BURNER WITH A PERFORATED FLAME HOLDER SUPPORT STRUCTURE

Abstract

A combustion system includes a fuel and oxidant source, a perforated flame holder, and a support structure that supports the perforated flame holder at a selected distance from the fuel and oxidant source. The fuel and oxidant source outputs fuel and oxidant onto the perforated flame holder. The perforated flame holder receives the fuel and oxidant and sustains a combustion reaction of the fuel and oxidant within the perforated flame holder.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority benefit from U.S. Provisional Patent Application No. 62/117,941, entitled “BURNER WITH A PERFORATED FLAME HOLDER SUPPORT STRUCTURE,” filed Feb. 18, 2015 (docket number 2651-224-02); which, to the extent not inconsistent with the disclosure herein, is incorporated by reference.

SUMMARY

According to an embodiment, a combustion system includes a furnace body defining a combustion volume. A fuel and oxidant source and a perforated flame holder are positioned within the combustion volume. A support structure is fixed to the furnace body and supports the perforated flame holder at a selected distance from the fuel and oxidant source. The fuel and oxidant source outputs fuel and oxidant onto the perforated flame holder. The perforated flame holder supports a combustion reaction of the fuel and oxidant within the perforated flame holder. Because the support structure supports the perforated flame holder at the selected distance from the fuel and oxidant source, the perforated flame holder can stably support the combustion reaction of the fuel and oxidant within the perforated flame holder.

According to an embodiment, a method for operating a combustion system includes supporting, with a support structure fixed to a furnace body, a perforated flame holder at a selected distance from a fuel and oxidant source; outputting fuel and oxidant from the fuel and oxidant source; and receiving the fuel and oxidant in the perforated flame holder positioned to receive the fuel and oxidant from the fuel and oxidant source. The method further includes supporting a majority of a combustion reaction of the fuel and oxidant within the perforated flame holder.

According to an embodiment, a combustion system includes an enclosure defining an interior volume, a fuel and oxidant source disposed within the enclosure and configured to output fuel and oxidant, and a perforated flame holder disposed to receive the fuel and oxidant from the fuel and oxidant source and to support a combustion reaction of the fuel and oxidant within the perforated flame holder. The combustion system further includes a first support arm coupled between the enclosure and the perforated flame holder and configured to support the perforated flame holder within the enclosure at a selected distance from the fuel and oxidant source.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a combustion system including a perforated flame holder supported by a support structure, 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 FIGS. 1 and 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. 1, 2 and 3, according to an embodiment.

FIG. 5A is a diagram of a combustion system including a perforated flame holder supported by a support structure mounted to a floor of a furnace, according to an embodiment.

FIG. 5B is a diagram of the combustion system of FIG. 5A in which the support structure includes brackets and a plurality of finger members on which the perforated flame holder rests, according to an embodiment.

FIG. 5C is a top view of the combustion system of FIG. 5B, according to an embodiment.

FIG. 5D is a diagram of the combustion system of FIG. 5A in which the support structure includes brackets on which the perforated flame holder rests, according to an embodiment.

FIG. 6A is a diagram of a combustion system including a perforated flame holder supported by a support structure mounted to a sidewall of a furnace, according to an embodiment.

FIG. 6B is a diagram of the combustion system of FIG. 6A in which the support structure includes an array of support rods on which the perforated flame holder rests, according to an embodiment.

FIG. 6C is a top view of the combustion system of FIG. 6B, according to an embodiment.

FIG. 7A is a diagram of a combustion system including a perforated flame holder supported by a support structure mounted to a ceiling of a furnace, according to an embodiment.

FIG. 7B is a diagram of the combustion system of FIG. 7A in which the support structure includes brackets and a plurality of finger members on which the perforated flame holder rests, according to an embodiment.

FIG. 8 is a diagram of a combustion system including a perforated flame holder supported by a cooled support structure cooled by a fluid coolant, according to an embodiment.

FIG. 9A is a diagram of a combustion system including a perforated flame holder supported by a plurality of tubes configured to pass a fluid coolant therethrough, according to an embodiment.

FIG. 9B is a top view of the cooled support structure of FIG. 9A, according to an embodiment.

FIG. 10 is a flow diagram of a process for operating a combustion system including a perforated flame holder and a support structure, according to an embodiment.

DETAILED DESCRIPTION

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. Other embodiments may be used and/or other changes may be made without departing from the spirit or scope of the disclosure.

FIG. 1 is a diagram of a combustion system 100, according to an embodiment. The combustion system 100 includes a furnace body 110 that defines a combustion volume 106 within the furnace body 110. A perforated flame holder 102 and a fuel and oxidant source 104 are positioned within the combustion volume 106. A support structure 108 is fixed to the furnace body 110 and supports the perforated flame holder 102 at a selected distance from the fuel and oxidant source 104.

