Low NOx staged combustor with swirl suppression

Claim 2

In a low NO x emission staged combustion burner of the type having a primary combustion chamber fired with a fuel-rich mixture of fuel and an oxygen-containing primary gas stream, followed by a secondary combustion chamber fired with a fuel mixture of hot fuel-containing gas exiting the primary chamber and an oxygen-containing secondary gas stream: swirl means for imparting swirl to the primary burning gas stream of fuel and oxygen-containing gas in the primary combustion chamber to cause the primary gas stream to fill the primary combustion chamber and to increase the residence time of the primary burning gas in the fuel-rich primary combustion chamber of reducing final NO x emissions; transition means for substantially constricting the cross-sectional area of the primary stream of burning gas exiting the primary combustion chamber and for feeding the constricted primary gas stream into the secondary combustion chamber for preventing backmixing of gases from the secondary combustion chamber and for preventing flame impingement on the walls of the secondary combustion chamber; secondary injector means for injecting a secondary oxygen-containing gas stream into the secondary combustion chamber and about the primary gas stream of burning gas exiting and said transition means in a direction generally parallel and coaxially thereto; swirl suppressing means made of a refractory non-metallic material disposed within and extending along said transition means and protruding into essentially only the outer periphery of the gas stream exiting the primary combustion chamber for substantially reducing the swirl of the outermost regions of the primary gas stream exiting said transition means and for substantially reducing turbulent mixing of the parallel and coaxially travelling primary and secondary gas streams and for reducing the flame temperature in the secondary combustion chamber and thermal NO x emissions therefrom.

Claim 3

The burner of claim 1 wherein said swirl suppression means includes refractory non-metallic protrusions on an inside wall of said transition means protruding into the outermost regions of the primary gas stream exiting the primary combustion chamber.

Claim 4

The burner of claim 2 wherein said protrusions are axially directed lands and grooves formed in the refractory non-metallic inside wall of said transition means.

Claim 5

The burner of claim 2 wherein said protrusions are made of a material selected from the group consisting of fibrous alumina refractory material, and castable refractory material.

Claim 6

The burner of claim 2 wherein said transition means includes a throat portion of minimum, cross-sectional area and corresponding to the region of primary gas stream flow of maximum flow velocity and wherein said protrusions protrude from said throat portion into the primary gas stream by an amount falling within the range of 10-20% of the average radius of the primary gas stream within said throat portion.

Claim 7

The burner of claim 5 wherein said throat portion has an axial length falling within the range of 50-100% of its diameter.

Claim 8

The apparatus of claim 1 wherein said swirl means imparts a swirl to the primary gas stream within the primary combustion chamber having a swirl number falling within the range of 0.3 to 0.5.

Claim 9

In a method for reducing NO x emissions from a staged combustion burner of the type having a primary combustion chamber fired with a fuel-rich mixture of fuel and an oxygen-containing primary gas stream followed by a secondary combustion chamber fired with a fuel mixture of hot fuel-containing gas exiting the primary chamber and an oxygen-containing secondary gas stream, the steps of: imparting swirl to the primary burning gas stream of fuel and oxygen-containing gas in the primary combustion chamber to cause the primary burning gas stream to fill the primary combustion chamber and to increase the residence time of the primary burning gas stream in the fuel-combustion zone for reducing final NO x emissions; substantially constricting the cross-sectional area of the primary gas stream exiting the primary combustion chamber to substantially increase its axial velocity to prevent backmixing of gases from the secondary combustion chamber and to prevent flame impingement on the walls of the secondary combustion chamber; feeding the constricted primary gas stream exiting the primary combustion chamber into the secondary combustion chamber; injecting an oxygen-containing secondary gas stream into the secondary combustion chamber and about the primary gas stream exiting the primary chamber, such secondary gas stream directed in a direction generally parallel and coaxially to said primary gas stream as fed into the secondary combustion chamber; and providing longitudinally extending portions about and protruding into the outer periphery of the constricted primary gas stream and suppressing the residual swirl in essentially only the outermost peripheral region of the constricted, primary gas stream exiting the primary combustion chamber for substantially reducing the turbulent mixing of the parallel and coaxial primary and secondary gas streams in the secondary combustion chamber with an attendant reduction in frame temperature and final thermal NO x emissions.

Claim 10

In a method for reducing NO x emissions from a staged combustion burner of the type having a primary combustion chamber fired with a fuel-rich mixture of fuel and an oxygen-containing primary gas stream followed by a secondary combustion chamber fired with a fuel mixture of hot fuel-containing gas exiting the primary chamber and an oxygen-containing secondary gas stream, the steps of: imparting swirl to the primary burning gas stream of fuel and oxygen-containing gas in the primary combustion chamber to cause the primary burning gas stream to fill the primary combustion chamber and to increase the residence time of the primary burning gas stream in the fuel-combustion zone for reducing final NO x emissions; substantially constricting the cross-sectional area of the primary gas stream exiting the primary combustion chamber to substantially increase its axial velocity to prevent backmixing of gases from the secondary combustion chamber and to prevent flame impingement on the walls of the secondary combustion chamber; feeding the constricted primary gas stream exiting the primary combustion chamber into the secondary combustion chamber; injecting an oxygen-containing secondary gas stream into the secondary combustion chamber and about the primary gas stream exiting the primary chamber, such secondary gas stream directed in a direction generally parallel and coaxially to said primary gas stream as fed into the secondary combustion chamber; and providing longitudinally extending portions about and protruding into the outer periphery of the constricted primary gas stream and suppressing the residual swirl in essentially only the outermost peripheral region of the constricted, primary gas stream exiting the primary combustion chamber for substantially reducing the turbulent mixing of the parallel and coaxial primary and secondary gas streams in the secondary combustion chamber with an attendant reduction in frame temperature and final thermal NO x emissions.

Claim 11

The method of claim 8 wherein the step of suppressing the residual swirl of the primary gas stream exiting the primary combustion chamber includes the step of: providing refractory non-metallic protrusions extending into the outermost peripheral regions of the primary gas stream in the flow-constricted region of the primary gas stream.

Claim 12

The method of claim 9 including the step of providing the protrusions with the form of elongated lands and grooves elongated in the axial direction of the primary gas stream.

Claim 13

The method of claim 9 wherein the step of providing the protrusions extending into the primary gas stream includes the step of casting the protrusions into a refractory non-metallic material forming the sidewalls of the flow-constricting region of the primary gas stream passageway.

Claim 14

The method of claim 8 including the step of proportioning the ratio of axial components of velocity of the primary and secondary gas streams to be within the range of 0.8 to 1.2.