This invention relates to a magnetic resonator system for Furnaces & Kilns which proposes an overall improvement in specific fuel consumption by correlating the fuel flow dynamics inside the fuel conduit, magnetic remanence and magnetic coercivity, achieved by positioning of high intensity magnetic material for exposing hydro carbon based fuels and polarizing the hydrocarbon clusters, for obtaining enhanced combustion and reduced emissions for Furnaces and Kilns.
The composite technology mechanism consists in using magnetic material to enhance combustion by studying the flow dynamics of various fuel types and correlating it with improvisations made for industrial processes. The variants in the composite technology mechanism can be scaled and migrated using mass customization principles. The furnaces to which this invention would be applicable would include, but not confined to, furnaces used in refineries, Chemical process plants, Forging: Auto motive components and specialized large size forgings, Heat Treatment: Auto motive components, bi-cycles and other large size heat treatment, Steel re-rolling Mills: making TMT rods, Bars, sheets and so on. Alloy steels: The alloy steels and products such as alloy balls for crushers, Ceramics and abrasives: ceramic tiles and Industrial ceramics; Industrial abrasives, for polarizing the hydrocarbon fuel such as Natural gas, Naphtha, Fuel gas, HFO, HSD, LDO, SKO, by the use of magnetic fields.
The concept of process value analysis was used to identify the value added and non-value added activities pertaining to, this invention.
It has been observed that under practical plant conditions, some of the procedures followed are:
□ Managing Load pattern
□ Maintaining the equipment
□ Capacity utilization
□ Treatment of fuel
The plant manager can control most of the first three, however fuel ability to produce the required output depends upon the hydrocarbon fuel itself and this parameter cannot be controlled at the plant level.
Around 60% -70% of the manufacturing companies involved use hydrocarbon fuel. Furnaces of different ratings are used depending upon the process requirements and fuels used are predominantly Naphtha, Fuel Gas, NG, LSHS, HFO for very large capacity furnaces and HSD, SKO for smaller and medium capacity furnaces.
This invention is based on polarization of Hydrocarbon fuels in liquid or gaseous form to increase the fuel burning efficiency by subjecting the said fuel flowing in containment vessels or conduits to a shaped uniform magnetic field having consistent directional flux. It is known that Hydrocarbon fuels have long branched geometric chains of carbon atoms which have the tendency to fold over on to themselves and on adjoining molecules due to intermolecular electromagnetic attraction existing between like molecules or atoms, which is known as Vander Walls forces.
Though the technology of manufacturing companies is diverse, the operational challenges of most of them are alike, such as, the maximization of the capacity utilization at the best overall plant efficiency. The scenario analysis leads to the conclusion that product pricing is competitive and rework on the rejects or complete or total rejects would generate the production loss and increase the process cycle time.
Escalating fuel bills have been a significant concern since the crude price hike has been a phenomenon worldwide. Process value analysis gives us an insight into the hydrocarbon fuel being the major cost driver and its impact on process cost is significant.
Process redesign such as switching of the fuel at the macro level would be a burden in terms of incurred capital costs of the project and its payback. The demand certainty and obsolescence of the technology are risks for long-term perspectives. A small percentage improvement in plant efficiency would lead to large absolute savings, which means incremental percentage savings in fuel would lead to large absolute savings in the hydro carbon fuel.
This invention proposes improvisation of combustion of the utility such as Naphtha/FG/HSD/HFO/LSHS/NG Fired furnaces. The invention can be mass customized for gaseous and liquid fuel types. A small percentage of improvement in SFC of the furnaces will save a large amount of fuel in absolute terms.
An improvement in the combustion efficiency, would improve the overall efficiency of the furnace. There are significantly three or four types of fuel used in furnaces such as HFO, LSHS, NG, FG and Naphtha. For all of them the phenomenon of combustion is common. Combustion in simplistic term is mixture of air and fuel-taking place at the burner tips guided by certain ratios, depending upon the type of fuel, capacity of the furnace and type of the burner.
According to the invention proposed herein, the magnetic resonator system for a furnace comprises attractive and repulsive pairs of magnets, alternately disposed, and surrounding the hydrocarbon fuel carrying conduit of the said furnace, to expose the said fuel flowing through the conduit to a high intensity magnetic field and polarize, and then de- cluster, the same thereby causing secondary atomization of polarized fuel to take place in the said furnace to make the polarized fuel readily react with air.
