Swirl block register design for wall fired burners

1. A swirl register [ 1000 ] for use in a furnace with a windbox comprising:

a first side plate [ 1110 ] being generally flat;

a second side plate [ 1120 ] being generally flat;

a plurality of swirl blocks [ 1150 ] having at least four walls enclosing a space, the swirl blocks [ 1150 ] spaced apart from each other and connected between the side plates [ 1110 , 1120 ] so as to cause the side plates [ 1110 , 1120 ] to be fixed generally parallel to each other, and to create a plurality of air ducts [ 1155 ] between the swirl blocks [ 1150 ];

a plurality of vane rods [ 1160 ] each having a first end and a second end, the first end of the vane rods [ 1160 ] extending generally perpendicularly through the second side plate [ 1120 ]; and

a plurality of vanes [ 1130 ] each attached to the first end of each vane rod [ 1160 ] and positioned within the air ducts [ 1155 ], such that the vanes [ 1130 ] are allowed to move between a closed position in which the vanes [ 1130 ] close the air ducts [ 1155 ] and at least one open position in which the air ducts [ 1155 ] are at least partially open when the vane rods [ 1160 ] are rotated.

2. The swirl register [ 1000 ] of claim 1 further comprising:

a linkage assembly [ 1200 ] having a plurality of drive links [ 1201 ], each drive link [ 1201 ] pivotally connected to one of the vane rods [ 1160 ] at their second end, the linkage assembly [ 1200 ] also having a plurality of tangential links [ 1203 ], each tangential link [ 1203 ] pivotally connected to at least one of the drive links [ 1201 ] such that motion of the linkage assembly [ 1200 ] causes rotation of all the attached vane rods [ 1160 ]; and

a drive source coupled to the linkage assembly [ 1200 ] causing motion of the linkage assembly [ 1200 ] and rotation of all attached vane rods [ 1160 ].

3. The swirl register [ 1000 ] of claim 2 wherein:

the linkage assembly [ 1200 ] and drive source are attached to the windbox front plate [ 1250 ].

4. The swirl register [ 1000 ] of claim 1 wherein the swirl register [ 1000 ] passes through said windbox of said furnace, further comprising:

a windbox front plate [ 1250 ] having a plurality of holes each adapted to receive a vane rod [ 1160 ] functioning to stabilize the vane rods [ 1160 ] while allowing them to rotate.

5. The swirl register [ 1000 ] of claim 4 wherein:

the vane rods [ 1160 ] extend through the windbox and the windbox front plate [ 1250 ] that is positioned outside of the windbox for providing easy access.

6. A method of providing a more reliable swirl register comprising the steps of:

providing a rigid air duct assembly [ 1100 ] having a plurality of swirl blocks [ 1150 ] each having at least four walls enclosing a space the swirl blocks [ 1150 ] spaced apart from each other creating a plurality of angled air ducts [ 1155 ] between the swirl blocks [ 1150 ];

providing a plurality of vanes [ 1130 ] inside of the air ducts [ 1155 ] adapted to adjust a rate of air flowing through the air ducts [ 1155 ] by selecting a position for the vanes [ 1130 ];

attaching a vane rod [ 1160 ] to each of the vanes [ 1130 ] to control their position remotely; and

providing a vane control mechanism [ 1600 ] attached to the vane rods [ 1160 ] in an easily accessible and clean location for controlling the vane rods [ 1160 ] and positions of the vanes [ 1130 ].

7. The method of claim 6 wherein the step of providing a rigid air duct assembly [ 1100 ] further comprises the steps of:

providing a first side plate [ 1110 ] having a perimeter; and

attaching the plurality of swirl blocks [ 1150 ] to the first side plate [ 1110 ] spaced from each other around the perimeter of the side plate [ 1110 ] to create a plurality of spaces between the swirl blocks angled with respect to a radial direction from a center of the side plate [ 1110 ],

attaching a second side plate [ 1120 ] to the swirl blocks [ 1150 ] such that the first side plate [ 1110 ] and the second side plate [ 1120 ] are substantially parallel to each other, and the second side plate [ 1120 ] closes the angled spaces creating the angled air ducts [ 1155 ].

8. The method of claim 6 wherein the vane control mechanism [ 1600 ] is positioned outside of a windbox configured for passing a secondary air therethrough.

9. A reliable swirl register [ 1000 ] for receiving secondary air from a windbox of a furnace and providing the secondary air into a stream of air and pulverized solid fuel passing through a fuel tube [ 10 ] comprising:

a rigid air duct assembly comprising:

a first side plate [ 1110 ],

a second side plate [ 1120 ],

a plurality of swirl blocks [ 1150 ] having at least four walls enclosing a space, the swirl blocks [ 1150 ] spaced from each other and positioned to create angled air ducts [ 1155 ] between them, the swirl blocks [ 1150 ] connecting the first side plate [ 1110 ]substantially parallel to the second side plate [ 1120 ], such that the first side plate [ 1110 ] and the second side plate enclosed the plurality of air ducts [ 1155 ];

a plurality of vanes [ 1130 ] within the air ducts [ 1155 ] adapted to select an air flow rate through the air ducts [ 1155 ] based upon their position; and

a vane control mechanism [ 1600 ] for accurately controlling the position of the vanes thereby defining the airflow rate through the air ducts [ 1155 ].

10. The reliable swirl register [ 1000 ] of claim 9 wherein the vane control mechanism [ 1600 ] is located outside of the windbox.

11. The reliable swirl register [ 1000 ] of claim 9 wherein the vane control mechanism [ 1600 ] comprises:

a plurality of vane rods [ 1160 ] each coupled to a vane [ 1130 ] and the vane rods [ 1160 ] are remotely actuated to adjust the position of the vanes [ 1130 ].

12. The reliable swirl register [ 1000 ] of claim 11 wherein the vane control rods [ 1160 ] are remotely operated from outside of the windbox.

13. The reliable swirl register [ 1000 ] of claim 11 further comprising:

a windbox plate [ 1250 ] attached to a windbox wall [ 20 ] for receiving and stabilizing the vane rods [ 1160 ].

14. The reliable swirl register [ 1000 ] of claim 9 wherein the vane control mechanism [ 1600 ] comprises:

a motor in a gearbox [ 1230 ] that together actuate the vane rods [ 1160 ].

15. The reliable swirl register [ 1000 ] of claim 9 wherein the swirl blocks [ 1150 ] are positioned to have at least two block walls [ 1151 , 1153 ] adjacent to each other, wherein at least one block wall [ 1151 , 1153 ] is angled with respect to a radial direction, the swirl blocks [ 1150 ] positioned such that the at least two adjacent block walls [ 1151 , 1153 ], the first side plate [ 1110 ] and the second side plate [ 1120 ] create the angled air duct [ 1155 ].