place, even when the burners are installed. Put differently, the burners 100, in some embodiments, do not need to be removed to be adjusted. Rather, they can be adjusted in their installed position. This is a large benefit which reduces downtime, decreases labor expenses, etc. If, for example, the pressure from the gas supply 115 increased or decreases, the air intake adjuster 204 can be adjusted, in-place, to account for the change in pressure. This can be accomplished while the burner 100 is installed. In one embodiment, the air intake adjuster 204 can be adjusted while the burner is operating.

FIG. 4 is a flow chart of a series of burners used with tanks in one embodiment. As depicted, FIG. 4 shows two tanks 407. A tank 407, as used herein, refers to both operational tanks as well as storage tanks. An operational tank is a tank used during production or in the process of a chemical, oil, or gas. An embodiment will be discussed utilizing storage tanks, but this is for illustrative purposes only and should not be deemed limiting.

In one embodiment the storage tanks 407 store oil and/or gas until the oil and gas is ready to be shipped and/or piped. Produced oil or gas is thus stored, often temporarily, close to the rig. When oil, for example, sits, the volatile gases within the oil collect in the headspace 408 of the tanks. If the gases within the headspace 308 is not removed, then the pressure in the tanks 407 build. Tanks 407 generally have emergency pressure relief valves which open after a threshold pressure has been met. In many instances, the emergency relief valves open at very low pressures, even at ounces of pressure. In one embodiment, the threshold pressure is about 4 ounces. However, the emergency venting is to be avoided due to environmental as well as regulatory concerns. Consequently, in one embodiment, the gases collected in the headspace 408 is removed and burned to alleviate the pressure in the tanks 407.

As depicted, the headspace 408 of the storage tanks 407 are directed to a header 409. The header 409 collects the gases and directs the gases to the gas supply line 115. The gas supply line 115 directs the gas to a combustor 411 comprising at least one burner 100. A combustor 411 is a tank or other structure which houses at least one burner. As depicted, the combustor 411 houses three burners 100. The number and size of the burners 100 will depend on the volume, pressure, and types of gasses to be combusted. As depicted, the combustor 411 comprises three burners 100 operating in parallel.

The burner 100 will operate as previously discussed. Because the burner 100 comprises an air intake adjuster 104, the ratio of reactants to air for each burner 100 can be independently adjusted. Thus, the ratio of reactants to air can differ amongst the three depicted burners 100. As noted, if the pressure from the tanks 407 changes, the air intake adjuster 104 for at least one burner 100 can be adjusted to compensate. The result is finely tuned burner. In one embodiment, the burner 100 has a destructive efficiency of greater than 99.99%.

In some embodiments, there is a need for combusting both high pressure and low pressure reactants. FIG. 5 is a flow chart of a combination combustor in one embodiment. As depicted in FIG. 5, a high pressure combustor 520 sits atop a low pressure combustor 521. The high pressure combustor 520 is downstream of the low pressure combustor 521. A high pressure combustor 520 encounters comparatively higher pressures than the low pressure combustor. The high pressure line 519 supplies high pressure reactants to the high pressure combustor 520. The pressure within the high pressure line 519 can range from about 0 to about 120 psi. In one embodiment the high pressure line 519 comprises a flare because it comprises an exposed flame.

The high pressure combustor 520 and the low pressure combustor can handle very different volumes. As discussed, in one embodiment a 24 inch low pressure combustor can handle a volume of about 100,000 SCFD, and the 24 inch high pressure combustor can handle volumes of between 1 and 6,000,000 SCFD. In one embodiment the high pressure combustor handles volumes of about 4,000,000 SCFD. In another embodiment the 18″ combustor can handle volumes of about 25,000 SCFD and have a high pressure attachment that will flow 1.2 MMSCFD. Conversely, in one embodiment, the pressure in the low pressure line 409 which supplies reactants to the low pressure combustor 521 ranges from about 0 to 1 psi. In one embodiment the low pressure line 409 and the high pressure line 519 originate from different sources. For example, in one embodiment the low pressure line 409 is coupled to storage tanks whereas a high pressure line is coupled to production vessels or a gas sales line. The high pressure line can comprise reactants similar to the low pressure line, though usually a lower btu. Whereas the btu for a low pressure line is typically greater than 2,000, in one embodiment, the typical btu for a high pressure line is between about 1,200 and about 1,500.