The fuel and oxidant source 104 outputs fuel and oxidant onto the perforated flame holder 102. The perforated flame holder 102 receives the fuel and oxidant from the fuel and oxidant source 104 and supports a combustion reaction of the fuel and oxidant within the perforated flame holder 102.

Characteristics of the combustion reaction within the perforated flame holder 102 depend, in part, on the distance between the fuel and oxidant source 104 and the perforated flame holder 102. The support structure 108 supports the perforated flame holder 102 in a stable position at the selected distance from the fuel and oxidant source 104. In this way, the combustion reaction of the fuel and oxidant can be stably supported within 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. 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 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 (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 and oxidant source 202 disposed to output fuel and oxidant into a combustion volume 204 to form a fuel and oxidant 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. 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. Referring to FIGS. 2 and 3, 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. As used herein, 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). 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 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.

According to an embodiment, the perforated flame holder 102 is configured to hold a majority of the combustion reaction 302 within the perforations 210. For example, on a steady-state basis, 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. According to an alternative interpretation, 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. 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 the combustion 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, 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. In some experiments, 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. According to an alternative interpretation, 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.

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 the perforated 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 the input face 212 of the perforated flame holder 102 and the fuel nozzle 218, within the dilution region D_D. 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. In still other instances, 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. 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 perforated flame holder body 208.

Referring especially to FIG. 3, 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. In some experiments, the location of maximum receipt of heat was apparently between ⅓ and ½ 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 inventors contemplate that the heat receiving regions 306 may lie nearer to the output face 214 of the perforated flame holder 102 under other conditions. Most probably, there is no clearly defined edge of the heat receiving regions 306 (or for that matter, the heat output regions 310, described below). For ease of understanding, the heat receiving regions 306 and the heat output regions 310 will be described as particular regions 306, 310.

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. Generally, the heat output regions 310 are nearer to the input face 212 than are the heat receiving regions 306. According to one interpretation, 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. According to another interpretation, 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. In this way, 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 inventors believe that 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. 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 the perforated flame holder 102, it is apparent that at least a majority of the individual reactions occur within the perforated flame holder 102. As the relatively cool fuel and oxidant mixture 206 approaches the input face 212, 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. 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 the combustion reaction 302 occurs. Accordingly, the combustion reaction 302 is shown as occurring within the thermal boundary layers 314. As flow progresses, the thermal boundary layers 314 merge at a merger point 316. Ideally, the merger point 316 lies between the input face 212 and output face 214 that define the ends of the perforations 210. At some position along the length of a perforation 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.

In an embodiment, 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. As used herein, the term reaction fluid refers to matter that travels through a perforation 210. Near the input 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 the combustion reaction 302, molecules of reactants and their constituent parts, any non-reactive species, reaction intermediates (including transition states), and reaction products. Near the output 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 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. Preferably, 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. 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 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.

Referring especially to FIG. 2, 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. For example, 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. 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 D_D. In some embodiments, a flue gas recirculation path 224 can be provided. Additionally or alternatively, 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. In another embodiment, 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. Preferably, 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. When 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, whether configured for entrainment in the combustion volume 204 or for premixing, 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. In another embodiment, 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. 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 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.

In an embodiment, 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).

Referring again to both FIGS. 2 and 3, the perforations 210 can be of various shapes. In an embodiment, the perforations 210 can include elongated squares, each having a transverse dimension D between opposing sides of the squares. In another embodiment, the perforations 210 can include elongated hexagons, each having a transverse dimension D between opposing sides of the hexagons. In yet another embodiment, the perforations 210 can include hollow cylinders, each having a transverse dimension D corresponding to a diameter of the cylinder. In another embodiment, 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. In some embodiments, 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. Alternatively, the perforations 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 of perforations 210 has a lateral dimension D between 0.1 inch and 0.5 inch. For example 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. In an embodiment, the perforated flame holder 102 can have a void fraction between 0.30 and 0.80. In another embodiment, 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. For example, the perforated flame holder 102 can be formed to include mullite or cordierite. Additionally or alternatively, 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 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, 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.

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 of perforations 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 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. 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 the fuel stream 206 contacts the input face 212 of the perforated flame holder 102, 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. 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 believe 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.

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 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. 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 with step 402, 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 the 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 402 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 402. In 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.

Proceeding from step 408, a fuel and oxidant mixture is provided to the perforated flame holder, as shown in step 410. The fuel and oxidant may be provided by a fuel and oxidant source that includes a separate fuel nozzle and oxidant (e.g., combustion air) source, for example. In this approach, the fuel and oxidant are output in one or more directions selected to cause the fuel and oxidant mixture to be received by the 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, flame rod, and/or other combustion sensing apparatuses. In an additional or alternative variant of step 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, the method 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 preheating step 402, outputting an alarm signal, igniting a stand-by combustion system, or other steps. If, in 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 410, 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 410, 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.

