Note: Descriptions are shown in the official language in which they were submitted.
CA 03047961 2019-06-20
[DESCRIPTION]
[Invention Title]
SMOKE TUBE BOILER
[Technical Field]
The present invention relates to a smoke tube boiler, and more specifically,
to a smoke
tube boiler having a structure which can prevent leakage of a mixed gas and an
exhaust gas,
thermal damage of an ignition bar assembly, and corrosion due to stagnation of
condensate,
and reliably block leakage of the condensate, in coupling the ignition bar
assembly through
one side portion of a mix chamber including a flat plate type burner.
[Background Art]
Generally, a boiler includes a heat exchanger in which heat exchange between a
combustion gas by the combustion of fuel and a heat medium is performed to
perform heating
or supply warm water using the heated heat medium. Such a boiler can include a
heat
exchanging part in which the heat exchanger is provided, a burner assembled on
the heat
exchanging part, and a combustion chamber provided between the burner and the
heat
exchanger and into which a combustion gas and air are supplied to perform
combustion.
FIG. 1 is a view schematically illustrating a configuration of a conventional
smoke
tube boiler.
The conventional smoke tube boiler includes a blower 10 configured to supply a
combustion gas and air, a cylindrical burner 20 configured to combust a mixed
air of the
combustion gas and the air, a combustion chamber 30 in which the mixed air is
combusted by
the burner 20, a heat exchanger 40 in which heat exchange between the
combustion gas
generated from the combustion chamber 30 and a heat medium is performed, an
insulation
1
CA 03047961 2019-06-20
material 50 configured to prevent the transfer of heat generated from the
combustion chamber
30 to an upper side near the cylindrical burner 20, and an ignition bar 60
installed through the
insulation material 50 and configured to ignite the mixed air.
The heat exchanger 40 can include an outer cylinder 41, a plurality of tubes
42
provided therein and through which the combustion gas generated from the
combustion
chamber 30 passes, and a water tank 43 in which the heat medium is
accommodated outside of
the tubes 42.
According to the configuration of the conventional smoke tube boiler, since
the
cylindrical burner 20 is provided having a vertically long shape, the overall
height of the
boiler is greatly increased such that the boiler cannot be compactly
manufactured.
Accordingly, there is a problem that an installation space is limited.
Further, in the conventional smoke tube boiler, when the ignition bar 60 is
installed
through a combustion chamber cover 12 installed between the blower 10 and the
cylindrical
burner 20, the insulation material 50 is applied to prevent thermal conduction
to the ignition
bar 60.
However, the insulation material 50 is cracked due to heat during combustion
or
broken into small grain shapes to cause problems such as blocking the tubes 42
which are
paths for the combustion gas of the heat exchanger 40, and when the combustion
chamber
cover 12 and a mix chamber 11 including the cylindrical burner 20 are
disassembled for
maintenance, damage to the insulation material 50 is inevitable.
Meanwhile, when the ignition bar 60 is installed at the heat exchanger 40, the
manufacturing process is increased due to the addition of unnecessary
processes and
components, and there is a risk of leakage of the heat medium..
2
CA 03047961 2019-06-20
As described above, a prior art related to a structure for assembling the
ignition bar on
the combustion chamber cover is disclosed in Registered Patent No. 10-0575187
and
Registered Patent No. 10-0581580.
Further, when a flat plate type burner having greater combustion performance
in
comparison with the cylindrical burner 20 is applied, a heat exchanger is
coupled to one side
of a mix chamber to which the flat plate type burner is coupled and a
combustion chamber is
foimed between the mix chamber and the heat exchanger. In this case, when an
ignition bar
assembly is coupled to the mix chamber by passing through one side portion, an
unburned
mixed gas can leak to the outside through a gap between the mix chamber and
the ignition bar
assembly. When such a unburned mixed gas (raw gas) leaks to the outside, there
is a
problem that it brings about a lethal threat to the human body.
When a sealing means configured to prevent leakage of the above-described
mixed gas
is installed, since high-temperature heat from the combustion chamber is
transferred to the
sealing means and thus the sealing means can be easily broken due to
deterioration, there is a
problem that it is difficult to install the sealing means while preventing
breakage due to the
deterioration.
Meanwhile, in a smoke tube heat exchanger disclosed in European Laid-Open
Patent
EP 2508834 and European Laid-Open Patent EP 2437022, an outer cylinder for
providing a
water tank in which a heat medium is accommodated is provided at the outside
of a tube. An
upper pipe plate forming an upper surface of the water tank and supporting an
upper end
portion of the outer cylinder is coupled to an upper end portion of the tube
and a lower pipe
plate forming a bottom surface of the water tank and supporting a lower end
portion of the
outer cylinder is coupled to a lower end portion of the tube.
3
CA 03047961 2019-06-20
In the case of the above-described smoke tube heat exchanger, since the heat
medium
accommodated in the water tank applies a high water pressure to the lower pipe
plate, the
lower pipe plate requires water pressure resistance against the high water
pressure to maintain
durability.
