FLOW RESTRICTORS FOR USE ON BURNERS

Abstract

A flow restrictor for use on burners used for combusting gases includes a central disk and opposing cylindrical members extending from opposing sides of the central disk. The central disk includes a central portion having multiple inner openings extending through the central disk and a peripheral portion having multiple outer openings extending through the central disk. Each of the opposing cylindrical members surrounds the central portion and the inner openings of the central disk. The peripheral portion and the outer openings of the central disk are disposed outside of the cylindrical members. Each of the cylindrical members is designed to be attached to an open end of a pipe of a burner.

Claims

1. A flow restrictor, comprising: a central disk that includes a central portion having a plurality of inner openings extending through the central disk and a peripheral portion having a plurality of outer openings extending through the central disk; and first and second cylindrical members extending from opposing sides of the central disk, wherein the first and second cylindrical members each surround the central portion and the inner openings of the central disk, and wherein the peripheral portion and the outer openings of the central disk are disposed outside of the first and second cylindrical members.

2. The flow restrictor of claim 1, wherein the central disk has a generally circular shape.

3. The flow restrictor of claim 1, wherein each of the plurality of inner openings has a generally circular shape.

4. The flow restrictor of claim 1, wherein each of the plurality of outer openings has a generally circular shape.

5. The flow restrictor of claim 1, wherein each of the plurality of inner openings has a diameter, wherein the diameter of each respective one of the plurality of inner openings is approximately the same size.

6. The flow restrictor of claim 1, wherein each of the plurality of outer openings has a diameter, wherein the diameter of each respective one of the plurality of outer openings is approximately the same size.

7. The flow restrictor of claim 1, wherein the plurality of inner openings comprises a number of inner openings in a range of 2 to 64 inner openings, and wherein each respective one of the plurality of inner openings has a diameter in a range of approximately 0.0625 inches to 0.5 inches.

8. The flow restrictor of claim 1, wherein the plurality of outer openings comprises a number of outer openings in a range of 2 to 64 outer openings, and wherein each respective one of the plurality of outer openings has a diameter in a range of approximately 0.5 inches to 0.75 inches.

9. The flow restrictor of claim 1, wherein the first cylindrical member is configured to attach to an open end of a first pipe, and wherein the second cylindrical member is configured to attach to an open end of a second pipe.

10. The flow restrictor of claim 9, wherein the first cylindrical member is configured to receive the open end of the first pipe within the first cylindrical member, and wherein the second cylindrical member is configured to receive the open end of the second pipe within the second cylindrical member.

11. The flow restrictor of claim 10, wherein the first cylindrical member has an inner diameter that is approximately equal to an outer diameter of the first pipe, and wherein the second cylindrical member has an inner diameter that is approximately equal to an outer diameter of the second pipe.

12. The flow restrictor of claim 9, wherein the inner openings are configured to restrict flow of a fluid through a flow path from the first pipe to the second pipe.

13. The flow restrictor of claim 1, wherein each of the first and second cylindrical members has a threaded inner surface.

14. The flow restrictor of claim 13, wherein the first cylindrical member is configured to attach to an open end of a first pipe, wherein the second cylindrical member is configured to attach to an open end of a second pipe, wherein the end of the first pipe has a threaded outer surface, wherein the end of the second pipe has a threaded outer surface, wherein the threaded inner surface of the first cylindrical member is compatible with the threaded outer surface of the end of the first pipe, and wherein the threaded inner surface of the second cylindrical member is compatible with the threaded outer surface of the end of the second pipe.

15. The flow restrictor of claim 14, wherein the inner openings are configured to restrict flow of a fluid through a flow path from the first pipe to the second pipe.

16. The flow restrictor of claim 1, wherein the flow restrictor is configured to be mounted onto a burner, wherein the inner openings are configured to restrict flow of a first fluid through a first flow path of the burner, and wherein the outer openings are configured to restrict flow of a second fluid through a second flow path of the burner.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present disclosure may be better understood with reference to the following figures. Matching reference numerals designate corresponding parts throughout the figures, which are not necessarily drawn to scale.

[0010] FIG. 1 is a perspective view illustrating an embodiment of a system comprising a burner mounted to a combustion chamber.

[0011] FIG. 2 is a perspective side view of an embodiment for the system comprising a burner shown in FIG. 1.