Referring again to FIG. 2, the burner system 200 includes a heater 228 operatively coupled to the perforated flame holder 102. As described in conjunction with FIGS. 3 and 4, 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.

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 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. For example, 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).

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 and oxidant mixture 206 to cause the fuel and oxidant mixture 206 to proceed to the perforated 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 a perforated flame holder 102 operating temperature, the flow rate may be increased to “blow out” the start-up flame. In another embodiment, 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.

In another embodiment, 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. For example, the electrical resistance heater 228 can be formed from KANTHAL® wire (available from Sandvik Materials Technology division of Sandvik AB of Hallstaham mar, Sweden) threaded through at least a portion of the perforations 210 defined by the perforated flame holder body 208. Alternatively, 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.

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 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. Optionally, 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. Additionally or alternatively, 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. 5A is a diagram of a combustion system 500, according to an embodiment. The combustion system 500 includes a furnace body having a sidewall 512, a floor 514, and a ceiling 516. The sidewall 512, the floor 514, and the ceiling 516 collectively define a combustion volume 506. A perforated flame holder 102 and a fuel nozzle 504 are positioned within the combustion volume 506. The perforated flame holder 102 is supported above the fuel nozzle 504 by a support structure 508. The support structure 508 includes support arms 509 fixed to the floor 514 of the furnace body. The support structure 508 holds the perforated flame holder 102 a selected distance above the fuel nozzle 504.

According to an embodiment, the fuel nozzle 504 outputs a stream 507 of fuel and/or a mixture of fuel and oxidant onto the perforated flame holder 102. The oxidant can be provided to the combustion volume independent of the fuel nozzle 504. The perforated flame holder 102 supports a combustion reaction of the fuel and oxidant 507 within the perforated flame holder 102.

The characteristics of the combustion reaction within the perforated flame holder 102 depend, in part, on a distance that the fuel and/or fuel and oxidant travel between the fuel nozzle 504 and the perforated flame holder 102. The perforated flame holder 102 may not support the combustion reaction of the fuel and oxidant if the perforated flame holder 102 is not positioned a proper distance from the fuel nozzle 504. The support structure 508 is configured to support the perforated flame holder 102 in a stable position at the selected distance from the fuel nozzle 504.

The support structure 508 includes one or more support arms 509 fixed to the floor 514 and coupled to the perforated flame holder 102. According to an embodiment, the support structure 508 includes two support arms 509 coupled to opposite sides of the perforated flame holder 102.

According to an embodiment, the support structure 508 is fixed to a side of the perforated flame holder 102. Alternatively, the perforated flame holder 102 can rest on the support structure 508.

According to an embodiment, the support structure 508 is fixed to the floor 514 by one or more screws or bolts. Alternatively, the support structure 508 can be fixed to the floor by a refractory cement material, by fitting into slots or grooves in the floor 514, or by gravity alone, for example.

According to an embodiment, the support structure 508 can include multiple finger members 515 (shown in FIG. 5C) on which the perforated flame holder 102 rests. The finger members 515 can be configured to allow the fuel and oxidant 507 to pass between the thin finger members 515 to enter into the perforated flame holder 102 without significantly inhibiting the fuel and oxidant 507 from entering into the perforated flame holder 102. According to an embodiment, the perforated flame holder 102 can include multiple perforated flame holder sections fixed together. Each perforated flame holder section can be positioned on and supported by at least one of the finger members 515.

According to an embodiment, the support structure 508 can be covered by a thermal insulator and coupled to a structure for extracting heat from the insulated structure. Such structures for extracting heat (not shown) may include the use of a fluid coolant such as air, flue gas, steam, or water. Heat may optionally be extracted from the fluid coolant electronically using a Peltier cooler or by other means known to those skilled in the art. In transient operation, thermal insulation alone may allow the structural material to remain sufficiently cool. These or other methods can help prevent the support structure 508 from overheating to the point of becoming structurally unsound, thereby jeopardizing the stability of the positioning of the perforated flame holder 102. For example, the inventors have found that ordinary high temperature steel materials may undergo plastic deformation under the influence of furnace temperatures. Providing insulation and/or fluid coolant are contemplated to provide sufficient protection to avoid plastic deformation.

According to an embodiment, the support structure 508 can be coupled to the perforated flame holder 102 by one or more of gravity; a refractory cement material; superalloy or ceramic screws, bolts, pins, or clamps; or by fitting into grooves or slots in the perforated flame holder 102, for example.

According to an embodiment, the support structure 508 can include one or more of a metal superalloy (such as Inconel or Hastelloy), a ceramic material, a refractory brick, a refractory material, or a fiber reinforced refractory material.

