US011255538B2

( 12 ) Kozlov
Unitedet alStates Patent ( 10) Patent No .: US 11,255,538 B2
. (45 ) Date of Patent : Feb. 22 , 2022
( 54 ) RADIANT INFRARED GAS BURNER ( 56 ) References Cited
( 71 ) Applicant: GAS TECHNOLOGY INSTITUTE , U.S. PATENT DOCUMENTS
Des Plaines , IL (US ) 1,830,826 A * 11/1931 Cox F23D 14/16
431/328
( 72 ) Inventors : Aleksandr Kozlov , Buffalo Grove, IL 3,044,538 A * 7/1962 Honger F23C 99/00
( US ) ; David Kalensky, Chicago, IL 431/329
(US ) ; Mark Khinkis , Morton Grove, IL (Continued )
(US ) ; Vladimir Shmelev, Moscow
(RU ); Nikolai Vasilik , Moscow (RU ) FOREIGN PATENT DOCUMENTS
( 73 ) Assignee : GAS TECHNOLOGY INSTITUTE , RU 2 506 314 C1 2/2014
Des Plaines , IL (US ) RU 2012 129 061 C1 2/2014

( * ) Notice : Subject to any disclaimer, the term of this OTHER PUBLICATIONS

patent is extended or adjusted under 35
U.S.C. 154 (b ) by 440 days . V. M. Shmelev, “ Surface Burning on a Foam Metal Matrix with the
Ceramic Coating” published May 2014 in Combustion Science and
( 21 ) Appl . No .: 16 /164,368 Technology; included as “ Surface_Burning_Shmelev_2014.pdf ' ( Year:
2014 ) . *
(22 ) Filed : Oct. 18 , 2018 (Continued )
(65 ) Prior Publication Data Primary Examiner Edelmira Bosques
US 2019/0049108 A1 Feb. 14 , 2019 Assistant Examiner - Martha M Becton
(74 ) Attorney, Agent, or Firm — Pauley Erickson &
Related U.S. Application Data Swanson
( 63 ) Continuation - in -part of application No. 15 /016,469 , ( 57 ) ABSTRACT
filed on Feb. 5 , 2016 , now Pat . No. 10,488,039 .
( Continued ) Methods and devices for gas mixture combustion on a
surface of a permeable matrix are provided which produce
(51 ) Int. Cl. or result in surface stabilized combustion ( SSC ) with
F23D 14/14 ( 2006.01 ) increasing amounts of radiation energy emitted by the
F23D 14/02 ( 2006.01 ) matrix surface and decreasing concentrations of pollutant
( Continued ) components in the combustion products. The gas mixture is
( 52 ) U.S. Ci. fed to a burner that includes a permeable matrix material
CPC
having a first thermal conductivity and configured to preheat
F23D 14/145 (2013.01 ) ; F23D 14/02 the combustible gas mixture as it travels through the matrix .
(2013.01 ) ; F23D 14/14 ( 2013.01 ) ; F23D The burner includes a plurality of thermal elements having
14/16 ( 2013.01 ) ; a thermal conductivity higher than and disposed in thermal
( Continued ) transfer communication with the matrix base material. The
( 58 ) Field of Classification Search permeable matrix base material forms aa combustion surface
CPC F23D 14/84 ; F23D 14/14 ; F23D 14/08 ; with at least a portion of the thermal elements exposed above
F23D 14/16 ; F23D 14/145 ; F23D 99/00 ; the combustion surface . The gas mixture is combusted at or
( Continued ) ( Continued )
110

114 , $ 132 4 140

2
112 124 132
1 1
***

ko 4 136
120 126
 US 11,255,538 B2
Page 2

near exit pores and channels formed at the permeable matrix 4,597,734 A * 7/1986 McCausland B22F 3/002
126/92 AC
material combustion surface.
4,599,066 A * 7/1986 Granberg F23D 14/145
431/260
19 Claims , 10 Drawing Sheets 4,604,054 A * 8/1986 Smith B23K 1/0053
431/328
4,643,667 A * 2/1987 Fleming F23D 14/16
431/328
Related U.S. Application Data 4,657,506 A * 4/1987 Ihlenfield F23D 14/145
126/92 R
4,746,287 A * 5/1988 Lannutti B28B 19/0038
( 60 ) Provisional application No. 62 / 113,868 , filed on Feb. 264/256
9 , 2015 . 4,810,587 A 3/1989 Losfeld B22F 3/002
428/549
(51 ) Int. Ci . 4,878,837 A * 11/1989 Otto C04B 38/067
431/328
F23D 14/16 ( 2006.01 ) 4,878,947 A * 11/1989 Helferich C04B 38/08
F23D 99/00 ( 2010.01 ) 106/602
(52) U.S. Ci . 4,883,423 A * 11/1989 Holowczenko C04B 30/02
431/328
CPC F23D 99/00 (2013.01 ) ; F23D 2203/005 4,886,044 A * 12/1989 Best A47J 37/0682
(2013.01 ) ; F23D 2203/105 (2013.01 ) ; F23D 126/39 C
2203/1012 (2013.01 ) ; F23D 2212/005 4,886,972 A * 12/1989 Nakai COOK 9/00
( 2013.01 ) ; F23D 2212/10 (2013.01 ) ; F23D 250/504 R
2212/20 (2013.01 ) ; F23D 2212/201 (2013.01 ) 4,889,481 A * 12/1989 Morris B32B 18/00
( 58 ) Field of Classification Search 431/328
CPC F23D 2212/201 ; F23D 2212/20 ; F23D 4,919,609 A * 4/1990 Sarkisian F23D 14/12
2212/10 ; F23D 2212/005 ; F23D 431/328
4,923,747 A * 5/1990 McCullough , Jr .... C04B 35/117
2203/105 ; F23D 2203/1012 ; F23D 428 /312.6
2203/005 4,977,111 A * 12/1990 Tong C04B 30/02
See application file for complete search history. 501 /95.1
5,062,408 A * 11/1991 Smith A47J 37/0682
( 56 ) References Cited 126/41 R
5,137,583 A * 8/1992 Parent F23D 14/12
U.S. PATENT DOCUMENTS 136/253
5,147,201 A 9/1992 Xiong
3,170,504 A * 2/1965 Lanning F23D 14/14 5,165,887 A * 11/1992 Ahmady F23D 14/16
431/328 126/92 AC
3,188,366 A * 6/1965 Flynn F23D 14/16 5,205,731 A * 4/1993 Reuther F23D 14/16
432/9 431/328
3,191,659 A * 6/1965 Weiss F23D 14/16 5,218,952 A * 6/1993 Neufeldt E01C 23/14
431/328 126/92 AC
3,199,573 A * 8/1965 Fiynn F23D 14/16 5,249,953 A * 10/1993 Roth F23D 14/16
431/329 126/92 AC
3,216,478 A 11/1965 Saunders F23D 14/18 5,326,257 A 7/1994 Taylor et al .
431/329 5,356,487 A * 10/1994 Goldstein HO2S 10/30
3,251,396 A * 5/1966 Nitsche F23D 14/125 136/253
431/328 5,360,490 A * 11/1994 Nelson F23D 14/12
3,270,798 A * 9/1966 Ruff F23D 14/18 136/253
431/329 5,380,192 A * 1/1995 Hamos F23D 14/02
3,330,267 A 7/1967 Bauer F24C 3/122 431/328
126/92 R 5,444,261 A * 8/1995 Kim G06F 1/1601
3,425,675 A *
2/1969 Twine C21D 1/74 250 / 493.1
432/199 5,476,375 A * 12/1995 Khinkis F24H 1/40
3,472,601 A * 10/1969 Ogawa F23D 14/12 431/7
431/328 5,500,054 A * 3/1996 Goldstein HO2S 10/30
3,726,633 A * 4/1973 Vasilakis F23D 14/14 136/246
431/329 5,566,607 A * 10/1996 Schleimer A473 37/0704
3,738,793 A * 6/1973 Reid F23D 14/16 126/25 R
431/328 5,622,491 A * 4/1997 Van Belle BO1F 5/045
3,751,213 A * 8/1973 Sowards F23C 99/00 431/328
431/328 5,711,661 A * 1/1998 Kushch F23D 14/12
3,833,338 A * 9/1974 Badrock F23D 14/16 431/326
431/328 5,749,721 A * 5/1998 Klinge F23D 14/16
3,912,443 A * 10/1975 Ravault B32B 9/005 431/328
431/328 5,762,885 A * 6/1998 Debbage B01D 53/8696
3,920,583 A * 11/1975 Pugh B01J 23/84 422/171
502/314 5,782,629 A * 7/1998 Lannutti F23D 14/16
4,377,618 A 3/1983 Ikeda et al . 431/326
4,416,619 A * 11/1983 Craig F23D 14/16 5,842,851 A * 12/1998 Pivot F23D 14/18
431/328 431/328
4,507,355 A * 3/1985 George DOOM 11/71 5,879,473 A * 3/1999 Sarraf HO2S 10/30
442/141 136/253
4,547,148 A * 10/1985 Holmer F23D 14/16 5,993,192 A * 11/1999 Schmidt F23D 14/18
431/328 431/12
 US 11,255,538 B2
Page 3

