Compact low emissions burner nozzle using additive manufacturing
A burner nozzle and a method of operating the burner nozzle can include a main air/fuel port located centrally within the burner nozzle, and a group of staged gas fuel ports that surrounds the main air-fuel port and which can direct fuel to an established flame zone downstream from the burner nozzle. Furthermore, a trapped vortex chamber can be formed in a wall of the main air/fuel port and can communicate with a group of primary gas ports in a fuel circuit, such that the trapped vortex chamber facilitates flame stability with respect to a flame produced by the burner nozzle.
1 . A burner nozzle, comprising:
a main body including at least a chamber base integrally coupled to a nozzle portion;
a main air/fuel port located centrally within the nozzle portion
an air inlet located centrally within the chamber base and in fluid communication with the main air/fuel port for receiving a flow of air;
a primary fuel manifold formed in the chamber base for receiving a first portion of a total nozzle fuel flow, the primary fuel manifold in fluid communication with a plurality of main fuel outlet ports;
a staged fuel manifold formed in the chamber base for receiving a second portion of the total nozzle fuel flow, the staged fuel manifold in fluid communication with a plurality of staged fuel outlet ports that surround the main air/fuel port and which directs fuel to an established flame zone downstream from the burner nozzle; and
a trapped vortex chamber formed in a wall of the main body and configured to facilitate flame stability with respect to a flame produced by the burner nozzle,
wherein:
a first number of the main fuel outlet ports are located to discharge a first percentage of the first portion of the total nozzle fuel flow into the air inlet upstream of the trapped vortex chamber, and
a second number of the main fuel outlet ports are located to discharge a second percentage the first portion of the total nozzle fuel flow into the trapped vortex generator.
2 . The burner nozzle of claim 1 , wherein after ignition inside the trapped vortex chamber of the burner nozzle the flame is stable and self-sustaining.
3 . The burner nozzle of claim 1 wherein each of the plurality of staged gas fuel ports is sized to split a percentage of the fuel and direct the fuel into the staged established flame zone downstream of a primary flame.
4 . The burner nozzle of claim 1 , wherein:
the second portion of the total nozzle fuel flow is a third percentage of the total nozzle fuel flow; and
the plurality of main fuel outlet ports and the plurality of staged fuel outlet ports are sized such that the first percentage, the second percentage, and the third percentage are unequal.
5 . The burner nozzle of claim 4 , wherein:
the first percentage is greater than the second percentage and less than the third percentage; and
the second percentage is less than the third percentage are unequal.
6 . The burner nozzle of claim 5 , wherein:
the first percentage, the second percentage, and the third percentage are 29%, 1%, and 70%, respectively.
7 . A multi-port burner nozzle assembly, comprising:
a multi-nozzle plate having a plurality of burner nozzle openings formed therein; and
a plurality of burner nozzles, each burner nozzle disposed within a different one of the burner nozzle openings, each burner nozzle comprising:
a main body including at least a chamber base integrally coupled to a nozzle portion;
a main air/fuel port located centrally within the nozzle portion
an air inlet located centrally within the chamber base and in fluid communication with the main air/fuel port for receiving a flow of air;
a primary fuel manifold formed in the chamber base for receiving a first portion of a total nozzle fuel flow, the primary fuel manifold in fluid communication with a plurality of main fuel outlet ports;
a staged fuel manifold formed in the chamber base for receiving a second portion of the total nozzle fuel flow, the staged fuel manifold in fluid communication with a plurality of staged fuel outlet ports that surround the main air/fuel port and which directs fuel to an established flame zone downstream from the burner nozzle; and
a trapped vortex chamber formed in a wall of the main body and configured to facilitate flame stability with respect to a flame produced by the burner nozzle,
wherein:
a first number of the main fuel outlet ports are located to discharge a first percentage of the first portion of the total nozzle fuel flow into the air inlet upstream of the trapped vortex chamber, and
a second number of the main fuel outlet ports are located to discharge a second percentage the first portion of the total nozzle fuel flow into the trapped vortex generator.
8 . The assembly of claim 7 , wherein:
the second portion of the total nozzle fuel flow is a third percentage of the total nozzle fuel flow; and
the plurality of main fuel outlet ports and the plurality of staged fuel outlet ports are sized such that the first percentage, the second percentage, and the third percentage are unequal.
9 . The assembly of claim 8 , wherein:
the first percentage is greater than the second percentage and less than the third percentage; and
the second percentage is less than the third percentage are unequal.