According to an embodiment, the support structure 508 includes support arms coupled between the floor 514 and the perforated flame holder 102.

FIG. 5B is a diagram of the combustion system 500 of FIG. 5A in which the support structure 508 includes brackets 513 fixed to the support arms 509. The support structure 508 includes a plurality of finger members 515 coupled to the brackets 513. The perforated flame holder 102 rests on the finger members 515.

According to an embodiment, the brackets 513 can be fixed to the perforated flame holder 102 by gravity; screws, bolts, or pins, refractory cement, or other suitable mechanisms or materials for fixing a bracket to a support arm. The brackets 513 can include a metal or a metal superalloy, a ceramic or refractory material, and/or other materials suitable for being placed in a high temperature combustion environment. The brackets 513 can be of the same material as the support arms 509 and/or continuous with the support arms 509.

According to an embodiment, the finger members 515 are rods, bars, or other relatively long and thin structure suitable for supporting the perforated flame holder 102. As shown more clearly in a top view of FIG. 5C, the finger members 515 are spaced apart from each other in such a way as to permit the fuel and oxidant 507 to enter the perforated flame holder 102. The finger members 515 can be discreet members positioned on the brackets 513 or a unitary grid positioned on the bracket 513. The finger members 515 can be fixed to the brackets 513 or can merely rest on the brackets 513. The finger members 515 can include a metal or a metal superalloy, a ceramic or refractory material, and/or other materials suitable for being placed in a high temperature combustion environment. The finger members 515 can be of the same material as the brackets 513 and/or the support arms 509.

FIG. 5C is the top view of the support structure 508 of FIG. 5B, according to an embodiment. The support structure 508 includes the support arms 509 positioned on the floor 514 of the furnace, the brackets 513 fixed to the support arms 509, and the finger members 515 positioned on the brackets 513. The finger members 515 are positioned in an array or a grid configuration. The perforated flame holder 102 (not shown in FIG. 5C) rests on the finger members 515. The finger members 515 are spaced apart so that fuel and oxidant 507 can enter the perforated flame holder 102.

FIG. 5D is a diagram of the combustion system 500 of FIG. 5A in which the support structure 508 includes brackets 513 fixed to the support arms 509. The perforated flame holder 102 rests directly on the brackets 513.

According to an embodiment, the brackets 513 can be fixed to the perforated flame holder 102 by a refractory cement material; metal, superalloy, or ceramic screws, bolts, pins, or clamps; or by fitting into grooves or slots in the perforated flame holder 102, for example. The brackets 513 can include a metal or a metal superalloy, a ceramic or refractory material, and/or other materials suitable for being placed in a high temperature combustion environment. The brackets 513 can be of the same material as the support arms 509.

FIG. 6A is a diagram of a combustion system 600, according to an embodiment. The combustion system 600 includes a furnace body having a sidewall 512, a floor 514, and a ceiling 516. The sidewall 512, the floor 514, and the ceiling 516 collectively define a combustion volume 506. A perforated flame holder 102 and a fuel nozzle 504 are positioned within the combustion volume 506. The perforated flame holder 102 is supported above the fuel nozzle 504 by a support structure 608. The support structure 608 includes support arms 609 fixed to the sidewall 512 of the furnace body. The support structure 608 holds the perforated flame holder 102 at a selected distance above the fuel nozzle 504.

According to an embodiment, the fuel nozzle 504 outputs a stream 507 of fuel and/or a mixture of fuel and oxidant 507 onto the perforated flame holder 102. The perforated flame holder 102 supports a combustion reaction of the fuel and oxidant within the perforated flame holder 102.

The characteristics of the combustion reaction within the perforated flame holder 102 depend, in part, on a distance that the fuel and oxidant travel between the fuel nozzle 504 and the perforated flame holder 102. The perforated flame holder 102 may not support the combustion reaction of the fuel and oxidant if the perforated flame holder 102 is not positioned a proper distance from the fuel nozzle 504. The support structure 608 is configured to support the perforated flame holder 102 in a stable position at a selected distance from the fuel nozzle 504.

The support structure 608 includes two or more portions each fixed to the sidewall 512 and coupled to the perforated flame holder 102. According to an embodiment, the support structure 608 includes two support structure portions coupled to opposite sides of the perforated flame holder 102.

According to an embodiment, the support structure 608 is fixed to a side of the perforated flame holder 102. Alternatively, the perforated flame holder 102 can rest on the support structure 608. According to an embodiment, the support structure may include two or more layers of support arms 609 arranged in alternating directions, such as in a crisscrossed arrangement.