[0012] FIG. 3 is a side view of the burner of FIG. 2.

[0013] FIG. 4 is a plan view of the burner of FIGS. 2 and 3.

[0014] FIG. 5A is a cross-sectional side view of the flow restrictor of FIG. 5B.

[0015] FIG. 5B is an end view of an embodiment of a flow restrictor used in the burner of FIGS. 2-4.

[0016] FIG. 6 is a block diagram of an embodiment of an experimental system for producing syngas in which a burner similar to that shown in FIGS. 2-4 was used.

DETAILED DESCRIPTION

[0017] Disclosed herein are burners suitable for use in producing synthesis gas (syngas). In some embodiments, the burners comprise diffusion burners that each include multiple burner units that are used in parallel. In such a case, the reactant flow speed and the reaction length required to complete the reaction are reduced as compared to systems comprising a single burner unit. Each of the burner units can include concentric pipes, including an inner pipe configured to deliver fuel and an outer pipe configured to deliver oxygen. In some embodiments, a flow restrictor is provided for each burner unit that controls both the flow of fuel and oxygen through their respective pipes. When such flow restrictors are used, the flow of reactants through the burner units is more balanced and more even flames can be produced.

[0018] In the following disclosure, various specific embodiments are described. It is to be understood that those embodiments are example implementations of the disclosed inventions and that alternative embodiments are possible. Such alternative embodiments include hybrid embodiments that combine aspects of different embodiments. All such embodiments are intended to fall within the scope of this disclosure.

[0019] FIG. 1 illustrates part of a syngas production system that comprises a burner 10 that is mounted to a combustion chamber 11 of a syngas reactor. By way of example, the combustion chamber 11 can be approximately 5 to 30 feet in diameter (e.g., 6 feet). The burner 10 delivers reactants, which at least include fuel (e.g., natural gas) and oxygen to the combustion chamber 11 using multiple burner units. It is noted that, in the context of this document, delivery of oxygen is intended to cover the delivery of any gas that is at least 70 percent oxygen in composition. Accordingly, when it is stated herein that oxygen is delivered to, through, or from the burner 10, this includes cases in which pure oxygen is delivered as well as cases in which a gas comprising oxygen as well as one or more other types of gas, such as nitrogen, is delivered.

[0020] As described below, each burner unit can be configured as a diffusion burner unit in which the fuel and oxygen are mixed after exiting their respective flow pipes. In some embodiments, those flow pipes can be concentrically arranged with each other. For example, inner pipes of each burner unit can be used to deliver the fuel while the outer pipes of each burner unit (that surround the inner supply pipes) can be used to deliver the oxygen. The exit ends of the fuel and oxygen flow pipes (not visible in FIG. 1) are positioned within the combustion chamber 11.

[0021] During operation of the syngas production system, a reaction is initiated when the reactants exit the burner units and enter the combustion chamber 11, which can be heated to a temperature above the autoignition temperature for the mixture (e.g., 600 C.). When the temperature in the combustion chamber 11 is above the autoignition temperature, the mixture automatically ignites and reacts to form a mixture of hydrogen (H.sub.2), carbon monoxide (CO), carbon dioxide (CO.sub.2), water (H.sub.2O), and unreacted methane (CH.sub.4) (assuming natural gas and oxygen as reactants). Accordingly, unlike conventional burners, the burner 10 does not require, and therefore does not include, any ignition devices, such as spark generators. The combustion chamber 11 is lined with insulation to contain the heat released from the reaction and to provide a hot surface for the initiation of the reaction. The burner geometry and operating conditions are selected such that a desired H.sub.2: CO molar ratio of syngas can be achieved. As an example, this molar ratio may be in the range of approximately 1.4 to 3.0.

[0022] Notably, steam can be mixed with the fuel to produce humidified fuel that gives the syngas product elevated partial pressures of H.sub.2O for subsequent reforming reactions. To achieve this, fuel and steam can be mixed upstream of the burner 10 in a static mixer. The steam temperature can be controlled such that the temperature of the humidified fuel is above the dew point, thus ensuring a single phase flowing into the burner. The inventors have determined that introducing steam into the syngas production system ensures stability and reproducibility in the reaction. In some embodiments, steam at temperatures in the range of approximately 150 C. to 350 C. can be delivered to a static mixer and can be used at ratios of 0 to 1.8 of steam to fuel mass flow with stable overall combustion performance (see FIG. 6).

