Experimental Study of a High-Efficiency Low-Emission Surface Combustor-Heater

The surface combustor-heater is a combined combustion/heat-transfer device in which the heat-exchange surfaces are embedded in a stationary bed of refractory material where gaseous fuel is burned. Because of intensive heat radiation from the hot solid particles and enhanced heat convection from the gas flow to the heat-exchange tubes, heat transfer is significantly intensified. Removing heat simultaneously with the combustion process has the benefit of reducing the combustion temperature, which suppresses NOx formation. A basic experimental study was conducted on a 60-kW bench-scale surface combustor-heater with two rows of water-cooled tube coils to evaluate its performance and explore the mechanism of combined convective-radiative heat transfer and its interaction with combustion in the porous matrix. Combustion stability in the porous matrix, heat-transfer rates, emissions, and pressure drop through the unit have been investigated for the variable parameters of operation and unit configurations. Experimental results have demonstrated that high combustion intensity (up to 2.5 MW/m2), high heat-transfer rates (up to 310 kW/m2), high density of energy conversion (up to 8 MW/m3), as well as ultra-low emissions (NOx and CO as low as 15 vppm*) have been achieved. The excellent performance of the test unit and the extensive data obtained from the present experimental study provide the basis for further development of high-efficiency and ultra low-emission water heaters, boilers, and process heaters based on the surface combustor-heater concept.