According to an embodiment, the support structure 608 is coupled to the sidewall 512 by gravity. In another embodiment the support structure 608 can be coupled to the sidewall 512 one or more screws, bolts, or pins. Alternatively or additionally, the support structure 608 can be fixed to the sidewall 512 by a refractory cement material, by fitting into slots or grooves in the sidewall 512.

According to an embodiment, the support structure 608 can include multiple finger members 515 (shown and described in relation to FIG. 5) on which the perforated flame holder 102 rests. The finger members 515 can be configured to allow the fuel and oxidant 507 to pass between the finger members 515 to enter into the perforated flame holder 102 without significantly inhibiting the fuel and oxidant from entering into the perforated flame holder 102. According to an embodiment, the perforated flame holder 102 can include multiple perforated flame holder sections fixed together. Each perforated flame holder section can be positioned on and supported by at least one of the thin finger members 515.

According to an embodiment, the support structure 608 can be covered by a thermal insulator and coupled to a method for extracting heat from the insulated structure. Such means of extracting heat (not shown) may include the use of a fluid coolant such as air, steam, or water. Heat may also be extracted electronically using a Peltier cooler or by other methods or structures known to those skilled in the art. In transient operation, thermal insulation alone may allow the structural material to remain sufficiently cool. These or other methods can help prevent the support structure 608 from overheating to the point of becoming structurally unsound, thereby jeopardizing the stability of the positioning of the perforated flame holder 102.

According to an embodiment, the support structure 608 can be coupled to the perforated flame holder 102 by one or more of gravity; a refractory cement; superalloy or ceramic screws, bolts, clamps, or pins; or by fitting into grooves or slots in the perforated flame holder 102; for example.

According to an embodiment, the support structure 608 can include one or more of a metal superalloy (such as Inconel or Hastelloy), a ceramic material, a refractory brick, a refractory material, or a fiber reinforced refractory material.

According to an embodiment, the support structure 608 includes support arms coupled between the wall 512 and the perforated flame holder 102.

FIG. 6B is a diagram of the combustion system 500 of FIG. 6A in which the arms 609 include a plurality of rods or tubes coupled the wall 512. The perforated flame holder 102 rests on the rods 609.

According to an embodiment, the support arms 609 are finger members 515 such as rods, tubes, bars, or other relatively long and thin structure suitable for supporting the perforated flame holder 102. The support arms 609 pass through the walls 512 and are supported thereby. As shown more clearly in a top view of FIG. 6C, the finger members 515 are spaced apart from each other in such a way as to permit the fuel and oxidant 507 to enter the perforated flame holder 102. According to an embodiment, the support arms 609 can be fixed to one or more brackets coupled to the walls 512. The support arms 609 can include a metal or a metal superalloy, a ceramic or refractory material, and/or other materials suitable for being placed in a high temperature combustion environment.

FIG. 6C is the top view of the support structure 608 of FIG. 5B, according to an embodiment. The support structure 608 includes the support arms 609 extending between the walls 512 of the furnace. The support arms 609 are positioned in an array or a grid configuration. The perforated flame holder 102 (not shown in FIG. 6C) rests on the support arms 609. The support arms 609 are spaced apart so that fuel and oxidant 507 can enter the perforated flame holder 102.

FIG. 7A is a diagram of a combustion system 700. The combustion system 700 includes a furnace body having a sidewall 512, a floor 514, and a ceiling 516. The sidewall 512, the floor 514, and the ceiling 516 collectively define a combustion volume 506. A perforated flame holder 102 and a fuel nozzle 504 are positioned within the combustion volume 506. The perforated flame holder 102 is supported above the fuel nozzle 504 by a support structure 708. The support structure 708 includes support arms 709 coupled to the ceiling 516 and the perforated flame holder 102. The support structure 708 holds the perforated flame holder 102 at a selected distance above the fuel nozzle 504.

According to an embodiment, the fuel nozzle 504 outputs a stream 507 of fuel and/or a mixture of fuel and oxidant onto the perforated flame holder 102. The perforated flame holder 102 supports a combustion reaction of the fuel and oxidant within the perforated flame holder 102.

The characteristics of the combustion reaction within the perforated flame holder 102 depend, in part, on a distance that the fuel and oxidant travel between the fuel nozzle 504 and the perforated flame holder 102. The perforated flame holder 102 may not support the combustion reaction of the fuel and oxidant if the perforated flame holder 102 is not positioned a proper distance from the fuel nozzle 504. The support structure 708 is configured to support the perforated flame holder 102 in a stable position at a selected distance from the fuel nozzle 504.

The support structure 708 includes one or more support arms 709 each fixed to the ceiling 516 and coupled to the perforated flame holder 102. According to an embodiment, the support structure 708 includes two support arms 709 coupled to opposite sides of the perforated flame holder 102.