[0023] Testing was performed to evaluate a single pipe-in-pipe burner having a diameter ratio of 2.0, a volume flow ratio of 0.6, and combustion chamber pressure of approximately 2 psig. Tables 1 and 2 present the results of this testing. The water data in Table 1 was obtained by mass-balance calculations and not actual measurements. The results confirm that the addition of steam to the fuel delivered to the burner resulted in increased production of CO.sub.2, decreased production of CO, and an increase in the amount of unreacted methane as compared to the case without steam. Significantly, the syngas ratio also increased as the amount of steam increased.

TABLE-US-00001 TABLE 1 Outlet gas composition including water. steam to fuel mass flow CO.sub.2 CO H.sub.2 CH.sub.4 H.sub.2O ratio (mol %) (mol %) (mol %) (mol %) (mol %) H.sub.2:CO 0 4.6 24.0 33.1 15.6 22.5 1.38 0.19 5.1 21.9 31.8 13.7 27.5 1.45 0.38 5.3 19.7 29.1 13.5 32.4 1.48 0.57 5.5 17.9 27.2 13.0 36.4 1.52

TABLE-US-00002 TABLE 2 Outlet gas composition excluding water. steam to fuel mass flow CO.sub.2 CO H.sub.2 CH.sub.4 ratio (mol %) (mol %) (mol %) (mol %) H.sub.2:CO 0 6.0 31.0 42.8 20.2 1.38 0.19 7.0 29.3 39.9 23.8 1.45 0.38 7.9 29.1 43.0 19.9 1.48 0.57 8.6 28.1 42.8 20.5 1.52

[0024] A flame was created using spark ignition for the cases listed in Tables 1 and 2. The heat of the flame provided the necessary temperature to sustain the reaction at the burner outlet as the fuel and oxygen continuously flowed. However, it was observed in some of the experiments that the reaction may continue even if the flame is extinguished due to the temperature of the chamber walls being above 600 C. Therefore, it is possible to start and sustain the partial oxidation reaction by introducing the mixture of fuel and oxygen into a combustion chamber that is at or above the autoignition temperature. Any method of heating the chamber walls to the required temperature can be used for this purpose. In this manner, the burner can operate without the need for a spark ignition system, which is commonly used in industry, and even operate without a flame present.

[0025] FIGS. 2-4 illustrate an example configuration for the burner 10 shown in FIG. 1, which is configured to deliver fuel, oxygen, and steam (mixed with the fuel) to a combustion chamber. By way of example, the burner 10 is a diffusion burner that is capable of delivering fuel at a rate of 3,382 lb./hr., oxygen at a rate of 3,624 lb./hr., and steam at a rate of 0-1000 lb./hr.

[0026] With reference first to FIG. 2, the burner 10 comprises a first plenum chamber 12 that is configured to receive humidified fuel via a first inlet 14 and a second plenum chamber 16 that is configured to receive oxygen via a second inlet 18. As shown in FIG. 2, each plenum chamber 12, 16 can be generally ring shaped and defines a hollow interior space. As is also shown in the figure, the plenum chambers 12, 16 are concentrically aligned and are arranged in a stacked and spaced configuration.

[0027] Extending from the first plenum chamber 12 toward the second plenum chamber 16 are multiple hollow inner supply pipes 20 that are in fluid communication with the interior space of the first plenum chamber. Accordingly, humidified fuel delivered to the first plenum chamber 12 via the first inlet 14 can flow into and through each of the inner supply pipes 20. In the illustrated example, there are eight such pipes 20, such that the burner 10 comprises eight separate diffusion burner units 22 from which humidified fuel and oxygen are output. It is noted, however, that a greater or a lesser number of burner units 22 can be used, if desired. For example, anywhere from 2 to 16 burner units 22 can be provided. As is apparent from FIG. 2, the inner supply pipes 20 are equally spaced from each other about the circumference of the first plenum chamber 12.

