Method of providing heat to a heat exchanger apparatus via a burner

Abstract

The disclosure is directed toward a method of providing heat to a heat exchanger via a burner. The burner includes a burner assembly and a large transparent door for viewing various components of the burner assembly and/or an integral pilot system. The burner can also include a windbox to manipulate air used by the burner assembly and/or an air manipulation device to ensure a proper air flow distribution in the burner assembly. The burner can also include a fan and a housing having holes disposed therein to permit fuel to enter various portions of the burner assembly.

What is claimed is: 
     
         1 . A method, the method comprising:
 forcing air into a burner assembly of a burner, the burner having a large transparent door disposed therein for viewing components of the burner assembly and providing access to components of the burner assembly;   mixing the air with a fuel in the burner assembly to create a mixture to be combusted; and   combusting the mixture to provide heat to a heat exchanger.   
     
     
         2 . The method of  claim 1  further comprising the step of mixing the air forced into the burner assembly with a portion of flue gas removed from the heat exchanger via a flue gas return system, the flue gas system comprising:
 an inlet to the flue gas return system in gaseous communication with the heat exchanger; 
 an outlet from the flue gas return system in gaseous communication with the burner assembly; and 
 a duct disposed between the inlet and outlet. 
 
     
     
         3 . The method of  claim 2  wherein the flue gas return system further comprises a damper that can be selectively opened and closed to control the amount and flow rate of flue gas entering the burner assembly. 
     
     
         4 . The method of  claim 1  wherein the large door has a diameter greater than about 16 inches. 
     
     
         5 . The method of  claim 1  wherein the large door has a diameter greater than about 28 inches. 
     
     
         6 . The method of  claim 1  wherein at least 50 percent of the large door is constructed of a transparent material. 
     
     
         7 . The method of  claim 1  wherein the burner further includes a fan for forcing air into the burner assembly, the burner assembly further comprising:
 a windbox to manipulate the flow of air exiting the fan; 
 a fuel injection section for providing fuel into the burner assembly to mix with the manipulated air exiting the windbox; 
 an integral pilot system to light and maintain a pilot flame; and 
 a throat section where primary combustion of the mixture of the air and fuel occurs. 
 
     
     
         8 . The method of  claim 8  wherein the integral pilot system is centrally disposed within the burner assembly and includes a fuel supply, an igniter and a diffuser to distribute a stabilizing diffusion flame into the throat section of the burner assembly. 
     
     
         9 . The method of  claim 9  wherein the fuel injection section provides the fuel into the burner assembly to mix with the manipulated air prior to the fuel and air encountering the stabilizing diffusion flame extending from the diffuser of the integral pilot system. 
     
     
         10 . The method of  claim 8  wherein the windbox includes an air distribution device disposed therein to create a uniform air profile to flow into the fuel injection section. 
     
     
         11 . The method of  claim 11  wherein the air distribution device is a substantially cylindrically shaped tube having a plurality of openings disposed therein that create baffles that extend along a length of the cylindrically shaped tube. 
     
     
         12 . The method of  claim 12  wherein the openings and the baffles are substantially triangular shaped and one corner of the opening is rounded and has a radius of curvature greater than about 1 inch. 
     
     
         13 . The method of  claim 12  wherein the air from the fan flows into the windbox and perpendicular to the length of the air distribution device. 
     
     
         14 . The method of  claim 8  wherein the burner assembly further includes an air manipulation device centrally disposed in the burner assembly and downstream from the windbox to ensure a proper air flow distribution of the fuel and air entering the throat section. 
     
     
         15 . The method of  claim 15  wherein the air manipulation device is a substantially cylindrically shaped tube having a plurality of openings disposed therein that create baffles that extend along a predetermined length of the cylindrically shaped tube. 
     
     
         16 . The method of  claim 16  wherein the openings and the baffles of the air manipulation device are substantially triangular shaped and one corner of the opening is rounded and has a radius of curvature greater than about 0.1 inch. 
     
     
         17 . The method of  claim 16  wherein the air manipulation device has a first end connected to a backside of the diffuser and a second end having the openings disposed therein. 
     