According to an embodiment, the support structure 708 is fixed to a side of the perforated flame holder 102. Alternatively, the perforated flame holder 102 can rest on the support structure 708.

According to an embodiment, the support structure 708 is fixed to the ceiling 516 by one or more superalloy or ceramic screws, bolts, or pins. Alternatively, the support structure 708 can pass through the ceiling 516 from outside the furnace body, or can be fitting into slots or grooves in the ceiling 516.

According to an embodiment, the support structure 708 can include multiple finger members 515 on which the perforated flame holder 102 rests. The finger members 515 can be configured to allow the fuel and oxidant 507 to pass between the thin finger members 515 to enter into the perforated flame holder 102 without significantly inhibiting the fuel and oxidant from entering into the perforated flame holder 102. According to an embodiment, the perforated flame holder 102 can include multiple perforated flame holder sections fixed together. Each perforated flame holder section can be positioned on and supported by at least one of the thin finger members 515.

According to an embodiment, the support structure 708 can be covered by a thermal insulator and coupled to a method for extracting heat from the insulated structure. Such means of extracting heat (not shown) may include the use of a fluid coolant such as air, flue gas, steam, or water. Heat may also be extracted electronically using a Peltier cooler or by other structures or methods known to those skilled in the art. In transient operation, thermal insulation alone may allow the structural material to remain sufficiently cool. These or other methods can help prevent the support structure 708 from overheating to the point of becoming structurally unsound, thereby jeopardizing the stability of the positioning of the perforated flame holder 102.

According to an embodiment, the support structure 708 can be coupled to the perforated flame holder 102 by gravity; a refractory cement; superalloy or ceramic screws, bolts, clamps, or pins; or by fitting into grooves or slots in the perforated flame holder 102.

According to an embodiment, the support structure 708 can include one or more of a metal superalloy (such as Inconel or Hastelloy), a ceramic material, a refractory brick, a refractory material, or a fiber reinforced refractory material.

According to an embodiment, the support structure 708 includes support arms coupled between the ceiling 516 and the perforated flame holder 102.

FIG. 7B is a diagram of the combustion system 700 of FIG. 7A in which the support structure 708 includes brackets 716 coupling the support arms 709 to the ceiling 516. The support structure 708 further includes brackets 713 coupled to lower ends of the support arms 709. A plurality of finger members 715 are coupled to the brackets 713. The perforated flame holder 102 rests on the finger members 715.

The brackets 716 can include a metal or a metal superalloy, a ceramic or refractory material, and/or other materials suitable for being placed in a high temperature combustion environment. The brackets can be of the same material as and/or continuous with the support arms 709.

According to an embodiment, the finger members 715 are rods, bars, or other relatively long and thin structure suitable for supporting the perforated flame holder 102. The finger members 715 are spaced apart from each other in such a way as to permit the fuel and oxidant 507 to enter the perforated flame holder 102. The finger members 715 can be discreet members positioned on the brackets 713 or a unitary grid positioned on the brackets 713. The finger members 715 can be fixed to the brackets 713 or can merely rest on the brackets 713. The finger members 715 can include a metal or a metal superalloy, a ceramic or refractory material, and/or other materials suitable for being placed in a high temperature combustion environment. The fingers 715 can be of the same material as the brackets 713 and/or the support arms 709.

FIG. 8 is a diagram of a combustion system 800, according to an embodiment. The combustion system 800 includes a furnace body 810 defining a combustion volume 106 within the furnace body 810. A perforated flame holder 102 and a fuel and oxidant source 104 are positioned within the combustion volume 106. A cooled support structure 808 is fixed to the furnace body 810 and supports the perforated flame holder 102 at a selected distance from the fuel and oxidant source 104. The cooled support structure 808 includes a fluid coolant 812 (also referred to as a fluid coolant) within a hollow portion of the support structure 808. A coolant source 814 is coupled to the cooled support structure 808.

The fuel and oxidant source 104 outputs fuel and oxidant onto the perforated flame holder 102. The perforated flame holder 102 receives the fuel and oxidant and supports a combustion reaction of the fuel and oxidant within the perforated flame holder 102.

Characteristics of the combustion reaction within the perforated flame holder 102 depend, in part, on a distance between the fuel and oxidant source 104 and the perforated flame holder 102. The cooled support structure 808 supports the perforated flame holder 102 in a stable position at the selected distance from the fuel and oxidant source 104.

According to an embodiment, the cooled support structure 808 can include an interior channel, such as a tube, a channel, or chamber through which the fluid coolant 812 can pass. In particular, the coolant source 814 can circulate or pass the fluid coolant 812 through the cooled support structure 808, thereby cooling the cooled support structure 808 and/or the perforated flame holder 102 and maintaining the cooled support structure 808 at a selected temperature or below a failure temperature.