In one embodiment, and as depicted, the low pressure combustor 521 and the high pressure combustor 520 are fluidly connected. As used herein, fluidly connected refers to a coupling such that both combustors operate as if sharing the same outer housing. Fluidly connected includes one combustor segmented into a high and a low pressure combustor. Fluidly connected also includes two separately manufactured combustors coupled such that gases and other fluids exiting the low pressure combustor 521 can freely enter the high pressure combustor 520. As an example, in one embodiment, and as depicted, the top of the low pressure combustor 521 is open to the bottom of the high pressure combustor 520. In this manner, air, reactants, combustion gasses, etc. from the low pressure combustor 521 flow upward into the high pressure combustor 520.

In one embodiment, and as depicted, the high pressure combustor 520 is directly coupled atop the low pressure combustor 521. This arrangement provides several benefits. First, gases from the low pressure combustor 521 can flow more freely to the high pressure combustor 520 than if they were directed through piping.

Second, this arrangement requires a reduced footprint than if the two combustors were not vertically arranged. Having a reduced footprint is an environmental advantage in that less land is required. Further, often the landowner desires to minimize the amount of land which is used for drilling and production.

Third, this arrangement is cheaper than having two separate combustors. Typically, a concrete foundation must be installed for each combustor. Further, each combustor requires separate piping, valves, controls, etc. Combining two combustors as depicted in FIG. 5 eliminates many of these redundancies, decreasing costs.

Fourth, a combination combustor is more efficient than separate combustors. The low pressure combustor 521 produces off-gas. This off-gas includes combusted reactants, un-burned reactants, air, and other chemicals. Even if the low pressure combustor 521 is highly efficient, there will always remain some reactants which are not combusted. The arrangement discussed herein allows some of the off-gasses produced by the low pressure combustor 521 to be combusted in the high pressure combustor 520. This provides an additional opportunity to incinerate off-gases, including un-combusted reactants, produced by the low pressure combustor 521. As such, the combination combustor has many environmental benefits.

Referring back to FIG. 5, FIG. 5 depicts an adjustable air intake 516. An adjustable air intake 516 includes any device known to restrict or otherwise control the flow of air through an opening. As depicted, the adjustable air intake 516 comprises a louver. Thus, as depicted, the adjustable air intake 516 comprises one or more adjustable flaps. The adjustable air intake 516 can be manually adjusted, or it can be automated.

The adjustable air intake 516 allows the amount of air introduced into both the low pressure combustor 521 and the high pressure combustor 520 to be controlled. The amount of air has an effect on the burner efficiency, temperature, etc. In one embodiment the combustor is otherwise sealed. Accordingly, in one embodiment, the air intake 516 is the only way through which air can be introduced to the combustor.

In one embodiment, and as depicted, the adjustable air intake 516 is located slightly upstream from the burner 100 in the low pressure combustor. Such a location allows the burner 100 in the low pressure combustor 521 to pull air through the adjustable air intake 516. This allows the low pressure combustor 521 to obtain the benefit of the adjustable air intake 516. While the figure depicts a single air intake adjuster 516, this is for illustrative purposes only and should not be deemed limiting. In other embodiments, for example, the combination combustor comprises two or more air intakes 516.

As depicted, the combination combustor comprises an ignition source 517. As depicted the ignition source 517 is located at the burner of the high pressure combustor 520. Thus, as depicted, the ignition source 517 is located near the top of the high pressure combustor 520. The ignition source 517 can comprise any device which provides a spark or a flame to provide ignition for the combustion. The ignition source 517 can comprise an ignitor which provides a spark which can subsequently cause ignition of the flammable gasses. In other embodiments, the ignition source 517 comprises a pilot light which supplies a small fire. In other embodiments the ignition source 517 comprises a continuous spark ignitor.

Ignition sources 517 are subject to fouling. The ignition sources 517 can become plugged, worn, and otherwise malfunction. Due to their location at the top of the combustor, previously, an operator would be forced to climb the combustor and remove, replace, or repair the malfunctioning ignition source 517. Because the combustor is operating at very high temperatures, the operator would have to wait until the combustor cooled before climbing. Consequently, this repair was unsafe, time consuming, and costly due to the downtime involved. Accordingly, as depicted, the combination combustor comprises an ignition track 518 which allows the ignition source 517 to be moveable along the length of the combustor. The ignition track 518 can comprise any track which allows an object to move along its length. This includes flexible support structures such as rope, wire, cables, etc. upon which the ignition source 517 is hoisted and lowered. In other embodiments the ignition track 518 comprises a rigid material such as a rigid track. In either embodiment, the ignition source 517 can be hoisted or lowered with any device known in art, including but not limited to, a pulley, rope, wires, hydraulics, wench, etc.