( 56 ) References Cited 2013/0273485 A1 * 10/2013 Lenoir F23D 14/14

431/329
U.S. PATENT DOCUMENTS 2015/0253005 A1 * 9/2015 Sutherland F23C 99/006
431/328
6,007,329 A * 12/1999 Meyer F23D 14/14 2016/0003471 A1 * 1/2016 Karkow F23D 14/78
431/326 431/2
6,159,001 A * 12/2000 Kushch F23D 14/14 2016/0024962 A1 * 1/2016 Luthra C04B 41/5024
431/7 428 /312.6
6,213,757 B1 * 4/2001 Kushch F23D 14/12 2016/0153288 A1 * 6/2016 Luthra C04B 41/009
431/7 428/215
6,257,868 B1 * 7/2001 Durst F23C 99/006 2016/0160664 A1 * 6/2016 Luthra C04B 41/52
431/11 428/332
6,354,831 B1 * 3/2002 Wilk , Jr F23D 14/16 2016/0230986 A1 8/2016 Shmelev et al .
126/512
6,428,312 B1 * 8/2002 Smelcer F23D 14/14 OTHER PUBLICATIONS
431/114
6,575,736 B1 * 6/2003 Aust F23D 14/14 Russian Journal of Physical Chemistry B , 2010 , vol . 4 , No. 4 , pp .
431/328 593-601 @Pleiades Publishing, Ltd. 2010 Original : Shmelev, V.M.,
7,011,516 B2 * 3/2006 Aust F23D 14/14
“ Combustion of Natural Gas at the Surface of a high - Porosity Metal
431/328
7,201,572 B2 * 4/2007 Wood C04B 35/565 Matrix ,” Chemical Physics, 2010 , vol . 29 , No. 7 , pp . 27-36 .
2

264/109 Kirdyashkin , A.I. et al . , “ Energy and spectral characteristics of the

7,291,010 B2 * 11/2007 Perlo F23C 13/00 radiation in the process of filtration combustion of natural gas , "
431/170 SCF, 2010 , vol . 46 , No. 5 , pp . 37-41 ( English Abstract ).
9,291,346 B2 * 3/2016 Lenoir F23D 14/14 Vasiliki, N.Y., et al . , “ Formation of the ceramic coating of the
9,709,265 B2 * 7/2017 Sutherland F23C 99/006 multi - detonation unit,” Combustion and Explosion , Torus Press ,
2003/0054313 A1 * 3/2003 Rattner F23D 14/16 2014. pp . 241-244 ( English Abstract ).
431/326 Shmelev, V.M., “ Surface Burning on a Foam Metal Matrix with the
2004/0132607 A1 * 7/2004 Wood C04B 35/63 Ceramic Coating , ” Combus. Sci . Technol., 2014 , 186 , pp . 943-952 .
501 /95.1 Wood, et al . , Susie , “ Porous Burners for Lean -burn Applicaitons,"
2005/0142512 A1 * 6/2005 Perlo F23D 14/30 2008 Progress in Energy and Combusion Science , 2008 , 34 , 667
431/326 684 .
2008/0227044 A1 * 9/2008 Cookson F23D 14/16 Kamal, M.M. , et al . , “ Gambustian in porous media , ” J. PowerEnergy ,
431/328 IMechE Feb. 23 , 2006 , vol . 220 , Part A , pp . 487-508 .
2010/0266972 A1 * 10/2010 Sullivan F23D 14/14
431/329 * cited by examiner
U.S. Patent Feb. 22 , 2022 Sheet 1 of 10 US 11,255,538 B2

Comparison between the coated and uncoated matrix surface ( left)

and the structure of the ceramic film ( right )

FIG . 1A FIG . 1B
U.S. Patent Feb. 22 , 2022 Sheet 2 of 10 US 11,255,538 B2

mwangan

The matrix surface temperature ( 1.2) and its reverse side temperature 0. 4) from the
power density for uncoated surface (2. 4) and coated surface ( 1 , 3 ) at differenct power density
( W ) with excess air factor Q = 1.1 . Points with a cross are from the ceramic coating matrix ;
points with the vertical line sre from the initial uncoated matrix .

FIG . 2
U.S. Patent Feb. 22 , 2022 Sheet 3 of 10 US 11,255,538 B2

NOX, CO, ppm

3

10 M

IA
OC ( uncated surface )
INOX ( coating surface

Flue gas CO and NOx corrected concentrations at different tiring rate ( F11).

FIG . 3
U.S. Patent Feb. 22 , 2022 Sheet 4 of 10 US 11,255,538 B2

NOX , CO , ppm

,,,,,,,,,,,

Flue gas CO and NOx corrected concentrations at different excess air ratio

FIG . 4
U.S. Patent Feb. 22 , 2022 Sheet 5 of 10 US 11,255,538 B2

22 2
20

16

12
Oxidizer gas
ma
w

w14
w

FIG . 5
U.S. Patent Feb. 22 , 2022 Sheet 6 of 10 US 11,255,538 B2

112
130
4 126
132
.120 7
.
FIG
140 116124
136
114

112 7

110
?

132
.
FIG
6

116
114
.
7
U.S. Patent Feb. 22 , 2022 Sheet 7 of 10 US 11,255,538 B2

212
017 s 230232 226
290
220 9
.
FIG
224
250
.
240
216214 He 236

212
210
S

250
8
.
FIG

216 i n t e rn e t i s t
214
250
U.S. Patent Feb. 22 , 2022 Sheet 8 of 10 US 11,255,538 B2

310 340
3
316
336 11
.
FIG
314
324 326

310 ?
314

11

316
-11
?324 |
* FIG
10
.

340
.

320
U.S. Patent Feb. 22 , 2022 Sheet 9 of 10 US 11,255,538 B2

FIG . 12A FIG . 12B

KT,emperature 29

::