[0028] With further reference to FIG. 2, the inner supply pipes 20 extend through the second plenum chamber 16. Unlike as with the first plenum chamber 12, however, the inner supply pipes 20 are not in fluid communication with the interior space of the second plenum chamber 16 so that oxygen provided to the second plenum chamber via the second inlet 18 cannot flow into or through the inner supply pipes. Extending from the second plenum chamber 16 in a direction facing away from the first plenum chamber 12 are multiple hollow outer supply pipes 24 that are in fluid communication with the interior space of the second plenum chamber. Accordingly, oxygen delivered to the second plenum chamber 16 via the second inlet 18 can flow into and through each of the outer supply pipes 24. As is apparent in FIG. 2, each outer supply pipe 24 concentrically surrounds an inner supply pipe 20 so that there is an equal number of outer supply pipes as inner supply pipes (eight in the illustrated example).

[0029] With such a configuration, humidified fuel can flow through the inner supply pipes 20 while oxygen simultaneously flows through the outer supply pipes 24 (and around the inner supply pipes) in the same direction. In some embodiments, the diameter ratio for the outer supply pipes 24 to the inner supply pipes 20 is in the range of approximately 1.5:1 to 2:1, and the oxygen-to-fuel volume flow ratio for each burner unit 22 is in the range of approximately 0.55 to 0.65. Ratios in these ranges result in flow velocities that create instability in the flow of the reactants that enhances mixing and results in a CO-rich syngas product. In some embodiments, the flow ratio further results in partial consumption of the fuel but complete consumption of the oxygen (i.e., a partial oxidation reaction). By way of example, each inner supply pipe 20 can have an outer diameter of approximately 1 to 6 inches (e.g., 2 inches) and each outer supply pipe 24 can have an outer diameter of approximately 2 to 12 inches (e.g., 4 inches). Each of the inner and outer supply pipes 20, 24 can be made of steel.

[0030] As depicted in FIGS. 2 and 3, mounted to the free end of each inner supply pipe 20 downstream of the second plenum chamber 16 is a flow restrictor 26 that is used to balance the flow of reactants through each burner unit 22. An example flow restrictor 26 is shown in FIGS. 5A and 5B. As shown in these figures, the flow restrictor 26 comprises a circular central disk 30 and first and second cylindrical members 32 and 34 that extend in opposite directions from opposite sides of the central disk. As shown most clearly in FIG. 5B, the central disk 30 comprises multiple inner openings 36 (5 openings in the example of FIG. 5) and multiple outer openings 38 (8 openings in the example of FIG. 5). The inner openings 36 extend through a central portion 40 of the disk 30 that is surrounded by the cylindrical members 32, 34, while the outer openings 38 extend through a peripheral portion 42 of the disk that is outside of the cylindrical members.

[0031] With reference back to FIGS. 2 and 3, the first cylindrical member 32 has an inner diameter that is approximately the same dimension as the outer diameter of the inner supply pipes 20 and, therefore, is configured to receive the free end of an inner supply pipe. In some embodiments, the inner surfaces of the first cylindrical members 32 and the free ends of the inner supply pipes 20 are threaded such that each flow restrictor 26 can be threaded onto the free end of an inner supply pipe. As is also shown in FIG. 3, received within each second cylindrical member 34 of each flow restrictor 26 is inner outlet pipe 44 that also delivers humidified fuel. Accordingly, the flow restrictors 26 act as couplers that each connect an inner supply pipe 20 to an inner outlet pipe 44. The inner surface of each second cylindrical member 34 as well as the proximal end of each inner outlet pipe 44 can be threaded such that, like the inner supply pipes 20, each inner outlet pipe can be threaded into a flow restrictor 26. Each inner outlet pipe 44 forms part of the outlet of the associated burner unit 22 and, therefore, is positioned near the flame produced by the burner unit 22. Because of this, each inner outlet pipe 44 can be made of a suitable high-temperature material, such as a ceramic material.

[0032] With reference again to FIG. 2, the outer supply pipes 24 have free ends that terminate upstream of the flow restrictors 26. Extending from those free ends are outer outlet pipes 46 that surround the inner outlet pipes 44 and also form part of the outlet of the associated burner unit 22. In some embodiments, the outer outlet pipes 46 connect to the outer supply pipes 24 with a threaded flange, which is described below. Like the inner outlet pipes 44, the outer outlet pipes 46 can be made of a suitable high-temperature material, such as a ceramic material. The central disk 30 of each flow restrictor 26 has an outer diameter that is approximately the same dimension as the inner diameter of the outer outlet pipes 44. Therefore, as shown in FIG. 2, each outer outlet pipe 46 can be passed over both an inner outlet pipe 44 and its associated flow restrictor 26 with little to no space between the edges of the central disk 30 and the inner surfaces of the outer outlet pipe.