It is the magnetic material having very high remanance and coercive force. There are two types of magnetic materials one Neodymium (two halves attracting) and the other strontium ferrite, (two halves repulsive). Depending upon the viscosity, specific gravity of the fuel and kinetic velocity of the fuel inside the fuel conduit, we choose a mixture of two types or single type only. For furnaces fired by HFO, HSD, AND SKO, where in the mass flow rate is 15 KG/HR -30 KG/HR per furnace consisting of single burner, one number double resonance type is used.
Double resonance type (repulsive pair), magnetic memory type (attractive pair), the said resonators being spaced from each other and arranged alternately one after another in series, for higher mass flow rate of the fuel in the fuel conduit, say greater than 30 Kg/hr such as magnetic memory type and double resonance type on the metallic fuel conduit, the magnetic resonators being placed at distances of 1 inch form each other and arranged alternately one after another in series such as magnetic memory type and double resonance type on the metallic fuel conduit, about 1 inch from the flexible metallic hose
This proposed invention will now be described with reference to the accompanying drawings which illustrate, by way of example, and not by way of limitation, in
Fig. 1A a double resonance type magnetic resonator (repulsive pair) Fig. 1B magnet of a repulsive pair
Fig. 2A a magnetic memory type Magnetic resonator (attractive pair) Fig. 2B magnet of an attractive pair
Fig. 1A double resonance type magnetic resonator (Repulsive Pair) K2 consists of two halves having a sintered ferrite magnetic composition and housed in a polypropylene case G2 of Length x Breadth x Height is 80 MM x 26 MM x 20 MM as in Fig 1 A. The dimensions of the magnets are 76 MM (L) x 25 MM (W) x 13 MM (H) as shown in Fig 1B.
The like poles (south pole - south pole) of the repulsive pair act on the intermolecular forces or Vander Waals Forces, specifically on the induced dipole interactions formed due to time fluctuating dipoles of the nonpolar molecular clusters, becoming prominent due to high mass flow rate of the fuel inside the conduit. It polarizes the hydro carbon fuel by fragmenting or acting upon the weak intermolecular forces with a magnetic material characteristic of Br 4.0 K Gauss, intrinsic Coercive force 3.9 Koe, BH Max energy 27-32 KJ/M3. Thus it facilitates the interactions between the electron and nuclear spins of fuel clusters, which is double resonance effect.
Fig. 2A a magnetic memory type resonator (Attractive Pair): An attractive pair (K1) of unlike poles (North Pole - South Pole) magnetic material of NdFeB having very high magnetic strength Br 14.5 K Gauss Max energy product 382-406 KJ/M3, Intrinsic coercive force 14.0 Koe, It is used for its higher coercive force. It is placed adjacent to the double resonance type and it is enclosed in the polypropylene case G1 consisting of two halves of Length x Breadth x Height- 33MM x 18MM x26MM, as shown Fig 2A. The magnet of an attractive pair is preferably of size 25.5MM (L) x 9.5 MM (W) x 9.5 MM (H) is enclosed in the said polypropylene case, as shown in fig 2B.lt has higher remanence than the double resonance type, and it helps to retain the polarization of the hydrocarbon fuel through magnetic induction of the already charged or polarized fuel cluster and this occurs after the fuel has passed through the double resonance magnetic repulsive pair. It retains the polarization effect and therefore it is a magnetic memory effect.
Figure 3A shows repulsive pairs of magnets K2, housed in the polypropylene cases G2, are disposed, as surrounding the metallic fuel conduit F of the said furnace fired by HFO, about 1 inch from the flexible metallic hose R; to expose the fuel flowing through the conduit to a high intensity magnetic field and polarize the fuel, and then de-cluster the same. Thus secondary atomization of polarized fuel takes place in the said furnace to make the polarized fuel readily react with air.
Each pair of magnets consists of two opposite halves fixed to the conduit F close to the burner manifold of the said furnace. Fixing of the two opposite halves to the conduit is carried out by clamp type of mounting S.
The number of pairs of magnets are predetermined by the length and circumference of the fuel conduit F and proximity to the burner manifold M outside the said furnace shell, mass flow rate of fuel in the conduit, and the type of fuel (liquid or gaseous).
Figure 3B shows repulsive pairs of magnets K2, housed in the
polypropylene cases G2, are disposed, as surrounding the metallic fuel
conduit F of the said furnace fired by HSD, about 1 inch from the flexible
metallic hose R; to expose the fuel flowing through the conduit to a high
intensity magnetic field and polarize the fuel, and then de-cluster the
same. Thus secondary atomization of polarized fuel takes place in the
said furnace to make the polarized fuel readily react with air.
Each pair of magnets consists of two opposite halves fixed to the conduit
F close to the burner manifold of the said furnace.