An ignition source 517 moveable along a track provides several benefits. First, it removes the need for an operator to climb atop the combustor to make repairs. Thus, a moveable ignition source 517 increases safety. Second, a moveable ignition source 517 reduces downtime and accordingly reduces the costs associated with downtime. As noted, previously an operator had to allow the combustor to cool, climb atop the combustor, and make repairs. This required the combustor to shut down, at least temporarily. This causes other processes to shut down, causing significant costs and lost revenue. With a moveable ignition source 517, if the ignition source becomes faulty the operator simply lowers the ignition source 517 along the track 518 and repairs or replaces the part as necessary. Thereafter, the ignition source 517 is hoisted upward along the track 518, and the combustor is ignited. A further benefit is the safety associated with staying on the ground.

FIG. 5 depicts a pilot line 523 which couples the ignition source 517 to the burner of the high pressure combustor 520. The pilot line 523 can supply a combustable pilot gas to or from the ignition source 517. The pilot line 523 can use reactants from the high pressure line 519, or the pilot line 523 can comprise a separate source (not shown). The pilot line 523 directs a flame to the burner of the high pressure combustor 520.

As depicted, the combination combustor further comprises a flame arrester 522. A flame arrester 522 is a device fitted to piping or other structure whose function is to allow flow but prevent the transmission of a flame. Thus, as seen in FIG. 5, the flame arrester 522 allows upward flow to the high pressure combustor 520 but prevents a flame from traveling upstream of the flame arrester 522. As noted, the high pressure line 519 is often coupled to production tanks, storage tanks, etc. which often contain flammable materials. If a flame were allowed to travel upstream and reach the tanks, the result could be catastrophic. Accordingly, a flame arrester 522 prevents flames from traveling beyond a specified point in a process.

A flame arrester 522 as used herein is differentiated from a detonation flame arrester. In one embodiment, a flame arrester 522 is built to withstand sub-supersonic velocities. In one embodiment, a flame arrester 522 is not approved for supersonic velocities. A detonation flame arrester, however, is an arrester which is built and approved to withstand extreme pressures that travel at supersonic velocities. In one embodiment the combination combustor comprises a flame arrester, whereas in other embodiments the combination combustor comprises a detonation flame arrester.

A detonator flame arrester is comparatively much more expensive than a flame arrester 522. The materials and complexity required to stop flames travelling at supersonic speeds necessitate a much higher price compared to a sub-supersonic flame arrester. As but one example, a 3″ flame arrester costs approximately $300-500. Conversely, a 3″ detonation flame arrester costs approximately $3,000 to $5,000. Accordingly, there is significant cost savings in utilizing a flame arrester.

In one embodiment, a flame arrester 522 is located adjacent to the high pressure combustor 520. Accordingly, in one embodiment, the flame arrester 522 is not located on the ground but is instead elevated. In one embodiment the flame arrester 522 is located a sub-sonic distance from the ignition source 517 when the ignition source 517 is in its operating location or from the location of the flame. A sub-sonic distance is a distance at which a blowback flame has not yet attained supersonic velocities. In one embodiment the sub-sonic distance is less than about 10 feet. Flames often increase in velocity during a blowback. Thus, controlling the distance between the ignition source 517, or the location of the flame, and the flame arrester 522 also controls the velocity of the flame during a blowback. By limiting the distance between the ignition source 517, or the location of the flame, and the flame arrester 522, in one embodiment, to a sub-sonic distance, such as 10 feet, the flame fails to reach supersonic velocities. As such, a comparatively lower grade arrester can be utilized. In one such embodiment, a flame arrester 522 which is not rated for supersonic velocities can be utilized. This results in significant capital cost savings. If an arrester was instead placed upon the ground, and not within the sub-sonic distance, then an arrester which is rated for supersonic velocities must be utilized as the blowback flame would have the time and distance to reach a supersonic velocity. As noted, such an arrested is much more expensive than a flame arrester 522 which is not rated for supersonic velocities.

While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.

