Design And Fabrication Of An Industrial Gas Burner

Electrical Electronics Engineering | Industrial Physics | Physics

The design and fabrication of an industrial gas burner involves a comprehensive process encompassing engineering principles, material selection, and manufacturing techniques. Key considerations in the design phase include optimizing combustion efficiency, ensuring safety standards compliance, and meeting specific performance requirements such as heat output and flame stability. Engineers meticulously analyze factors like fuel type, air-to-fuel ratio, and combustion chamber geometry to achieve optimal combustion performance. Material selection is critical to withstand high temperatures and corrosive environments while maintaining structural integrity. Fabrication techniques involve precision machining, welding, and assembly to construct components such as burner heads, fuel delivery systems, and control mechanisms. Rigorous testing and quality assurance procedures are implemented to validate performance and safety before deployment in industrial applications. Successful implementation of this project demands expertise in thermal engineering, materials science, and manufacturing processes, ultimately delivering a reliable and efficient industrial gas burner system.

ABSTRACT

Burners play an integral role in oil and gas well pads. They generate the heat necessary for separating the oil, gas and water mixture and to keep the gases in their vapor phase during transportation through pipelines. Burners typically use a portion of the gas coming out of the ground as the fuel to produce the flame for heating. The gases extracted from the ground enter the burner skid (commonly referred to as burner fuel train) at a high pressure and hence they need to be pressure controlled for use in burners. This work is on fabrication of an industrial gas burner.

TABLE OF CONTENTS

COVER PAGE

TITLE PAGE

APPROVAL PAGE

DEDICATION

ACKNOWELDGEMENT

ABSTRACT

CHAPTER ONE

INTRODUCTION

1.1 BACKGROUND OF THE PROJECT

OBJECTIVE OF THE PROJECT
HOW COMBUSTION OCCUR IN BURNER
SIGNIFICANCE OF THE PROJECT
APPLICATION OF THE PROJECT
LIMITATION OF THE PROJECT

CHAPTER TWO

LITERATURE REVIEW

REVIEW OF FUEL GAS
HISTORICAL BACKGROUND OF FUEL
FLAME TEMPERATURES OF COMMON GASES AND FUELS
EXPLOSIVE LIMITS AND IGNITION TEMPERATURES OF COMMON GASES
COMBUSTION VALUES OF COMMON GASES

CHAPTER THREE

METHODOLOGY

MAJOR COMPONENTS OF INDUSTRIAL GAS BURNER
PICTORIAL DIAGRAM GAS BURNER
WORKING PRINCIPLE OF THE PROJECT

CHAPTER FOUR

ASSEMBLY AND TESTING
BURNER CONFIGURATION
TESTING THE CONFIGURATION
SELECTION OF BURNER

CHAPTER FIVE

CONCLUSION
RECOMMENDATION
REFERENCES

CHAPTER ONE

1.0 INTRODUCTION

A burner is a mechanical device that supplies required amount of fuel and air creates condition for rapid mixing of fuel and air produces a flame which transfers thermal energy to furnace and charge.

In oil burners, oil is atomized into a fine spray by a spray nozzle and air is supplied for combustion in the spray chamber. Alternatively oil may be atomized by high speed air to produce a fine dispersion of droplets into air.

There are liquid fuel and gaseous fuel burners. In liquid fuel burner, oil is heated and atomized either mechanically or by high speed gaseous jet.

This work focuses on an industrial gas burner is a device which is used to generate a flame, in order to heat up products using a gaseous fuel such as acetylene, natural gas, or propane for industrial purpose. Some burners have an air inlet to mix the fuel gas with air, to enable complete combustion. Acetylene is commonly used in combination with oxygen.

The gas burner has many applications such as soldering, brazing and welding, the latter using oxygen instead of air for producing a hotter flame, which is required for melting steel. For laboratory uses, a natural-gas fueled Bunsen burner is used. For melting metals with melting points of up to 1100 °C (such as copper, silver, and gold), a propane burner with a natural drag of air can be used.

1.1 OBJECTIVE OF THE PROJECT

The objective of this work is to design a device which is used to generate a flame, in order to heat up products using a gaseous fuel such as acetylene, natural gas, or propane.

1.2 HOW COMBUSTION OCCUR IN BURNER

The release of potential energy of fuel by combustion with air requires several

stages, namely.

Mixing of air and fuel
Ignition of the mixture
Chemical reaction
Disposal of products of combustion from the reaction site so that fresh reactants are available. Except mixing of air and fuel, all other stages are extremely fast such that it is said that if fuel and air are mixed, fuel is burnt. Accordingly mixing is the slowest step in the process of combustion, this can be understood by considering that each mole of carbon theoretically requires 1 mole of oxygen for complete combustion. But 1 mole of oxygen is obtained from 4.76 moles of air. That means 3.76 moles of nitrogen are present with 1 Mole of oxygen. Nitrogen is inert and does not take part in combustion therefore mixing of air+ fuel is important.

1.3 SIGNIFICANCE OF THE PROJECT

An industrial gas burner is a device which is used to generate a flame, in order to heat up products using a gaseous fuel such as acetylene, natural gas, or propane. Some burners have an air inlet to mix the fuel gas with air, to enable complete combustion. Acetylene is commonly used in combination with oxygen.

1.4 APPLICATION OF THE PROJECT

The hottest and most efficient of all fuel gases use in gas burner, acetylene (C₂H₂) provides high levels of productivity thanks to good localized heating with a minimum of thermal waste. It also requires the least amount of oxygen to ensure complete combustion. This flammable, colourless gas is lighter than air so does not accumulate at low levels, where it could cause a potential hazard. It is generally supplied dissolved in acetone or DMF (dimethylformamide) in specially designed cylinders to prevent decomposition.

A low flame moisture content makes this fuel gas a good choice for many critical heating processes. Typical applications include flame heating, flame gouging, welding, flame hardening, flame cleaning, flame straightening, thermal spraying, spot-heating, brazing, texturing, profile-cutting, branding wooden pallets, wood-ageing and carbon coating.

Acetylene is the only fuel gas recommended for underground working conditions because it is lighter than air. It is also the only fuel gas, for instance, which can be used to weld steel.

In cutting, oxy-acetylene gives the fastest preheating and piercing times of any fuel gas combination.

Benefits include:

Improved cut quality
Higher cutting speeds
Faster cut initiation time
Reduced oxygen use.

1.5 LIMITATION OF THE PROJECT

this device can be hazardous when not properly handled

CHAPTER TWO

2.0 LITIERATURE REVIEW

2.1 REVIEW OF FUEL GAS

Fuel gas is any one of a number of fuels that under ordinary conditions are gaseous. Many fuel gases are composed of hydrocarbons (such as methane or propane), hydrogen, carbon monoxide, or mixtures thereof. Such gases are sources of potential heat energy or light energy that can be readily transmitted and distributed through pipes from the point of origin directly to the place of consumption.

Fuel gas is contrasted with liquid fuels and from solid fuels, though some fuel gases are liquefied for storage or transport. While their gaseous nature has advantages, avoiding the difficulty of transporting solid fuel and the dangers of spillage inherent in liquid fuels, it also has limitation. It is possible for a fuel gas to be undetected and collect in certain areas, leading to the risk of a gas explosion. For this reason, odorizers are added to most fuel gases so that they may be detected by a distinct smell. The most common type of fuel gas in current use is natural gas…