Specific Power , W /an

FIG . 13
U.S. Patent Feb. 22 , 2022 Sheet 10 of 10 US 11,255,538 B2

LOTRONagatedmix

KRDFaedblniustvxoeyn . se recipeskive my

virsecucestive e

?
Specific Power , Warya

FIG . 14

AN
*
By

$
XON3Xw1OLI4N3E 0To,ytenea.tion * .
r

???? head

FIG . 15A FIG . 15B

 US 11,255,538 B2
1 2
RADIANT INFRARED GAS BURNER A device is known for the implementation of gas surface
combustion on the outside surface of a sleeve of woven
CROSS REFERENCE TO RELATED ceramic fibers. The sleeve is worn on a perforated metal
APPLICATIONS carrier, through which the fuel / oxidant gas mixture is fed to
5 the fabric sleeve . A disadvantage of this device is that the
This application is a continuation - in -part application of heating of the gas mixture while the gas mixture passes
U.S. patent application Ser. No. 15 /016,469 , filed on 5 Feb. through the perforated metal carrier is insufficient to ignite
2016 and which parent patent application claims the benefit (and maintain ) combustion of the gas mixture . The sleeve of
of U.S. Provisional Patent Application Ser. No. 62/ 113,868 , woven ceramic fibers substantially prevents heat transfer
filed on 9 Feb. 2015. Each of these cross referenced appli- 10 between the combustion products and the surface of the
cations is hereby incorporated by reference herein in its perforated metal carrier. Thus, an auxiliary triggering device
entirety and made a part hereof, including but not limited to is used to initiate (and maintain ) combustion of the gas
those portions which specifically appear hereinafter. mixture over the outer surface of the woven ceramic fiber
BACKGROUND OF THE INVENTION 15 sleeve .
Another existing device burns gas on the surface offaa thick
Field of the Invention layer of ceramic fibers and polymers deposited on the
surface of a corrosion resistant mesh screen . The thickness
This invention relates generally to pre - mix combustion of the layer of ceramic fibers and the polymers is selected to
technology. The invention can be used in and for the 20 prevent corrosion heating of the mesh screen . The thickness
development of ecologically clean , compact, cost - effective of the layer of ceramic fibers and polymers is from 6.35 mm
heat generators and infrared radiators such as for use in to 12.7 mm . A disadvantage of this device is the fact that
numerous various applications in the residential, commer- during operation the gas mixture is preheated and burnt
cial , and industrial areas . within the thick layer surface of ceramic fibers and polymers
25 are burnt out and degrade.
Description of Related Art Radiant infrared permeable matrix gas burners operate
using the SSC principle when gaseous fuel premixed with
Surface Stabilized Combustion ( SSC ) of gaseous fuel oxidizer (e.g. air) is combusted on the surface of the per
oxidant mixtures on a permeable matrix can reduce emis- meable matrix . Compared to conventional combustion, such
sions of flue gas pollutants (e.g. , NOX , CO , UHC ) , increase 30 SSC processing occurs at a lower temperature, because of
radiation density, and increase thermal efficiency all of highly intense heat transfer from the reaction zone to the
which factors are important to the design of advanced body of the matrix and surroundings . A portion of the
compact cost - effective radiation heating combustion thermal energy from the combustion zone is converted to
devices. Through the effective utilization of SSC , radiation infrared radiation from the surface of the matrix . This
heat flux from the matrix surface can be increased up to 80% 35 approach to combustion of gases has several advantages,
of the heat flux providing from 20 to 40% of the total energymainly : i ) ability to generate intense radiative energy flows
released from combustion by infrared radiation . Such radia- that are highly desirable for many heating applications , and
tion enhancement is primarily due to surface combustion on ii ) reduction of nitrogen oxides (NOx ) emissions by an order
the matrix . Based on intensive heat exchange between the of magnitude. Extensive theoretical and experimental
combustion products and the matrix , the matrix surface is 40research is available on SSC of or for aa flat matrix . However,
heated to high temperatures . The peak flame temperature there are significant shortcomings with SSC on a flat matrix ,
and resulting combustion products temperature in the com- including low specific power ( -30 W / cm ), high carbon
bustion zone is in turn reduced which reduces the corribus- monoxide ( CO ) emissions, and a narrow stable operating
tion products NOx concentration . range ( limited turndown ratio ).
The distance between the combustion zone and the matrix 45 As identified above , SSC on a permeable matrix desirably
surface is dependent on the thermal conductivity of the gas reduces NOx emissions during combustion of a gaseous fuel
mixture exit layer of the matrix . With the gas mixture exit and increasing radiation energy flux density, which is of
layer exhibiting a relatively high thermal conductivity, the interest for the creation of environmentally friendly, com
flame is located at some distance from the matrix surface . In pact heat generators and powerful sources of infrared radia
such case , most of the energy released by combustion is 50 tion . With such combustion of a gaseous fuel in SSC mode ,
carried by the combustion products. A small part of the the fraction of the radiation energy from the surface of the
energy released by combustion is transferred to the perme- permeable matrix is 20-40 % of the total energy released
able matrix . A portion of the heat transferred to the matrix during combustion . This is explained by the fact that the
is radiated to the load and a portion is transferred back to the combustion of the gaseous fuel occurs at the surface of the
gas mixture and stabilizes the surface combustion . 55 matrix . Due to intensive heat transfer between the combus
One existing method and apparatus for the SSC of fuel/ tion products and the surface of the matrix in the SSC mode ,
oxidant gas mixtures involves SSC on a permeable matrix of the matrix surface is heated to a high temperature. As a
particles of a heat- resistant metal alloy containing iron , result, the temperature of the combustion products in the
chromium and aluminum . Refractory alloys containing alu- combustion zone is decreased which leads to a reduced
minum are on the surface of the matrix . When heated in the 60 concentration of nitrogen oxides in the combustion products.
presence of oxygen, a dense aluminum oxide film 1 micron As identified above , there are known devices for SSC of
in thickness is developed which prevents further oxidation gaseous fuel on the surface of a permeable element consist
of the surface and protects the surface from corrosion . ing of particles of a metal alloy containing iron, chromium
However, such aa thin film of aluminum oxide significantly and aluminum . To optimize the process of stabilized com
affects only the chemical oxidation processes of the surface 65 bustion , it is necessary to maintain a high rate of heat
and has no significant effect on the heat exchange between exchange of the gaseous fuel with the surface of the matrix .
the combustion products and the surface of the burner. In the combustion zone, the heat flow from the combustion
 US 11,255,538 B2
3 4
products to the surface must be maintained at a certain level or with a layer of material having a thermal conductivity
to be sufficient for steady state SSC and limited to avoid or several times reduced as compared to the thermal conduc
prevent flame quenching. tivity of the matrix material .
To increase burner efficiency, a reverberatory screen in the In accordance with one aspect of the invention , to opti
form of a metal mesh or metal perforated plate installed 5 mize the SSC process , it is desirable to maintain a high rate
above the matrix surface has been used . The reverberatory of heat exchange between the pore and channel surfaces
screen is heated by combustion products and radiates to the within the body of the matrix and the gas mixture as
matrix surface thus increasing its temperature and radiant optimization of preheating of the mixture can desirably
heat flux from the matrix surface thus increasing combustion 10 avoid flame extinction . In the combustion zone , the flow of
stability and reducing NOx and CO emissions . heat from the combustion products to the surface is prefer
An industrial burner realizing the described principles and ably maintained at a level to avoid the flame extinction
achieving low NOx and CO emissions is known. The burner providing steady state SSC . To optimize the combustion
consists of an air - fuel mixer, a perforated plate for SSC , and process and achieve enhanced SSC , the permeable matrix is
light metal mesh reverberatory screen above the plate . It is 15 preferably a combined matrix comprising a material with a
shown that the screen increases surface temperature of the high thermal conductivity (e.g. , metal ) coated with a mate
matrix . The distance between the reverberatory screen and rial with a low thermal conductivity ( e.g. , ceramics ).
the matrix surface is dependent on the height of the flame. Experiments have shown that with the flame immersed in
A disadvantage of such a radiant matrix burner with the pores and channels of the ceramic coated side of the
reverberatory screen is the relatively low effectiveness of the 20 permeable matrix , both the heat flux from the combustion
reverberatory screen . Moreover, inclusion and use of such a products to the coated side of the matrix and the surface
screen coated with a special ceramic foam significantly temperature of the coated side of the matrix increase.
complicates fabrication of the burner. Increasing the temperature of the matrix according to the
Also known is aa radiant burner containing a housing with Stefan - Boltzmann law leads to an increase in the energy flux
a perforated plate ( or radiation shield) and equipped with a 25 emitted by the matrix surface. The possibility of stable
radiating nozzle in the output section of the housing. A operation of the burner in such conditions is determined by
disadvantage of this type of burner is high hydraulic resis- the thermal characteristics of the matrix material of the
tance which negatively affects combustion stability at low burner. The technology provides the formation of a ceramic
fuel pressure. Moreover, the radiation shield does not pro- coating such as of aluminum oxide on the surface of a matrix
vide a reduction of carbon monoxide in the combustion 30 such as of highly permeable volumetric porous metal foam .
products below 0.008 % ( 80 ppm) . In accordance with an aspect of the invention , one of the
Another known device is a radiant burner containing features of the subject method of forming coatings is the