Fixing of the two opposite halves to the conduit is carried out by clamp
type of mounting S.
The number of pairs of magnets are predetermined by the length and circumference of the fuel conduit F proximity to the burner manifold M outside the boiler shell, mass flow rate of fuel in the conduit, and the type of fuel (liquid or gaseous).
Figure 3C shows repulsive pairs of magnets K2, housed in the polypropylene cases G2, are disposed, as surrounding the metallic fuel conduit F of the said furnace fired by SKO, about 1 inch from the flexible metallic hose R; to expose the fuel flowing through the conduit to a high intensity magnetic field and polarize the fuel, and then de-cluster the same. Thus secondary atomization of polarized fuel takes place in the said furnace to make the polarized fuel readily react with air.
Each pair of magnets consists of two opposite halves fixed to the conduit F close to the burner manifold of the said furnace. Fixing of the two opposite halves to the conduit is carried out by clamp type of mounting S.
The number of pairs of magnets are predetermined by the length and circumference of the fuel conduit F proximity to the burner manifold M outside the boiler shell, mass flow rate of fuel in the conduit, and the type of fuel (liquid or gaseous). This polarization method of hydro carbon is based on the cycle: Polarization - Alignment - Action of LORENTZ Force - De-clustering and this cycle continues until the polarized fuel reaches the point of combustion. This cycle also retains the polarization effect.

I Claim:
1. A magnetic resonator system for a furnace comprising at least one of two types of magnetic resonators for being installed on the individual fuel conduits carrying fuel, such as, naphtha, furnace oil, HSD, SKO or natural gas, to the burners of the said furnace, namely,(1) for the HFO fuel type furnace, HSD type furnace and SKO type furnace: double resonance type (repulsive pair), magnetic memory type (attractive pair), the said resonators being spaced from each other and arranged alternately one after another in series, for higher mass flow rate of the fuel in the fuel conduit, say greater than 30 Kg/hr such as magnetic memory type and double resonance type on the metallic fuel conduit, the magnetic resonators being placed at distances of 1 inch form each other and arranged alternately one after another in series such as magnetic memory type and double resonance type on the metallic fuel conduit, about 1 inch from the flexible metallic hose; next, for lower fuel mass flow rate in the fuel conduit, say less than 30Kg/hr, only a pair of double resonance type mounted on the fuel conduit closer to the burner manifold outside the furnace shell, about 1 inch from the flexible metallic hose.
2 A magnetic resonator system as claimed in Claim 1 wherein the hydrocarbon fuel is selected from gaseous and liquid fuel, such as, natural gas, fuel gas, heavy furnace oil, diesel, naphtha. 3. A magnetic resonator system as claimed in Claim 1 or Claim 2 wherein each pair of magnets consists of two opposite halves fixed to the fuel conduit on either side thereof, close to the burner manifold of the said furnace.
4. A magnetic resonator system as claimed in Claim 3 wherein the two opposite halves are fixed to the fuel conduit on either side thereof by clamp type of mounting.
5. A magnetic resonator system as claimed in Claim 3 wherein the two opposite halves are fixed to the fuel conduit on either side thereof by chain type of mounting.
6. A magnetic resonator system as claimed in any one of the preceding Claims wherein the attractive pair of magnets is mounted closer to the burner manifold outside the furnace shell than the repulsive pair of magnets.
7. A magnetic resonator system as claimed in any one of the preceding Claims wherein the number of pairs of magnets, either of types of magnetic resonators, are predetermined by the length and circumference of the fuel conduit; proximity to the combustion chamber; mass flow rate of fuel in the conduit; and the type of fuel (liquid or gaseous).
8. A magnetic resonator system as claimed in any one of the preceding Claims wherein the pairs of magnets are enclosed in a polypropylene case.
9. A magnetic resonator system as claimed in any one of the preceding Claims wherein a magnet of an attractive pair is of size 25.5MM (L)x 9.5 MM (W) x 9.5 MM (H); and a magnet of a repulsive pair is of size 76 MM (L) x 25 MM (W) x 13 MM (H).
10. A magnetic resonator system as claimed in any one of the preceding Claims wherein a magnet of an attractive pair is made of neodymium alloy NDFEB of grade N50 M, sintered, Br 14.5 K Gauss Max energy product 382-406 KJ/M3, Intrinsic coercive force 14.0Koe; and a magnet of a repulsive pair is made from ceramic ferrite material of grade Y30 H-2, Br 4.0 K Gauss, intrinsic coercive force 3.9 KOe, BH Max energy 27-32 KJ/M3.