[0033] The above-described configuration of the first plenum chamber 12, inner supply pipes 20, flow restrictors 26, and inner outlet pipes 44 results in a first (fuel) flow path that enables humidified fuel delivered to the first plenum chamber to flow through the inner supply pipes, through the inner openings 36 of the flow restrictors (FIG. 5A), and through the inner outlet pipes into the combustion chamber. In similar manner, the above-described configuration of the second plenum chamber 16, the outer supply pipes 24, the flow restrictors 26, and the outer outlet pipes 46 results in a second (oxygen) flow path that enables oxygen delivered to the second plenum chamber to flow through the outer supply pipes, through the outer openings 38 of the flow restrictors (FIG. 5A), and through the outer outlet pipes into the combustion chamber. The fuel and oxygen mix with each other downstream of the exit ends of the outlet pipes 44, 46 within the combustion chamber and ignite.

[0034] The flow restrictors 26 play a significant role in producing the desired syngas. Specifically, the flow restrictors 26 build pressure within both the fuel and oxygen flow paths upstream of the flow restrictors (i.e., within the inner and outer supply pipes 20, 24) that balances the flow of the humidified fuel and oxygen across the various burner units 22. The size and number of the openings 36, 38 formed within the flow restrictors 26 can be varied to obtain a desired pressure and, therefore, the desired balancing. As an example, the five inner openings 36 can each have a diameter of approximately 5/16 in., and the eight outer openings 38 can each have a diameter of approximately in. The appropriate sizes and numbers of the inner openings 36 and the outer openings 38 can be determined on a case-by-case basis with consideration of the particular needs of the application. Generally speaking, however, the number of inner openings 36 can range from approximately 2 to 64 and their diameters can range from approximately 1/16 (0.0625) to (0.5) inches, and the number of outer openings 38 can range from approximately 2 to 64 and their diameters can range from approximately (0.5) to (0.75) inches. Computer simulations have shown that the flow rate varies less than 3% from burner unit 22 to burner unit 22 with these dimensions and the flow restrictor geometry shown in FIGS. 5A and 5B. In addition to restricting and balancing reactant flows, use of the flow restrictors 26 enables replacement of the inner outlet pipes 44, when necessary, and maintains the alignments between the various concentric pipes.

[0035] With reference next to FIGS. 2 and 3, the burner 10 further includes mounting flanges 48 that facilitate mounting of the burner to the combustion chamber 11 (see FIG. 1). In addition, the flanges 48 can be threaded so as to facilitate connection of the outer supply pipes 24 and the outer outlet pipes 46.

[0036] The above-described burner 10 provides benefits that are not provided by conventional burners that only include a single burner unit. By operating multiple burner units 22 in parallel, the overall flow speed and hence reaction length (i.e., the length required to complete the reaction) is reduced as compared to when a single burner unit is used. Computer simulations have predicted the reaction length for the burner 10 is approximately 9 feet for a flow rate of 3,382 lb/hr for fuel and 3,624 lb/hr for oxygen (volume flow ratio of 0.6) through the burner. Notably, the reaction length for a single burner unit at this flow rate would be over 60 ft.

[0037] An experimental gas and steam supply system was designed to perform testing of a burner having a configuration similar to the burner 10 described above. FIG. 6 illustrates the primary components, the mass balance, and process conditions for this experimental system. The steam flow controller did not maintain a consistent flow of steam during the testing, so useful data regarding the burner performance with steam was not collected. However, data for burner operation without steam was collected. The results are shown in Table 3. The time-averaged input flow rates for oxygen and natural gas were 753 kg/hr and 625 kg/h, respectively (an average volume ratio of 0.56). The results show that the burner 10 generates syngas with a ratio less than 2.0 while achieving lower levels of CO.sub.2 and CH.sub.4, as compared to a conventional burner.

TABLE-US-00003 TABLE 3 Outlet gas composition including water. steam to fuel mass flow CO.sub.2 CO H.sub.2 CH.sub.4 H.sub.2O ratio (mol %) (mol %) (mol %) (mol %) (mol %) H.sub.2:CO 0 4.0 27.7 51.8 6.5 10.1 1.87