two - layer matrix with different permeability. With or in such ability to apply dense ceramic coatings to a surface with high
a burner, the gas mixture is burned in the volume of the adhesion and at high speeds with minimal impact to the
upstream layer with a larger porosity. A result of the volu- 35 surface, thus allowing the coating to be applied to brittle
metric combustion is very high temperature of the matrix surfaces . At the same time , the technology allows a high
surface. This leads to a significant increase of the burner speed application of ceramic powder particles to form a
radiation efficiency. Common disadvantages of this type of ceramic coating having a higher ductility as compared to
burner is the complexity and high cost of manufacturing those provided or resulting from other methods of applica
two -layer matrix . Such a burner requires the use of high 40 tion . The plasticity of such a resulting ceramic coating
temperature materials and a thicker matrix compared to allows it to operate in a stable manner in or wider conditions
existing one -layer burner designs . Further, the immersion of of high temperature gradients. The optical transparency of
the flame front deeply into the matrix leads to overheating of the ceramic coating (e.g. , alumina or zirconia ) provides that
the matrix and increased concentration of nitrogen oxides . at a coating thickness of 50 to 200 microns heat can
For these and other reasons, there is a need and aa demand 45 effectively be dissipated by radiation from the combustion
for new and improved burner designs that overcome at least zone , dipping below the surface of the matrix . This is very
some of these problems or shortcoming of previous burner important, since the emissivity of the metallic matrix is
designs . several times higher than that of the ceramic coating ( e.g. ,
alumina or zirconia ), providing significantly higher radiation
SUMMARY OF THE INVENTION 50 flux .
The invention , in accordance with specific particular
One aspect of present invention involves the ability to embodiments, comprises or involves significant features not
redistribute the flows of heat released by burning of the gas previously known. For example, particular embodiments of
mixtures, thereby increasing the temperature of the emitting the invention may desirably employ or involve the applica
surface of the matrix and thus increase the portion of the heat 55 tion and / or use of aa thick coating : having a low coefficient
that is carried away from the permeable matrix in the form of thermal conductivity and transparent in the infrared
of radiation . wavelength range , and having high ductility at the working
The subject method and apparatus, in accordance with surface of the burner and on the surface of the pores or
selected embodiments, involves or includes starting the gas channels of the matrix near the outlet of the gas mixture .
combustion process through pre -heating of the gas mixture 60 These features combine to increase the temperature and the
as it moves through the permeable matrix . The proposed flux of radiant energy from the metallic matrix and to
process may further include the utilization of a bulk perme- increase the strength and the service life of the burner,
able matrix formed from metal having high thermal con- increase burner efficiency and reduce pollutant emissions.
ductivity which allows preheating the gas mixture to a Another aspect of the present development relates to a
temperature close to the temperature of ignition . The surface 65 radiant infrared gas burner device. In accordance with one
of the matrix and the surface of the pores and channels near embodiment, a radiant infrared permeable matrix gas burner
the gas mixture exit of the matrix are preferably coated by operates using the surface stabilized combustion ( SSC )
 US 11,255,538 B2
5 6
principle when gaseous fuel premixed with oxidizer ( e.g. , conductive elements inserted into the body of the matrix and
air) is combusted on the surface of the permeable matrix . transferring heat downstream of the matrix body, additional
One aspect of present invention involves the ability to heat transferred to the matrix surface by radiation from the
redistribute the flows of heat released by the burning of the surface of thermal elements located in combustion zone . To
gas mixtures , thereby increasing the temperature of the 5 expand the area of sustainable combustion, i.e. , to achieve
emitting surface of the matrix and thus increase the portion high values of combustion power density on the matrix
of the heat that is carried away from the permeable matrix surface , it is necessary to supply the combustible gas mix
in the form of radiation . The temperature of the combustion ture through the matrix with a specific high flow rate or high
products is reduced which leads to reduced NOx emissions velocity of the gas medium under conditions of high poros
in the combustion products and an extended range of stable 10 ity and matrix permeability . However, as matrix porosity
combustion . increases, the effective thermal conductivity of the matrix
A subject method and apparatus, in accordance with material decreases . Combustion of the gaseous fuel accord
selected embodiments, include or involve preheating of the ing to embodiments of the proposed method can be charac
gas mixture ( e.g. , gaseous fuel and oxidizer / air) during terized in that by introducing thermal conducting elements
movement ( flow) of the mixture through the permeable 15 into the body of the matrix, additional heat is supplied to the
matrix . A distinctive feature of at least certain embodiments body and surface of the permeable matrix . More intense heat
the present invention is the heating of the gas mixture to transfer between the matrix and air- gas mixture flowing
even a higher temperature due to the heat recovery from the through the matrix leads to an increased temperature of the
combustion products into the body of the matrix by means gas mixture at the matrix exit, and as a result, to a potentially
of the inclusion and use of thermal elements in thermal 20 higher combustion power density of the burner . As the
transfer communication with the matrix , as well as addi- surface temperature of the matrix increases when burner
tional radiation heating of the matrix surface from the power density is increased , the temperature of the combus
radiation of the surfaces of thermal elements located in the tion products decreases, which is unusual and not obvious .
region of the combustion products. In selected embodi- Conducted experimental results have shown that in this case
ments , the thermal elements take the form of thermal con- 25 the concentrations of NOx and CO emissions in combustion
ductive elements such as disposed to at least partially products are decreased . An increased surface temperature of
penetrate the matrix . the matrix in accordance with the Stefan - Boltzmann law
In accordance with selected embodiments , the matrix is leads to an increased energy flux radiated by the surface . A
an assembly of bars of highly porous metal or metal alloy decreased temperature of the combustion products leads to
(e.g. , FeCrAl or FeCrAIY ) foam or pressed wire and thermal 30 a decreased energy flux by the combustion products. The
elements, e.g. , thermal conductive elements ( recuperators ), energy released during the combustion of the gaseous fuel is
in the form of plates ( or rods , fins, etc. ) such as made of high redistributed in such a way that the amount of radiation
temperature and high conductivity material and such as energy emitted by the burner is increased, the amount of
desirably at least partially protruded above the matrix sur- energy carried away by the combustion products is
face . Placing thermal conductive elements in the matrix has 35 decreased . A decreased temperature of the combustion prod
made it possible to provide additional convective - radiation ucts leads to a decreased concentration of nitrogen oxides in
heat recovery from combustion products to the matrix . The the products . The decreased concentration of carbon mon
surface temperature of the matrix with thermal conductive oxide under these conditions can be explained by the larger
elements is increased by more than 200K , as a result, the residence time of the combustion products in the high
maximum value of radiation flux density from the matrix 40 temperature zone in the space between the thermal conduc
surface is increased by 1.7 times . The SSC mode on the tive elements over the matrix surface and more complete
matrix with heat recuperation can be realized in a wider oxidation of carbon monoxide .
range of combustion /burner power density values as com
pared to conventional radiant infrared permeable matrix gas BRIEF DESCRIPTION OF THE DRAWINGS
burner, namely, the upper limit of the range is extended from 45
45 W / cm² to 120 W /cm². The concentration of carbon FIG . 1A is a comparative image between aa coated and an
monoxide in the combustion products is decreased by more uncoated matrix surface .
than twofold , the concentration of nitrogen , oxides is FIG . 1B is an image showing the structure of a ceramic
decreased by 1.5 times in the matrix with heat recuperation. film .
Aspects of the invention include a unique new feature of 50 FIG . 2 is a graphical representation of matrix surface
the radiant infrared permeable matrix burner such as radia- temperature and its reverse side temperature for coated and
tive - convective -conductive heat transfer to the body and to uncoated surfaces versus combustion power densities (W) at
the surface of the matrix by means of high temperature steel an excess air factor, a = 1.1 .
thermal elements , e.g. , thermal conductive elements . This FIG . 3 is a graphical representation of corrected flue gas
feature allows increasing the temperature of the matrix and 55 NOx and CO concentrations versus combustion power den
the radiation energy flux from the matrix, expanding the area sity ( W ) at a= 1.1 .
of stable combustion, improving robustness and increasing FIG . 4 is a graphical representation of corrected flue gas
efficiency of the burner device , and also reducing the con- NOx and CO concentrations versus excess air ratios at a
centration of toxic components in the combustion products . combustion power density ( W ) 33 W / cm².
With selected embodiments of the subject method of 60 FIG . 5 is aa simplified schematic showing a premix burner
gaseous fuel combustion on the surface of permeable matrix , in accordance with one embodiment of the invention .
one or more of the following can be realized : extended FIG . 6 is a plan side view of a simplified burner assembly
region of stable combustion , increased amount of energy in accordance with one embodiment of the invention .
emitted by the heated matrix surface, reduced concentration FIG . 7 is cross - sectional view of the burner assembly
