Fiber matrix burner composition with aluminum alloys and method of formulation

• US 4,746,287 A
• Filed: 01/17/1986
• Issued: 05/24/1988
• Est. Priority Date: 01/17/1986
• Status: Expired due to Term

• Current Assignee: Gas Technology Institute (GTI Energy)
• Original Assignee: Gas Research Institute (GTI Energy)
• Inventors: Lannutti, John J.
• Primary Examiner(s): NOT, DEFINED
• Application Number:
  US06/820,720
• Time in Patent Office: 858 Days
• Field of Search: 264/44, 264/45.3, 264/46.4, 264/46.7, 264/46.9, 264/256, 431/328, 501/95
• US Class Current: 431/328
• CPC Class Codes: B28B 19/0038 lining the outer wall of hollow objects, e.g. pipes
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 14/34 Metals , e.g. ferro-silicon
• CPC Class Codes: C04B 14/46 Rock wool ; Ceramic or silicate fibres C04B14/40, C04B14/42 take precedence
• CPC Class Codes: C04B 30/02 containing fibrous materials
• CPC Class Codes: C04B 38/0605 by sublimating
• CPC Class Codes: C04B 40/0263 Hardening promoted by a rise in temperature C04B40/024 takes precedence
• CPC Class Codes: F23D 14/16 using permeable blocks
• CPC Class Codes: F23D 2203/105 Porous plates
• CPC Class Codes: F23D 2212/201 Fibres

Abstract

A fiber matrix burner and method of manufacture in which a shaped burner element is formed by accreting a slurry onto a foraminous support. The slurry is comprised of ceramic fibers, a binding agent, a vaporizable filler, and a powdered, normally non-flammable aluminum alloy having a melting point between 660° C. and 1,000° C. After the drying and firing, a porous matrix of the fibers is formed which flamelessly combusts a fuel-air mixture. During combustion, the aluminum alloy inhibits growth of alumina crystals on the fiber surface to prolong burner life and, in addition, protects the burner both from extreme temperature and flashback.

Claims

1. A fiber matrix burner made by the process of preparing an aqueous slurry comprising inorganic fibers, an inorganic binding agent gel, a non-reactive vaporizable filler and a powdered, normally non-flammable aluminum alloy with a melting point between 660°

C. and 1000°

C., said alloy being incorporated into the slurry in the proportion of 1/4 to 4 grams per gram of said fibers, withdrawing moisture from the slurry while accreting the fibers on the surface of a foraminous support to form a burner structure, heating the structure to remove residual moisture, and heating the structure at a temperature sufficient to vaporize the filler to produce a matrix of interconnected pores throughout the structure with the fibers having a coating which includes the aluminum alloy.

2. A burner made by the process of claim 1 in which the aluminum alloy contains more than 1% of a metal selected from the group consisting of copper, zirconium, iron, chromium, silicon, magnesium, zinc and titanium.

3. A burner made by the process of claim 1 in which the powdered aluminum alloy is present in the slurry in the amount of 5 to 80 grams of alloy per gallon of the binding agent gel.

4. In a method of manufacturing a fiber matrix burner adapted for use in a combustion apparatus by accreting a shaped fibrous element on a foraminous support from a slurry composition comprising a plurality of ceramic fibers, an inorganic binding agent and a vaporizable filler in which heat is applied to vaporize the filler and to form pores in the element, the improvement comprising incorporating a powdered normally non-flammable aluminum alloy with a melting point between 660°

C. and 1000°

C. into the slurry composition prior to the step of accreting the element on the support, said alloy being incorporated into the slurry in the proportion of from 1/4 to 4 grams per gram of said fibers.

5. A method as in claim 4 in which the aluminum alloy contains more than 1% of a metal selected from the group consisting of copper, zirconium, iron, chromium, silicon, magnesium, zinc and titanium.

6. A method of molding a combustion element comprising the steps of forming a slurry composition containing a powdered normally non-flammable aluminum alloy, ceramic fibers, an inorganic binding agent gel, and a non-reactive vaporizable filler interspersed throughout the slurry, said alloy being incorporated into the slurry in the proportion of from 1/4 to 4 grams per gram of said fibers, and vaporizing the filler leaving a matrix of interconnected pores extending through the element.

7. A method as in claim 6 in which the powdered aluminum alloy is present in the slurry in the amount of 5 to 80 grams of alloy per gallon of the binding agent gel.

8. A method as in claim 6 in which the aluminum alloy contains more than 1% of a metal selected from the group consisting of copper, zirconium, iron, chromium, silicon, magnesium, zinc and titanium.