Additional Disclosure

  • Clause 1. A burner comprising:
    • a burner shroud coupled to an upstream mixing tube, wherein said burner shroud comprises at least two swirlers;
    • a gas coupler upstream from said mixing tube, wherein said gas coupler comprises at least one air inlet;
    • an air intake adjuster coupled to said gas coupler, wherein said air intake adjuster is adjustable relative to said air inlet.
  • Clause 2. The burner of any proceeding or preceding clause wherein said burner comprises a low-swirl burner.
  • Clause 3. The burner of any proceeding or preceding clause wherein said mixing tube comprises channels.
  • Clause 4. The burner of any proceeding or preceding clause further comprising a Venturi located downstream of said mixing tube.
  • Clause 5. The burner of any proceeding or preceding clause wherein said air intake adjuster comprises a threaded sleeve.
  • Clause 6. The burner of any proceeding or preceding clause wherein said gas coupler is coupled to a gas supply.
  • Clause 7. The burner of any proceeding or preceding clause wherein said shroud comprises an inner diameter and an outer diameter, and wherein said mixing tube has an inner and outer diameter, and wherein said inner diameter of said shroud is greater than the outer diameter of the mixing tube resulting in a void between the mixing tube and the surrounding shroud.
  • Clause 8. The burner of any proceeding or preceding clause wherein said at least two swirlers are located in said void.
  • Clause 9. A system for combusting reactants, said system comprising:
    • at least one burner, said at least one burner comprising:
      • a burner shroud coupled to an upstream mixing tube, wherein said burner shroud comprises at least two swirlers;
      • a gas coupler upstream from said mixing tube, wherein said gas coupler comprises at least one air inlet;
      • an air intake adjuster coupled to said gas coupler, wherein said air intake adjuster is adjustable relative to said air inlet;
    • at least one tank comprising a headspace;
    • a gas supply line coupling the headspace of said at least one tank to the at least one burner, wherein said at least one burner is downstream from said at least one tank.
  • Clause 10. The system of any proceeding or preceding clause wherein said at least one burner is located in a combustor.
  • Clause 11. The system of any proceeding or preceding clause wherein said burner comprises a 99.99% destruction efficiency.
  • Clause 12. The system of any proceeding or preceding clause wherein said system comprises between three and five burners.
  • Clause 13. The system of any proceeding or preceding clause wherein said burner comprises a low-swirl burner, and wherein said mixing tube comprises channels.
  • Clause 14. The system of any proceeding or preceding clause further comprising a Venturi located downstream of said mixing tube.
  • Clause 15. The system of any proceeding or preceding clause wherein said air intake adjuster comprises a threaded sleeve.
  • Clause 16. The system of any proceeding or preceding clause wherein said gas supply line has a through put of between 25,000 and 250,000 SCFD.
  • Clause 17. The system of any proceeding or preceding clause said air intake adjuster is adjusted to achieve a 2:1 oxygen to reactants ratio.
  • Clause 18. The system of any proceeding or preceding clause further wherein said at least one burner is located within a low pressure combustor, and wherein said system further comprises a high pressure combustor coupled to the top of said low pressure burner.
  • Clause 19. The system of any proceeding or preceding clause further comprising a flame arrester and an ignition source, wherein said ignition source is retractable, and wherein said flame arrester is within a sub-sonic distance of said ignition source.
  • Clause 20. The system of any proceeding or preceding clause wherein said shroud comprises an inner diameter and an outer diameter, and wherein said mixing tube has an inner and outer diameter, wherein said inner diameter of said shroud is greater than the outer diameter of the mixing tube resulting in a void between the mixing tube and the surrounding shroud, and wherein said at least two swirlers are located in said void.
  • Clause 21. A system for combusting reactants, said system comprising:
    • a low pressure combustor coupled to a low pressure line;
    • a high pressure combustor, wherein said high pressure burner is coupled to the top of said low pressure burner;
    • a flame arrester coupled to a high pressure line;
    • an ignition source coupled to said high pressure combustor.
  • Clause 22. The system of any proceeding or preceding clause wherein said low pressure combustor comprises at least one burner, wherein said at least one burner comprises:
    • a burner shroud coupled to an upstream mixing tube, wherein said burner shroud comprises at least two swirlers;
    • a gas coupler upstream from said mixing tube, wherein said gas coupler comprises at least one air inlet;
    • an air intake adjuster coupled to said gas coupler, wherein said air intake adjuster is adjustable relative to said air inlet.
  • Clause 23. The system of any proceeding or preceding clause wherein said low pressure combustor comprises between three and five burners.
  • Clause 24. The system of any proceeding or preceding clause wherein said burner comprises a low-swirl burner, wherein said mixing tube comprises channels, and further comprising a Venturi located downstream of said mixing tube.
  • Clause 25. The system of any proceeding or preceding clause wherein said air intake adjuster comprises a threaded sleeve.
  • Clause 26. The system of any proceeding or preceding clause wherein said shroud comprises an inner diameter and an outer diameter, and wherein said mixing tube has an inner and outer diameter, wherein said inner diameter of said shroud is greater than the outer diameter of the mixing tube resulting in a void between the mixing tube and the surrounding shroud, and wherein said at least two swirlers are located in said void.
  • Clause 27. The system of any proceeding or preceding clause wherein said flame arrester is within a sub-sonic distance of said ignition source.
  • Clause 28. The system of any proceeding or preceding clause wherein said sub-sonic distance is less than about 10 feet.
  • Clause 29. The system of any proceeding or preceding clause wherein said ignition source is retractable.
  • Clause 30. The system of any proceeding or preceding clause further comprising a track.
  • Clause 31. The system of any proceeding or preceding clause further comprising an adjustable air intake.
  • Clause 32. The system of any proceeding or preceding clause wherein said high pressure combustor and said low pressure combustor are fluidly connected.
  • Clause 33. The system of any proceeding or preceding clause wherein said low pressure combustor has a capacity of between about 25,000 and 250,000 SCFD, and wherein said high pressure combustor has a capacity of between about 1,200,000 and about 4,000,000 SCFD.
  • Clause 34. The system of any proceeding or preceding clause wherein said high pressure combustor comprises a flare.
  • Clause 35. The system of any proceeding or preceding clause wherein said high pressure line has pressures between 1 to about 120 psi, and wherein said low pressure line comprises a pressure between about 0 to about 1 psi.
  • Clause 36. The system of any proceeding or preceding clause wherein said high pressure line is coupled to a production vessel or a gas line whereas said low pressure line is coupled to storage tanks.