of toxic components in the combustion products, preheating 65 shown in FIG . 6 and taken along the line 7-7 of FIG . 6 .
of the gas mixture when it flows through the matrix channels FIG . 8 is a plan side view of a simplified burner assembly
or pores , higher temperature of the matrix due to thermal in accordance with one embodiment of the invention .
 US 11,255,538 B2
7 8
FIG . 9 is cross - sectional view of the burner assembly through the material ( ceramic ) matrix on the surface that is
shown in FIG . 8 and taken along the line 9-9 of FIG . 8 . transparent to IR radiation . Effective heat radiation is
FIG . 10 is a partial cross - sectional side view of a simpli- achieved with a coating material having a high transparency
fied burner assembly in accordance with one embodiment of in the infrared spectrum . In experiments, coating materials
the invention . 5 of alumina and zirconia were successfully utilized at or with
FIG . 11 is cross -sectional view of the burner assembly coating thicknesses of 50 to 200 microns. Moving the
shown in FIG . 10 and taken along the line 10-10 of FIG . 10 combustion zone to below or under the surface of the matrix
FIGS . 12A and 12B illustrate a tested prototype of radiant reduces the flame temperature which in accordance with the
infrared matrix burner assemblies with thermal conductive laws of chemical kinetics results in a decrease in the
elements in accordance with one embodiment of the subject 10 concentration of nitrogen oxides in the combustion products.
development. Further, the concentration of carbon monoxide can desirably
FIG . 13 is a graphical representation of surface tempera- be reduced under these conditions, such reduction at least in
tures versus burner power density for different type of part attributable to an increase in the residence time within
matrixes in accordance with one embodiment of the subject the combustion zone of a high temperature and a more
development. 15 complete oxidation of carbon monoxide .
FIG . 14 is a graphical representation of relative radiation In accordance with selected preferred embodiments , the
flux density versus combustion power density ( specific thickness of the high thermal conductivity permeable matrix
power ) in accordance with one embodiment of the subject base material is at least 5 millimeters.
development In accordance with selected preferred embodiments , the
FIGS . 15A and 15B are graphical representations of the 20 thickness of the high thermal conductivity permeable matrix
concentrations of nitrogen oxides and carbon monoxide (as base material is no more than 30 millimeters .
measured ), respectively, versus combustion power density In accordance with selected preferred embodiments, the
realized in experimental testing discussed below using ther- thickness of the coating of a low thermal conductivity high
mal conducting elements ( plates ) thickness = 0.7 mm . Here optical transmittance material is at least 10 micrometers .
1 , 2 and 3 correspond to the burner matrix with thermal 25 In accordance with selected preferred embodiments, the
conductive elements, conventional uncoated matrix and thickness of the coating of a low thermal conductivity high
conventional coated matrix . optical transmittance material is no more than 500 microm
eters .
DETAILED DESCRIPTION In accordance with selected preferred embodiments, the
30 ratio of the thermal conductivity of the matrix base material
In accordance with one embodiment, there is provided a to the thermal conductivity of the coating layer material is at
method of burning combustible gas mixtures on the surface least 3 .
of the permeable matrix with increasing amounts of radia- In accordance with selected preferred embodiments , the
tion energy emitted by or from the heated surface of the ratio of the thermal conductivity of the matrix base material
matrix and decreasing the emission concentration of unde- 35 to the thermal conductivity of the coating layer material is no
sirable species , such as pollutants, such as nitrogen oxide , in more than 10 .
the combustion products. Preheat of the fuel/oxidant gas The heat flux density per permeable matrix radiation
mixture is preferably carried out as the gas mixture moves surface area provided by a burner, in accordance with
through the pores and channels of the permeable matrix . selected preferred embodiments, is at least 5 w/cm² .
Combustion of the gas mixture near the surface of the 40 The heat flux density per permeable matrix radiation
permeable matrix by the method is preferably provided by surface area provided by a burner, in accordance with
introducing between the combustion products and the sur- selected preferred embodiments, is no more than 200 w/ cm² .
face of the matrix , matrix pores and channels surfaces near In accordance with selected preferred embodiments, the
the combustion products exit a material with a thermal permeable matrix material comprises a metal material, a
conductivity significantly lower than that of the matrix base 45 cermet material or a combination thereof.
material, and by transfer of the combustion zone to the In accordance with selected preferred embodiments, the
surface of the pores and channels of the permeable matrix at permeable matrix material is chromal, kanthal, heat - resistant
the gas mixture exit . Heat exchange between the combustion steel , carbide of a titanium , aluminum , iron, chromium ,
products and the matrix base material is preferably carried yttrium or a combination of two or more of such materials.
out through a large contact area of the flame and the walls 50 Those skilled in the art and guided by the teachings herein
of the pores and channels. Experiments have shown that provided will understand and appreciate that methods of
moving the region of the combustion zone to under the burning combustible gas mixtures on the surface of a
surface of the permeable matrix increases the surface tem- permeable matrix providing surface stabilized combustion
perature and reduces the temperature of combustion, as well ( SSC ) as herein provided desirably produce or result in
as reduces the concentration of nitrogen oxides and carbon 55 increasing amounts of radiation energy emitted by the hot
monoxide in the combustion products . Increasing the tem- surface of the permeable matrix and decreasing concentra
perature of the burner according to the Stefan - Boltzmann tions of toxic components in the combustion products.
law leads to an increase in the radiation energy flux emitted
by the matrix surface ; decreasing the temperature of the METHOD EXAMPLE
combustion products and leading to aa decrease of the energy 60
carried away by the combustion products. Experiments to test the effectiveness of the invention were
The energy released during the combustion of the gas carried out on a burner with an array of highly permeable
mixture is preferably distributed so that the amount of metal foam ( PMF ) having a thickness of 14 mm , a bulk
radiation energy emitted by the burner increases, and the porosity and surface permeability corresponding to 0.9 to
amount of energy carried away by the combustion products 65 0.4 . The matrix was of a material called Chromal. On the
is reduced . Heat dissipation by radiation from the surface of surface of the matrix, a coating of ceramic aluminum oxide
the matrix base material coated with the layer is carried out with aa thickness of 200 microns was applied ( see FIG . 1 ) via
 US 11,255,538 B2
9 10
the gas dynamic method and using a multichamber detona- least in part, on the ceramic coating of the combustion
tion unit . The starting material utilized in the coating powder surface of a metallic permeable matrix . The ceramic , coating
was AMPERIT 740.0 Al2O3 , procured from H.C. Starck can desirably function or otherwise serve to achieve or
GmbH . The coefficient of thermal conductivity of the coat- realize one or more of the following: increased energy
ing material is less than six times the coefficient of the 5 recuperation or recovery inside the matrix ; increased heat
thermal conductivity of the matrix material. Tests were transfer to the load ; increased thermal efficiency ; improved
carried out with mixtures of natural gas and air at a heat- or higher combustion stability ; decreased peak flame tem
density of 20 W / cm² to 80 W / cm², and changes in the excess perature ; and reduced emissions of undesirable species such
air ratio ranging from 1.0 to 1.4 . Under all the experimental as NOx , CO , and unburned hydrocarbons (UHC ) .
conditions performed with the matrix , with a coating of 10 In accordance with one embodiment of the invention, a
aluminum oxide, a change of the surface combustion mode gas burner device or assembly desirably includes a fuel inlet
was observed . On coated matrices, the flame front was for receiving a gaseous fuel; an oxidizer inlet for receiving
submerged beneath the surface of the matrix , the matrix an oxidizer gas ; a mixer for mixing gaseous fuel and
surface temperature increased and the concentration of nitro- oxidizer gas to produce a combustible gas mixture ; a high
gen oxides and carbon monoxide in the combustion products 15 thermal conductivity permeable matrix base material to
decreased provide surface stabilized combustion at the exit of the
The surface temperatures and concentrations of nitric mixture by or from the pores and channels of the base
oxide and carbon monoxide in the combustion products are material which is coated by the layer of the low thermal
shown in FIGS . 2 , 3 and 4. Experiments have demonstrated conductivity material have high optical transmittance in the
the effectiveness of the invention . The temperature of the 20 infrared spectrum .
mold surface with aa ceramic coating over the entire range of In accordance with another embodiment of the invention ,
parameters was about 200 K higher than the temperature of a gas burner device or assembly desirably includes a fuel
the uncoated matrix . The radiation flux from the coated inlet for receiving a gaseous fuel; an oxidizer inlet for
matrix was two (2 ) times greater as compared to that of the receiving an oxidizer gas ; a chamber to ensure that gaseous
uncoated matrix . The increase in the radiation flux was 25 fuel and oxidizer are produced into a proper combustible gas
accompanied by a decrease in combustion temperature of mixture; a high thermal conductivity permeable matrix base
the combustion products , which reduced the concentration material providing surface stabilized combustion at pores
of nitrogen oxides . Under conditions of high heat load ( e.g. , and /or channels of or at the boundary exit of the mixture to
80 W/cm² ) , the concentration of nitrogen oxides in the base material coat layered with low thermal conductivity
combustion products for the ceramic - coated matrix was up 30 material having high optical transmittance in the infrared