     
         18 . The method of  claim 18  wherein the fuel injection section further includes a housing disposed between the windbox and the throat section, the housing has a plurality of holes disposed therein to permit the passage of fuel into the burner assembly. 
     
     
         19 . The method of  claim 19  wherein the holes disposed in the housing vary in size to facilitate the depth at which the fuel is injected into the fuel injection section to more thoroughly mix the manipulated air exiting the windbox and the fuel passing through the holes. 
     
     
         20 . A method, the method comprising:
 forcing air into a burner assembly of a burner, the burner assembly having an integral pilot system to light and maintain a pilot flame is centrally disposed within the burner assembly, the integral pilot system includes a fuel supply, an igniter and a diffuser to distribute a stabilizing diffusion flame into a throat section of the burner assembly;   mixing the air with a fuel in the burner assembly to create a mixture to be combusted; and   combusting the mixture to provide heat to a heat exchanger.   
     
     
         21 . The method of  claim 21  wherein the fuel injection section provides the fuel into the burner assembly to mix with the manipulated air prior to the fuel and air encountering the stabilizing diffusion flame extending from the diffuser of the integral pilot system. 
     
     
         22 . The method of  claim 21  wherein the burner assembly further includes an air manipulation device centrally disposed in the burner assembly and downstream from the windbox to ensure a proper air flow distribution of the fuel and air entering the throat section. 
     
     
         23 . The method of  claim 23  wherein the air manipulation device is a substantially cylindrically shaped tube having a plurality of openings disposed therein that create baffles that extend along a predetermined length of the cylindrically shaped tube. 
     
     
         24 . The method of  claim 24  wherein the openings and the baffles of the air manipulation device are substantially triangular shaped and one corner of the opening is rounded and has a radius of curvature greater than about 0.1 inch. 
     
     
         25 . The method of  claim 24  wherein the air manipulation device has a first end connected to a backside of the diffuser and a second end having the openings disposed therein. 
     
     
         26 . A method, the method comprising:
 forcing air into a burner assembly of a burner, the burner comprising:
 a windbox disposed between a fan and a fuel injection section of a burner assembly to manipulate the flow of air exiting the fan, the windbox having an air distribution device disposed therein to create a uniform air profile to flow into the fuel injection section; and 
 an air manipulation device centrally disposed in the burner assembly and downstream from the windbox to ensure a proper air flow distribution of fuel and air exiting the fuel injection section; 
 mixing the air with a fuel in the burner assembly to create a mixture to be combusted; and 
 combusting the mixture to provide heat to a heat exchanger. 
   
     
     
         27 . The method of  claim 27  wherein the air distribution device is a substantially cylindrically shaped tube having a plurality of openings disposed therein that create baffles that extend along a length of the cylindrically shaped tube. 
     
     
         28 . The method of  claim 27  wherein the openings and the baffles are substantially triangular shaped and one corner of the opening is rounded and has a radius of curvature greater than about 1 inch. 
     
     
         29 . The method of  claim 28  wherein the air from the fan flows into the windbox and perpendicular to the length of the air distribution device. 
     
     
         30 . The method of  claim 27  wherein the air manipulation device is a substantially cylindrically shaped tube having a plurality of openings disposed therein that create baffles that extend along a predetermined length of the cylindrically shaped tube. 
     
     
         31 . The method of  claim 31  wherein the openings and the baffles of the air manipulation device are substantially triangular shaped and one corner of the opening is rounded and has a radius of curvature greater than about 0.1 inch. 
     
     
         32 . The method of  claim 31  wherein the air manipulation device has a first end connected to a backside of the diffuser and a second end having the openings disposed therein. 
     
     
         33 . A method, the method comprising:
 forcing air into a fuel injection section disposed in a burner assembly of a burner, the fuel injection section having a housing disposed between a fan and a throat section, the housing having a plurality of holes disposed therein to permit the passage of fuel into the fuel injection section of the burner assembly;   mixing the air with a fuel in the burner assembly to create a mixture to be combusted; and   combusting the mixture to provide heat to a heat exchanger.   
     
     
         34 . The method of  claim 34  wherein the holes disposed in the housing vary in size to facilitate the depth at which the fuel is injected into the fuel injection section to more thoroughly mix the manipulated air exiting the windbox and the fuel passing through the holes.