Claims

1. A system for combusting reactants, said system comprising:

a low pressure combustor coupled to a low pressure line;
a high pressure combustor, wherein said high pressure burner is coupled to the top of said low pressure burner;
a flame arrester coupled to a high pressure line;
an ignition source coupled to said high pressure combustor.

2. The system of claim 1 wherein said low pressure combustor comprises at least one burner, wherein said at least one burner comprises:

a burner shroud coupled to an upstream mixing tube, wherein said burner shroud comprises at least two swirlers;
a gas coupler upstream from said mixing tube, wherein said gas coupler comprises at least one air inlet;
an air intake adjuster coupled to said gas coupler, wherein said air intake adjuster is adjustable relative to said air inlet.

3. The system of claim 2 wherein said low pressure combustor comprises between three and five burners.

4. The system of claim 2 wherein said burner comprises a low-swirl burner, wherein said mixing tube comprises channels, and further comprising a Venturi located downstream of said mixing tube.

5. The system of claim 2 wherein said air intake adjuster comprises a threaded sleeve.

6. The system of claim 2 wherein said shroud comprises an inner diameter and an outer diameter, and wherein said mixing tube has an inner and outer diameter, wherein said inner diameter of said shroud is greater than the outer diameter of the mixing tube resulting in a void between the mixing tube and the surrounding shroud, and wherein said at least two swirlers are located in said void.

7. The system of claim 1 wherein said flame arrester is within a sub-sonic distance of said ignition source.

8. The system of claim 7 wherein said sub-sonic distance is less than about 10 feet.

9. The system of claim 1 wherein said ignition source is retractable.

10. The system of claim 1 further comprising a track.

11. The system of claim 1 further comprising an adjustable air intake.

12. The system of claim 1 wherein said high pressure combustor and said low pressure combustor are fluidly connected.

13. The system of claim 1 wherein said low pressure combustor has a capacity of between about 25,000 and 250,000 SCFD, and wherein said high pressure combustor has a capacity of between about 1,200,000 and about 4,000,000 SCFD.

14. The system of claim 1 wherein said high pressure combustor comprises a flare.

15. The system of claim 1 wherein said high pressure line has pressures between 1 to about 120 psi, and wherein said low pressure line comprises a pressure between about 0 to about 1 psi.

16. The system of claim 1 wherein said high pressure line is coupled to a production vessel or a gas line whereas said low pressure line is coupled to storage tanks.

Patent History
Publication number: 20160123575
Type: Application
Filed: Nov 14, 2014
Publication Date: May 5, 2016
Inventor: John D. Bridges (Midland, TX)
Application Number: 14/541,244
Classifications
International Classification: F23C 1/00 (20060101); F23D 23/00 (20060101); F23C 5/08 (20060101);