to two ( 2 ) times less than for the uncoated matrix . The spectrum .
concentration of carbon monoxide for matrices with a Such gas burner devices can be characterized as a high
ceramic coating was approximately one -third ( 1/3 ) less than infrared radiation ultra - low pollutants emission pre - mixed
for uncoated matrices. gas burners. Such gas burners can desirably achieve NOx
Turning to FIG . 5 , there is shown a premix burner 35 levels below 3 vppm , CO levels below 5 vppm and UHC
assembly generally designated by the reference numeral 10 , levels below 3 vppm , at desirably high thermal efficiency, at
in accordance with one embodiment of the invention . The excess air ratio of below 1.05 . Further such burners can
burner assembly 10 of the invention preferably includes a desirably achieve stable operation under a wide range of
mixer 16 for mixing gaseous fuel and oxidizer gas with a excess oxidant rations ( e.g. , 0.1 to 4.0 , for example ). Ultra
fuel inlet for receiving a gaseous fuel; and an oxidizer inlet 40 low emission high efficiency gas - fired burners are very
for receiving an oxidizer gas , resulting in production a gas important in many residential, commercial and industrial
mixture . The burner 10 further includes high thermal con- applications.
ductivity permeable matrix base material 20 to provide FIGS . 6 and 7 illustrate a simplified burner assembly 110
surface stabilized combustion at the exit of the mixture by or in accordance with one embodiment of the invention .
from the pores and channels. The base material is preferably 45 The burner assembly 110 includes a generally rectangular
coated by the layer of the low thermal conductivity material burner housing 112 , and a high thermal conductivity per
22 having high optical transmittance in the infrared spec- meable matrix base material 114 to provide surface stabi
trum . The burner 10 of the subject invention preferably lized combustion at the exit of a combustible gas mixture of
results in embedded combustion located between the high fuel and oxidizer by or from the pores and channels in the
thermal conductivity base material 20 and the low thermal 50 permeable matrix 114 .
conductivity material 22 . The permeable matrix 114 includes , at least partially
The combustible gas mixture burner assembly 10 is a contains or has associated therewith a plurality of thermal
high - infrared radiation ultra - low pollutants emission pre- elements 116 such as in the form of thermal conductive
mixed gas burner assembly that includes a fuel inlet 12 for elements . As will be appreciated by those skilled in the art
receiving a gaseous fuel; an oxidizer inlet 14 for receiving 55 and guided by the teachings herein provided, the broader
an oxidizer gas ; a chamber 16 , e.g. , a mixer or mixing practice of the invention is not necessarily limited by or to
chamber, to ensure that gaseous fuel and oxidizer are pro- the use of thermal elements of specific shape or form or of
duced into a proper combustible gas mixture; a burner specific materials or compositions. In accordance with
device 18 to which the combustible fuel -oxidizer mixture is selected preferred embodiments, however, the thermal ele
introduced and including or having a high thermal conduc- 60 ments desirably comprise a high temperature metal or metal
tivity permeable matrix base material 20 providing surface alloy material such as stainless steel , heat - resistant steel ,
stabilized combustion at the pores and channels of the graphite, chromium , iron, iridium , lithium , nickel, Inconel®
boundary exit of this mixture to base material coat layered or Hastelloy® nickel-based alloy, and combinations thereof.
22 with low thermal conductivity material having high In such and similar embodiments, the thermal elements
optical transmittance in the infrared spectrum . 65 can be desirably spaced apart from adjacent thermal ele
As detailed herein , a novel burner design in accordance ments by a distance between 2 millimeters and 60 millime
with at least one embodiment of the invention is based , at ters and , in some preferred embodiments the spacing
 US 11,255,538 B2
11 12
between adjacent thermal elements is in a range of 5 form of the thermal conductive elements, in accordance with
millimeters to 15 millimeters . particular embodiments thermal conductive elements in the
Further, in accordance with certain preferred embodi- shape or form of plates , rods, bars, rings , fins and combi
ments, the thickness of the permeable matrix base material nations thereof, for example can be utilized .
is desirably in a range of from 5 millimeters to 30 millime- 5 In such embodiments wherein the matrix combustion
ters and the thickness of the thermal elements are in a range surface is at least in part coated with a coating material, the
of from 0.1 millimeters to 5 millimeters . coating material having a thermal conductivity less than the
Further, in accordance with certain preferred embodi permeable matrix material thermal conductivity and is opti
ments, the thermal elements extend or protrude beyond the cally transparent to 1R radiation, the surface of the perme
downstream surface of the matrix for a length equal to 0.5-5 10 able matrix base material at least in part coated with the
of the distance between elements. In particular embodi coating material desirably emits an increased amount of
ments, the thermal elements extend or protrude beyond the radiation energy and aa decreased concentration of pollutant
downstream surface of the matrix for a length of 5 to 15 components in the combustion products as compared to the
millimeters.
A gaseous fuel combustible mixture stream 120 is fed to 15 permeable matrix base material without the coating material.
FIGS . 8 and 9 illustrate a burner assembly 210 in accor
or introduced to the burner assembly 110 with the burner dance with another embodiment of the invention .
assembly 110 acting thereon to produce or result in com
bustion products stream 124. More specifically, the gaseous The burner assembly 210 includes a generally circular
fuel combustible mixture stream 120 is fed to or introduced burner housing 212 and a high thermal conductivity perme
to the permeable matrix 114 such as at matrix upstream 20 able matrix base material 214 to provide surface stabilized
surface 126 . combustion at the exit of a combustible gas mixture of fuel
Similar to some embodiments described above, the per- and oxidizer by or from the pores and channels in the
meable matrix 114 can , if desired, be coated such as on a permeable matrix 214 .
downstream surface 130 thereof by a layer of a low thermal The permeable matrix 214 includes , at least partially
conductivity material 132 having high optical transmittance
25 contains or has associated therewith a plurality of thermal
in the infrared spectrum such as described above. If desired ,
elements 216 .
and as shown, downstream exposed or protruding surfaces Similar to the above - described burner assembly 110 , a
or portions of the thermal conductive elements 116 can ingaseous fuel combustible mixture stream 220 is fed to or
whole or in part be similarly coated with the a low thermal
introduced to the burner assembly 210 with the burner
conductivity material 132 . 30 assembly 210 acting thereon to produce or result in com
In the burner assembly 110 , the thermal elements 116 are
bustion products stream 224. More specifically, the gaseous
at least partially disposed in the permeable matrix base fuel combustible mixture stream 220 is fed to or introduced
material 114. More specifically, the thermal elements 116to the permeable matrix 214 such as at matrix upstream
include a base end 136 flush with the upstream matrix surface 226 .
surface 126 and a free end 140 , generally opposite the base
35 Similar to some embodiments described above, the per
end 136 , and protruding or extending beyond the down- meable matrix 214 can , if desired , be coated such as on a
stream matrix surface 130 . downstream surface 230 thereof by a layer of a low thermal
Operation of the radiant infrared gas burner assembly 110 conductivity material 232 having high optical transmittance
is based on volumetric surface stabilized combustion ( SSC ) in the infrared spectrum such as described above .
using a permeable matrix burner with thermal conductive 40 In the burner assembly 210 , the thermal elements 216
elements. The volumetric nature of the burner is based at rather than being partially disposed in the permeable matrix
least in part on a 3D design that combines the permeable base material are disposed adjacent the permeable matrix
metal matrix design with thermal conductive elements made base material 214 , more specifically, adjacent the down
of highly thermally conductive material. As shown , a mix- stream matrix surface 230. In this particular embodiment,
ture 120 of gaseous fuel (e.g. , natural gas ) and oxidizer ( e.g. , 45 the thermal elements 216 are spaced apart from the adjacent
air) is fed to the burner assembly 110 composed of a downstream matrix surface 230 at least in part by the width
permeable metal matrix 114 ( e.g. , foam , mesh , pressed wire , of the layer of a low thermal conductivity coating material
etc. composed of a high temperature metal or metal alloy ) in 232. Thus, as shown in FIG . 9 , the base ends 236 of the
the burner housing 112. The mixture is pre -heated as it thermal elements 216 are desirably directly adjacent the
travels through the bulk body of the matrix . The heated gas 50 layer of the coating material 232. As with the thermal
mixture is then combusted within or near the exit pores elements 116 in the burner assembly 110 , the thermal
and / or channels at the surface 130 of the permeable matrix elements 216 include aa free end 240 , generally opposite the
material. The matrix surface 130 can be coated with a thin base end 236 , and protruding or extending beyond the
layer of ceramic material 132 (e.g. , aluminum oxide) that downstream matrix surface 230 .
has a thermal conductivity significantly lower than the 55 In the burner assembly 210 the thermal elements 216 are
thermal conductivity of the material forming the matrix and retained or held in desired position relative to the permeable
has a high optical transmittance in the infrared spectrum . matrix 214 by support structures 250 joined , connected or
Metallic thermal conductive elements 116 such as also made otherwise forming a part or portion of the burner housing
of a high temperature alloy and such as can penetrate into the 212. Moreover, in this embodiment, no coating of low
bulk volume of the burner matrix 114 are added for radia- 60 thermal conductivity material having high optical transmit
tive -convective -conductive heat recuperation of energy tance in the infrared spectrum such as described above , is
from the products of combustion 124 to the matrix body and applied onto the thermal conductive elements 216 .