According to an embodiment, the fluid coolant can be a liquid and/or a gas. The coolant can include water, flue gas, water vapor, or any other suitable fluid for cooling tubes 909 (shown in FIG. 9) and/or the perforated flame holder 102. Optionally, the cooled support structure may vent the coolant to the combustion volume 106. For example, the support structure can be cooled by air, and the air may be vented to deliver oxygen oxidant upstream from the perforated flame holder 102 to combine with fuel and contribute oxidant to the fuel and oxidant mixture 206. In another example, the support structure can be cooled by water, and the water may be vented downstream from the perforated flame holder to quickly reduce temperature of the combustion products, or upstream from the perforated flame holder to reduce an incidence of flashback.

FIG. 9A is a diagram of a combustion system 900, according to an embodiment. The combustion system 900 includes a furnace body having a sidewall 512. The combustion system 900 includes a cooled support structure 908 and a perforated flame holder 102 supported by the cooled support structure 908.

According to an embodiment, the cooled support structure 908 includes tubes 909 passing through the sidewall 512 of the furnace body and coupled to a coolant source 814. Each tube 909 includes an interior channel 911 through which fluid coolant can pass. The coolant source 814 passes the fluid coolant through the tubes 909. The perforated flame holder 102 rests on the tubes 909.

As the fluid coolant is passed through the interior channels 911 of the tubes 909 the fluid coolant absorbs heat from the tubes 909, thereby cooling the tubes 909. As the tubes 909 are cooled, the perforated flame holder 102 is also cooled. In this way, the temperature of the tubes 909 forming the support structure can be kept within a selected temperature range.

According to an embodiment, the tubes 909 can include a refractory material such as quartz, silicon carbide, or another material capable of withstanding a high temperature combustion environment.

FIG. 9B is a top view of the cooled support structure 908 of FIG. 9A, according to an embodiment. The support structure 908 includes the tubes 909 passing through the walls 512 of the furnace. The tubes 909 are positioned in an array or a grid configuration. The perforated flame holder 102 (not shown in FIG. 9B) rests on the tubes 909. The tubes 909 are spaced apart so that fuel and oxidant can enter the perforated flame holder 102.

According to an embodiment, the tubes 909 are connected with U shaped connectors outside the furnace walls 512 such that the tubes 909 form a single tube through which the fluid coolant can pass. Alternatively, each tube 909 can be a separate tube coupled to the coolant source 814 and through which the fluid coolant passes.

FIG. 10 is a flow diagram of a method 1000 for operating a combustion system including a perforated flame holder and a support structure, according to an embodiment. At 1002, the perforated flame holder is supported within a combustion volume by the support structure. In particular, the support structure holds the perforated flame holder at a selected distance from a fuel and oxidant source. At 1004, fuel and oxidant is output from the fuel and oxidant source. At 1006, the fuel and oxidant is received at the perforated flame holder. At 1008, a combustion reaction of the fuel and oxidant is supported within the perforated flame holder.

According to an embodiment, the support structure can be fixed to a sidewall, a ceiling, or a floor of a furnace defining the combustion volume. Because the support structure is fixed to one or more selected portions of the furnace body, the support structure can stably support the perforated flame holder at a selected distance from the fuel and oxidant source.

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

1. A combustion system comprising:

a furnace body defining an interior combustion volume;

a fuel and oxidant source configured to output fuel and oxidant into the interior combustion volume;

a perforated flame holder disposed within the interior combustion volume to receive the fuel and oxidant from the fuel and oxidant source and to support a combustion reaction of the fuel and oxidant within the perforated flame holder; and

a support structure disposed within the interior volume and fixed to the furnace body and configured to support the perforated flame holder at a selected distance from the fuel and oxidant source.

2. The combustion system of claim 1, wherein the support structure is fixed to a floor of the furnace body.

3. The combustion system of claim 2, wherein the support structure includes a first and a second support arm each mounted to the floor.

4. The combustion system of claim 3, wherein the support structure includes an array of finger members extending between the first and second support arms and on which the perforated flame holder rests.

5. The combustion system of claim 4 including one or more brackets coupled to the support arms and the array of finger members.

6. The combustion system of claim 1, wherein the support structure is fixed to a sidewall of the furnace body.

7. The combustion system of claim 6, wherein the support structure suspends the perforated flame holder from the sidewall of the furnace body.

8. The combustion system of claim 6, wherein the support structure includes a first and a second support structure portions fixed to respective sidewalls of the furnace body.

9. The combustion system of claim 6 wherein the support structure includes a plurality of rods extending between sidewalls of the furnace body and on which the perforated flame holder rests.

10. The combustion system of claim 9, wherein the rods are arranged in an array including gaps between adjacent rods allowing the fuel and oxidant to pass to the perforated flame holder.

