Burner for furnace, tile used in association with same, and method of controlling a flame of a burner

Abstract

A burner and a tile for producing a flame in a furnace. The burner includes a pre-mixer with a venturi that mixes fuel with a first portion of combustion air. The mixture of the fuel and combustion air is passed through the tile. The tile also passes additional portions of combustion air there through. The tile includes flow channels for passing the gases so that it is the tip of the burner. The tile may include a wall to form a staged fuel tile with flow channels splitting the mixture of fuel and combustion air so that some exits the tile inside of the wall, and some exits the tile outside of the wall. The tile may be two pieces. Also a process for improving a flame produced by such a burner and with a tile.

What is claimed is: 
     
         1 . A burner for a furnace, the burner comprising:
 a wind box having a first end, a second end, and a body extending between the first end and the second end, the body of the wind box forming a cavity;   a fuel line having an outlet, the fuel line passing through the body of the wind box into the cavity of the wind box;   a pre-mixer having an open first end, an open second end, and a body cavity there between with a portion having a venturi, the open first end of the pre-mixer being disposed near the outlet of the fuel line and being configured to receive combustion air from the cavity of the wind box to mix with fuel from the fuel line; and,   a tile having an inner surface, an outer surface, and a first plurality of flow channels extending through the tile, the outer surface of the tile being adjacent to the second end of the wind box and being adjacent to the open second end of the pre-mixer, the inner surface including a plurality of outlets for the flow channels from the first plurality of flow channels, a first plurality of outlets being disposed on a circumference of a first circle and a second plurality of outlets being disposed on a circumference of a second circle, the circumference of the second circle being larger than the circumference of the first circle.   
     
     
         2 . The burner of  claim 1  further comprising:
 a plurality of second flow channels configured to receive combustion air from the cavity of the wind box. 
 
     
     
         3 . The burner of  claim 2  further comprising:
 the inner surface of the tile including a wall extending away therefrom. 
 
     
     
         4 . The burner of  claim 3  wherein the first plurality of outlets are disposed within the wall on the inner surface of the tile. 
     
     
         5 . The burner of  claim 4  wherein the second plurality of outlets are disposed outside of the wall on the inner surface of the tile. 
     
     
         6 . The burner of  claim 5  further comprising:
 the flow channels from the second plurality of flow channels each having an outlet disposed inside of the wall on the inner surface of the tile. 
 
     
     
         7 . The burner of  claim 1  wherein the pre-mixer comprises a first material, and wherein the tile comprises the first material. 
     
     
         8 . The burner of  claim 7  wherein the pre-mixer is integral with a portion of the tile. 
     
     
         9 . The burner of  claim 1  further comprising:
 the tile comprising an inner piece and an outer piece, the outer piece being integral with the pre-mixer. 
 
     
     
         10 . The burner of  claim 1 , wherein the flow channels from the first plurality and the flow channels from the second plurality are in fluid communication within the body of the tile. 
     
     
         11 . A tile for a burner of a furnace, the tile comprising:
 a body with an inner surface having a wall and an outer surface;   a first plurality of flow channels extending through the body of the tile, the flow channels of the first plurality configured to receive and pass a mixture of fuel and combustion air through the body of the tile, wherein a first flow channel from the first plurality of flow channels has an outlet disposed outside of the wall on the inner surface of the tile, and wherein a second flow channel from the first plurality of flow channels has an outlet disposed inside of the wall on the inner surface of the tile; and,   a second plurality of flow channels extending through the tile, the flow channels of the second plurality configured to receive and pass combustion air through the tile.   
     
     
         12 . The tile of  claim 11  further comprising:
 the flow channels from the second plurality of flow channels each comprising an outlet disposed within the wall on the inner surface of the tile. 
 
     
     
         13 . The tile of  claim 12  wherein the first flow channel and the second flow channel are in communication within the body of the tile. 
     
     
         14 . The tile of  claim 11  further comprising a venturi pre-mixer disposed near the bottom surface of the tile. 
     
     
         15 . The tile of  claim 11  wherein the tile comprises an inner piece and an outer piece, the outer piece being integral with a pre-mixer having a venturi. 
     
     
         16 . A process for controlling a flame of a burner used in a furnace, the process comprising:
 passing fuel through a conduit to an outlet, wherein the outlet of the conduit is disposed at an inlet of a pre-mixer having a venturi;   mixing fuel in the pre-mixer with a first portion of combustion air;   passing the mixture of fuel and combustion air from the venturi pre-mixer to a tile;   splitting the mixture of fuel and combustion air within the tile into a first portion and a second portion;   passing the first portion of the mixture of fuel and combustion air and the second portion of the mixture of fuel and combustion air through the tile; and,   passing a second portion of combustion air though the tile, and,   wherein tile includes a wall, and wherein the first portion of the mixture of fuel and combustion air exits the tile within the wall and the second portion of the mixture of fuel and combustion air exits the tile outside of the wall.   
     
     
         17 . The process of  claim 16  wherein the tile includes a plurality of flow channels for passing at least one portion of the mixture of fuel and combustion air through the tile. 
     
     
         18 . The process of  claim 16  wherein the tile includes a plurality of flow channels for passing the second portion of combustion air through the tile. 
     
     
         19 . The process of  claim 18  wherein the second portion of combustion air exits the tile inside of the wall. 
     
     
         20 . The process of  claim 19  wherein the pre-mixer is integral with the tile.