gaseous fuel -air mixture . The thermal conductive elements FIGS . 10 and 11 illustrate a burner assembly 310 in
116 can be suitably prepared, formed , or constructed such as accordance with yet another embodiment of the invention .
in a variety of shapes or forms such as tailored to a specific 65 The burner assembly 310 includes a generally cylindrical
or particular application . Thus, while the broader practice of high thermal conductivity permeable matrix base material
the invention is not necessarily limited by or to the shape or 314 to provide surface stabilized combustion at the exit of a
 US 11,255,538 B2
13 14
combustible gas mixture of fuel and oxidizer by or from the tive element plates during combustion were heated due to
pores and channels in the permeable matrix 314 . convective heat transfer with combustion products and
The permeable matrix 314 includes , at least partially radiation from the surface of the matrix , as well as radiation
contains or has associated therewith a plurality of thermal of combustion products. Since the thermal conductivity of
elements 316 . 5 the material of the plates is an order of magnitude higher
A gaseous fuel combustible mixture stream 320 is fed to
or introduced to the burner assembly 310 with the burner than one
the thermal conductivity of the porous foam material,
could expect an effective supply of additional heat to the
assembly 310 acting thereon to produce or result in com- matrix body.
bustion products stream 324. More specifically, the gaseous The experiments were carried out using flat matrices of
fuel combustible mixture stream 320 is fed to or introduced 10
to the permeable matrix 314 such as at matrix upstream thickness four types:conventional matrices of chromal foam of 8 mm
surface 326 . , as well as the matrix with thermal conductive
In the burner assembly 310 , the thermal elements 316 are plates introduced by the present invention . To increase the
at least partially disposed in the permeable matrix base lifetime of the matrix at high temperature, the surfaces of
material 314. More specifically, the thermal elements 316 15 somea of the conventional and new matrices were covered
include a base end 336 flush with the upstream matrix with a thin layer of aluminum oxide ( ceramic ). A coating of
surface 326 and aa free end 340 , generally opposite the base alumina with thickness of 20 um was applied on the surfaces
end 336 , and protruding or extending beyond the down of the matrices using a multi - chamber detonation plant.
stream matrix surface 330 . Experiments have shown that a stable surface combustion
It is to be understood and appreciated that the burner 20 mode in the new matrix is realized in a wider range of values
assemblies 110 , 210 and 310 , similar to the burner assembly of combustion power density in comparison with conven
10 shown in FIG . 5 and described above , may each further tional matrices. The combustion power density is the ratio of
include a fuel inlet for receiving a gaseous fuel; an oxidizer the burner firing ( W) to the surface area of the matrix with
inlet for receiving an oxidizer gas ; and a chamber, e.g. , a combustion . Stable surface combustion in the new matrix
mixer or mixing chamber, to ensure that gaseous fuel and 25 with an excess air factor a = 1.1 is realized in the range of
oxidizer are produced into a proper combustible gas mix- combustion power density from 15 W /cm2 to 100 W / cm².
ture . For the conventional uncoated matrix , the range of combus
Experimental Support tion power density was from 20 W / cm² to 70 W / cm² ( see
Unlike a conventional infrared burner with a reverbera
tory screen installed above the surface of the flat matrix for 30 FIG . 13 ) . Expansion of the region of stable combustion
energy recovery by radiation to the combustion surface of density Wis /explained
( > 100 cm2 ) with a change in the combustion power
the matrix , the burner assembly of the present invention due to its additionalbyheating increased burning rate of the mixture
in the matrix body.
provides radiative - convective - conductive heat recovery FIG . 13 is a graphical presentation of surface tempera
from the products of combustion to the matrix surface and
to its body. Initial analytical modeling and laboratory testing 35 tures versus burner power density for different types of
have shown that radiative - convective - conductive heat recu matrixes in accordance with one embodiment of the subject
development. In FIG . 13 , surface temperatures on the
peration by the thermal conductive elements is significantly
more effective than radiation recuperation by a conventional upstream ( T1 , T3 , T5 , T7 ) and downstream (T2 , T4 , T6 , T8 )
reverberatory screen , potentially able to achieve combustion sides of the radiant infrared matrices versus burner power
burner power density of 110 W / cm². 40 density for different types of matrixes : T1 and T2 uncoated
In the experiments , the characteristics of SSC for flat matrix with thermal conductive elements, T3 and 14 - un
conventional matrix and present volumetric matrix with coated conventional matrix , T5 and T6_ceramic coated
thermal conductive elements were compared. The layout of matrix with thermal conductive elements, T7 and T8 ce
the present matrix and the photograph are shown in FIGS . ramic coated conventional matrix are shown .
12A and 12B . The matrices were assembled from permeable 45 As shown in FIG . 13 , thermal conductive elements pro
metal foam bars . vide significant surface temperature increase (by up to
Highly porous chromal foam ( porosity 0.87-0.9 ) with a 200K) on downstream side of the matrix in comparison with
section of 8x8 mm , a length of 80 mm was used as matrix . conventional uncoated matrix at the same power density .
Stainless steel plates of 0.2 mm , 0.7 mm or 1.3 mm thick The matrix surface temperature on the other ( upstream ) side
were used as thermal conductive elements incorporated in 50 of the matrix is also increased by up 200K . Similar effect of
the matrix body. The height of the plates was 16 mm and the the matrix temperature increase (by 150-200K) is observed
length was 80 mm . The bottom end faces of the plates were when the matrix downstream surface is ceramic coated .
flush to the foam bars . The top end faces of the plates were FIG . 14 is a graphical presentation of relative radiation
protruded 8 mm above the foam barbs. The matrices were flux density versus combustion power density ( specific
located horizontally in the burner housing. A gas mixture of 55 power) in accordance with one embodiment of the subject
natural gas and air was fed from the bottom of the matrix development. FIG . 14 shows effects of combustion power
Natural gas and air flow rates were measured using Bronk- density , ceramic coating and thermal conductive elements
horst flow meters . Combustion occurred on the top surface on radiation heat flux from the matrix burner. Relative
of the matrix . The temperature of the top surface of the radiation flux density in FIG . 14 represents ratio of the
matrix and radiation from the matrix in the 8-14 um region 60 measured radiation flux to the maximum value of measured
were measured using an infrared pyrometer AR882 . The radiation flux for conventional uncoated matrix . It was
temperature of the bottom side of the matrix was measured found that thermal conductive elements significantly affect
using a chromel- alumel thermocouple. Composition of the the radiant heat transfer increasing the radiation flux density
combustion products was determined using a Testo 335 gas from the matrix by up to 1.7 times at tested conditions . The
analyzer. Total radiation flux density from the matrix was 65 higher the combustion power density, the higher effect of the
measured using a pyrometric sensor IRA710ST1 in the thermal conductive elements on the radiant flux . Ceramic
spectral range from visible to 14 um . The thermal conduc- coating increases the radiation flux density from conven
 US 11,255,538 B2
15 16
tional uncoated matrix by up to 20 % , while the matrix including methods and devices , has broad applicability to
downstream surface temperature remains approximately the various combustible gas mixtures . For example, in particular
same . embodiments the invention can be applied or used in con
Measured temperature values of the downstream surface junction with combustible gas mixtures formed of various
of coated matrix with thermal conductive elements exceed 5 fuel materials, including natural gas , methane, biogas , syn
the temperature values for uncoated conventional matrix by gas , hydrogen, turbine exhaust gas and combinations of two
more than 150K . With such a large difference in the tem- or more of such materials, for example, and various oxidant
peratures, a noticeable difference in the values of the radia- materials, including oxygen , air, oxygen -enriched air and
tion flux density can be expected. combinations thereof, for example.
The thermal conductive elements essentially affect the 10 The invention , including methods and devices, can be
composition of the combustion products or pollutant emis- suitably applied to a wide range of residential, commercial
sions . The measured concentrations of nitrogen oxides and industrial applications including, for example and with
(NOx) and carbon monoxide (CO ) are shown in FIGS . 15A out unnecessary limitation, water fair heaters/ furnaces, gas
and 15B , respectively . The concentration of NOx in com- turbines, syngas generators, dryers, furnaces, boilers and
bustion products is reduced by up to 1.5 times due to ceramic 15 such other applications as may be appreciated by those
coating of the matrix downstream surface. Similar effect of skilled in the art and guided by the teachings herein pro
NOx suppression was observed when thermal conductive vided .
elements were used . These can be explained due to reduction The subject development illustratively disclosed herein
of the temperature in combustion zone . suitably may be practiced in the absence of any element,
An even more significant effect of thermal conductive 20 part, step , component, or ingredient which is not specifically
elements on CO emissions was observed in the experiments. disclosed herein .
The CO concentration in combustion products of a perme- While in the foregoing detailed description the subject
able matrix with thermal conductive elements dropped up to development has been described in relation to certain pre
three times in comparison with conventional uncoated ferred embodiments thereof, and many details have been set
matrix and up to two times in comparison with coated 25 forth for purposes of illustration , it will be apparent to those
matrix , thus showing that thermal conductive elements are skilled in the art that the subject development is susceptible
more effective for NOx and CO reduction compared to to additional embodiments and that certain of the details