11. The combustion system of claim 1, wherein the support structure is fixed to a ceiling of the furnace body.

12. The combustion system of claim 11, wherein the support structure suspends the perforated flame holder from the ceiling of the furnace body.

13. The combustion system of claim 11, wherein the support structure includes a first and a second support arms each mounted to the ceiling of the furnace body.

14. The combustion system of claim 13, wherein the support structure includes an array of finger members extending between the first and second support arms and on which the perforated flame holder rests.

15. The combustion system of claim 14 including one or more brackets coupled to the support arms and the array of finger members.

16. The combustion system of claim 13, wherein the support structure includes one or more brackets that attach the support arms to the ceiling of the furnace body.

17. The combustion system of claim 1, wherein the support structure is fixed to a side of the perforated flame holder.

18. The combustion system of claim 1, wherein the perforated flame holder rests on the support structure.

19. The combustion system of claim 1, wherein the support structure is a cooled support structure having an interior channel configured to pass a fluid coolant therethrough to cool the support structure and/or the perforated flame folder.

20. The combustion system of claim 19, comprising a coolant source configured to pass the fluid coolant through the cooled support structure.

21. The combustion system of claim 20, wherein the support structure includes a plurality of tubes arranged in an array and on which the perforated flame holder rests, the tubes being coupled to the coolant source and configured to pass the fluid coolant therethrough.

22. The combustion system of claim 1, wherein the support structure is fixed to the furnace body by one or more metal, superalloy, or ceramic screws, bolts, or pins.

23. The combustion system of claim 1, wherein the support structure includes multiple finger members on which the perforated flame holder rests, the finger members being thin and configured to allow the fuel and oxidant to enter into the perforated flame holder.

24. The combustion system of claim 23, wherein the perforated flame holder includes multiple perforated flame holder sections fixed together, each perforated flame holder section being positioned on at least one of the thin finger members.

25. The combustion system of claim 1, wherein the support structure is covered by a thermal insulator.

26. The combustion system of claim 1, wherein the support structure is operatively coupled to a cooling mechanism and covered by a thermal insulator.

27. The combustion system of claim 1, wherein the support structure is coupled to the perforated flame holder by one or more of ceramic screws, bolts, pins, or clamps.

28. The combustion system of claim 1, wherein the support structure is fixed to two or more of a wall, a floor, and/or a ceiling of the furnace body.

29. The combustion system of claim 1, wherein the support structure includes one or more materials selected from the group consisting of: a metal superalloy, a ceramic material, a refractory brick, a refractory material, and a fiber reinforced refractory material.

30. The combustion system of claim 1, wherein the perforated flame holder includes:

an input face proximal to the fuel and oxidant source;

an output face distal from the fuel and oxidant source;

a plurality of perforations extending between the input face and the output face and configured to hold a majority of the combustion reaction within the perforations.

31. The combustion system of claim 1, wherein the fuel source includes a fuel nozzle configured to output the fuel onto the perforated flame holder.

32. The combustion system of claim 31, wherein the support structure supports the perforated flame holder at the selected distance from the fuel nozzle.

33. A method comprising:

supporting, with a support structure fixed to a furnace body, a perforated flame holder at a selected distance from a fuel and oxidant source;

outputting fuel and oxidant from the fuel and oxidant source;

receiving the fuel and oxidant in the perforated flame holder positioned to receive the fuel and oxidant from the fuel and oxidant source; and

supporting a majority of a combustion reaction of the fuel and oxidant within the perforated flame holder.

34. The method of claim 33, wherein the support structure is fixed to a sidewall of the furnace body.

35. The method of claim 33, wherein the support structure is fixed to a floor of the furnace body.

36. The method of claim 33, wherein the support structure is fixed to a ceiling of the furnace body.

37. The method of claim 33, wherein the support structure includes an interior channel.

38. The method of claim 37, comprising cooling the support structure by passing a fluid coolant through the interior channel of the support structure.

39. A combustion system, comprising:

an enclosure defining an interior volume

a fuel and oxidant source disposed within the enclosure and configured to output fuel and oxidant;

a perforated flame holder disposed to receive the fuel and oxidant from the fuel and oxidant source and to support a combustion reaction of the fuel and oxidant within the perforated flame holder; and

a first and a second support arms coupled between the enclosure and the perforated flame holder and configured to support the perforated flame holder within the enclosure at a selected distance from the fuel and oxidant source.

40. The combustion system of claim 39, wherein the enclosure includes a wall, the first and second support arms being fixed to the wall.

41. The combustion system of claim 39, wherein the enclosure includes a floor, the first and second support arms being fixed to the floor.

42. The combustion system of claim 39, wherein the enclosure includes a ceiling, the first and second support arms being fixed to the ceiling.