ceramic coating case . This can be explained by CO oxida- described herein can be varied considerably without depart
tion to CO2 between in the region between thermal conduc- ing from the basic principles of the invention . Thus, it is to
tive elements . 30 be understood that various modifications and improvements
The use of the thermal conductive elements in the infrared can be made without departing from the spirit and scope of
burner shows high potential for increased radiation and the invention . Further, the scope of the invention is defined
burner efficiency as well as reduction of both NOx and CO by the appended claims and all changes that fall within the
emissions . Design optimization of the thermal conductive meaning and range of equivalents are intended to be
elements can be done in order to further improve the burner 35 embraced therein .
efficiency and reduce NOx and CO emissions .
In accordance with selected preferred embodiments, the What is claimed is :
placement of the thermal elements relative to the permeable 1. A method of burning a combustible gas mixture, the
matrix is selected from one or more of the following: at least method comprising:
in part penetrating the matrix , flush with an upstream surface 40 feeding the combustible gas mixture to aa burner compris
of the matrix , and protruding beyond a downstream surface ing a permeable matrix base material and a plurality of
of the matrix . thermal elements disposed in thermal transfer commu
In accordance with selected preferred embodiments, the nication with the permeable matrix base material,
thermal conductivity permeable matrix base material is of a wherein the permeable matrix base material is aa metal
thickness of from 5 millimeters to 30 millimeters and the 45 foam material , porous metal material, or a pressed
thermal elements are of a thickness of from 0.1 millimeters metal wire material that forms a combustion surface
to 5 millimeters. and at least a portion of the thermal elements are in
In accordance with selected preferred embodiments, the contact with the permeable matrix base material and
thermal elements are in a form selected from a group exposed above the combustion surface, the permeable
consisting of plates , rods , bars, rings, this and combinations 50 matrix base material having a first thermal conductivity
thereof and the distance between adjacent thermal elements and the thermal elements having a thermal conductivity
is between 2 millimeters and 60 millimeters . higher than the permeable matrix material thermal
In accordance with selected preferred embodiments, at conductivity ;
least a portion of a downstream surface of the permeable preheating the combustible gas mixture as it passes
matrix is coated with a coating material having a thermal 55 through the permeable matrix material; and
conductivity less than the permeable matrix base material combusting the preheated combustible gas mixture at or
thermal conductivity and is optically transparent to IR near exit pores and channels formed at the combustion
radiation . surface of the permeable matrix material and between
In accordance with selected preferred embodiments, the thermal elements exposed above the combustion sur
permeable matrix is rectangular in plan view . 60 face ;
In accordance with selected preferred embodiments, the wherein the preheating includes a combustion heat trans
permeable matrix is circular in plan view. fer to the permeable matrix base material through the
In accordance with selected preferred embodiments, the thermal transfer communication with the thermal ele
permeable matrix is cylindrical and the plurality of thermal ments .
conductive elements radially extend therefrom . 65 2. The method of claim 1 wherein at least one of the
Those skilled in the art and guided by the teachings herein thermal elements is at least partially disposed in the perme
provided will understand and appreciate that the invention , able matrix base material.
 US 11,255,538 B2
17 18
3. The method of claim 1 wherein the permeable matrix a fuel inlet for receiving a gaseous fuel;
base material comprises a metal material selected from the an oxidizer inlet for receiving an oxidizer gas ; and
group consisting of chromal, kanthal, heat - resistant steel , a mixer for mixing gaseous fuel and oxidizer gas to
carbide of titanium , aluminum , iron, chromium , yttrium and produce a combustible gas mixture .
combinations thereof. 5
12. The radiant infrared premixed gas burner of claim 10
4. The method of claim 1 wherein the thermal elements wherein at least one of the thermal elements is at least
comprise a high temperature metal or metal alloy material partially disposed in the permeable matrix base material.
selected from the group consisting of stainless steel , heat 13. The radiant infrared premixed gas burner of claim 12
resistant steel , graphite, chromium , iron, iridium, lithium , wherein placement of the thermal elements relative to the
nickel , nickel -based alloy and combinations thereof. 10
permeable matrix is selected from one or more of the
5. The method of claim 1 wherein the thermal elements following: at least in part penetrating the matrix , flush with
are of a form selected from a group consisting of plates, an upstream surface of the matrix , and protruding beyond a
rods , bars , rings , fins and combinations thereof. downstream surface of the matrix .
6. The method of claim 1 wherein the thermal elements
are spaced apart from adjacent thermal elements by a 15 14. The radiant infrared premixed gas burner of claim 10
distance of 2 millimeters to 60 millimeters . wherein the permeable matrix base material is of a thickness
7. The method of claim 1 wherein the permeable matrix of from 5 millimeters to 30 millimeters and the thermal
base material has an upstream matrix surface and a down elements are of a thickness of from 0.1 millimeters to 5
stream matrix surface and wherein the thermal elements millimeters.
include a base end flush with the upstream matrix surface 20 15. The radiant infrared premixed gas burner of claim 10
and extend for a length of 1 to 15 millimeters beyond the wherein the thermal elements are in a form selected from a
downstream matrix surface . group consisting of plates , rods, bars , rings , fins and com
8. The method of claim 1 wherein the combustion surface binations thereof and the distance between adjacent thermal
is at least in part coated with a coating material, the coating elements is between 2 millimeters and 60 millimeters .
material having a thermal conductivity less than the perme- 25 16. The radiant infrared premixed gas burner of claim 10
able matrix material thermal conductivity and is optically wherein the thermal elements protrude beyond the combus
transparent to IR radiation, and tion surface of the matrix in a height equal to 0.5-5 times the
wherein the surface of the permeable matrix base material distance between elements .
at least in part coated with the coating material emits an 17. The radiant infrared premixed gas burner of claim 10
increased amount
concentration of radiation
of pollutant energy and
components a decreased
in the combus 30 wherein the permeable matrix is cylindrical with a central
tion products as compared to the permeable matrix base axis and each thermal element of the plurality of thermal
material without the coating material; elements is planar shaped and extends radially from within
wherein the burner comprises a ratio of thermal conduc the permeable matrix .
tivity of the permeable matrix base material and to the 35 18. The radiant infrared premixed gas burner of claim 10
coating material is from 3 to 10 ; and additionally comprising a coating of a material optically
wherein the coating material comprises a ceramic and transparent to IR radiation on at least a portion of aa down
wherein the coating is of a thickness of 10 to 500 stream surface of the permeable matrix surface and thermal
microns and the permeable matrix base material com elements .
prises a metal material . 40 19. A radiant infrared premixed gas burner, the burner
9. The method of claim 8 wherein the at least a portion of comprising:
the thermal elements exposed above the combustion surface a permeable matrix base material providing surface sta
is coated with the coating material . bilized combustion of a combustible gas mixture upon
10. A radiant infrared premixed gas burner, the burner exit of the combustible mixture through pores and
comprising: 45
channels of the base material, the permeable matrix
a permeable matrix base material providing surface sta- base material having a first thermal conductivity and
bilized combustion of aa combustible gas mixture upon configured to preheat the combustible gas mixture as it
exit of the combustible mixture through pores and travels through the permeable matrix material, and
channels of the base material, the permeable matrix a plurality of thermal elements disposed in thermal trans
base material being a metal foam material, porous 50 fer communication with the permeable matrix base
metal material, or a pressed metal wire material , and material, wherein the permeable matrix base material
having a first thermal conductivity and configured to forms a combustion surface and at least a portion of the
preheat the combustible gas mixture as it travels thermal elements are exposed above the combustion
through the permeable matrix material, and surface , the thermal elements having a thermal con
a plurality of thermal elements disposed in thermal trans- 55 ductivity higher than the permeable matrix material
fer contact with the permeable matrix base material , thermal conductivity, and the thermal elements config
wherein the permeable matrix base material forms a ured to transfer thermal energy of the surface stabilized
combustion surface and at least a portion of the thermal
elements are exposed above the combustion surface, combustion to the permeable matrix base material for
the thermal elements having a thermal conductivity 60 the preheat, wherein at least a portion of a downstream
higher than the permeable matrix material thermal surface of the permeable matrix and the at least a
conductivity , and the thermal elements configured to portion of the thermal elements exposed above the
transfer thermal energy of the surface stabilized com combustion surface is coated with a coating material
bustion to the permeable matrix base material for the having a thermal conductivity less than the permeable
preheat. 65 matrix base material thermal conductivity and is opti
11. The radiant infrared premixed gas burner of claim 10 cally transparent to IR radiation , wherein the coating
additionally comprising: material comprises a ceramic and wherein the coating
 US 11,255,538 B2
19 20
is of a thickness of 10 to 500 microns and the perme
able matrix base material comprises a metal material.
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