However, the lower pipe plate provided in the conventional smoke tube heat
exchanger
has a configuration inadequate to disperse water pressure and thus has weak
durability.
Further, the conventional smoke tube boiler is formed in a structure provided
with a
condensate collector under the lower pipe plate and a sealing member
configured to prevent
leakage of condensate between an edge portion of the lower pipe plate and an
edge portion of
the condensate collector, and the sealing member is configured to support a
lower end portion
of a side surface portion of the lower pipe plate.
However, according to a coupling structure of the sealing member between the
lower
pipe plate and the condensate collector, the condensate generated from the
smoke tube heat
exchanger stagnates between the lower end portion of the side surface portion
of the lower
pipe plate and the sealing member to cause corrosion of the lower pipe plate,
and when the
sealing member is configured in a generally disclosed shape, the leakage of
the condensate
cannot be reliably blocked. A prior art related to a sealing structure of the
conventional
condensate collector is disclosed in Korean Laid-Open Patent No. 10-2005-
0036152 and the
like.
[Disclosure]
[Technical Problem]
4
The present invention is directed to providing a smoke tube boiler capable of
preventing
leakage of a mixed gas and an exhaust gas through a gap between a mix chamber
and an ignition
bar assembly.
Also, the present invention is directed to providing a smoke tube boiler
including a
cooling means configured to significantly decrease the size of an insulation
material to prevent
blockage of a flow path due to damage of the insulation material and
configured to block heat
transfer to an ignition bar assembly or an ignition bar sealing means near the
ignition bar
assembly when installing the ignition bar assembly through a mix chamber.
Also, the present invention is directed to providing a smoke tube boiler
having a structure
capable of improving the water pressure resistance of a lower pipe plate,
preventing corrosion
due to stagnation of condensate in the lower pipe plate, and reliably blocking
leakage of the
condensate.
Also, the present invention is directed to providing a smoke tube boiler
having a
decreased height and capable of improving heat exchange efficiency in
comparison with a
conventional boiler.
[ Technical Solution]
In one aspect, the present invention provides a smoke tube boiler comprising:
a mix
chamber disposed on a combustion chamber and having a mixing space in which a
combustion
gas and air are mixed, and a flat plate type burner positioned over the entire
area of the mixing
space; an ignition bar assembly configured to pass through one side portion of
the mix chamber
at a position spaced apart from one side of the flat plate type burner and
extend in a downward
direction from the flat plate type burner transversely across an upper portion
of the combustion
5
Date Recue/Date Received 2021-11-16
chamber; a sealing means provided at a position spaced apart from the one side
of the flat plate
type burner to block leakage of a mixed gas of the mixing space and an exhaust
gas of the
combustion chamber to the outside through a gap between the mix chamber and
the ignition bar
assembly; and a cooling means configured to block transfer of the combustion
heat generated
from the combustion chamber to the sealing means.
The present disclosure relates to a smoke tube boiler including: a mix chamber
having a
mixing space in which a combustion gas and air are mixed and a flat plate type
burner and
disposed on a combustion chamber; an ignition bar assembly configured to pass
through one side
portion of the mix chamber to be assembled and extend in a downward direction
from the flat
plate type burner across an upper portion of the combustion chamber; and a
sealing means
configured to block leakage of a mixed gas of the mixing space and an
5a
Date Recue/Date Received 2022-05-13
CA 03047961 2019-06-20
exhaust gas of the combustion chamber to the outside through a gap between the
mix chamber
and the ignition bar assembly.
A mix chamber flange and a burner flange may be provided at the one side
portion of
the mix chamber to meet each other to seal the mixing space, and the ignition
bar assembly
may pass through the mix chamber flange and the burner flange at a location
spaced apart
from the mixing space to be assembled.
The sealing means may include a first sealing member provided at a portion in
which
the mix chamber flange and the burner flange meet each other to prevent
leakage of the mixed
gas.
An insulation material configured to block transfer of combustion heat
generated from
the combustion chamber may be provided on the first sealing member. The size
of the
insulation material may be significantly decreased unlike a conventional art.
A coupling plate through which the ignition bar assembly passes to be coupled
thereto
may be provided on the one side portion of the mix chamber, and the sealing
means may
include a second sealing member provided between an upper portion of the one
side portion of
the mix chamber and the coupling plate to prevent leakage of the exhaust gas.
A plurality of contact protrusions formed to protrude to the outside may be
formed at
predetermined intervals on an outer side surface of the second sealing member.
The ignition bar assembly may include an ignition bar and a flame sensing bar,
an
ignition bar coupling plate through which the ignition bar passes to be
coupled thereto and a
flame sensing bar coupling plate through which the flame sensing bar passes to
be coupled
thereto may be provided on the one side portion of the mix chamber, and the
sealing means
may be provided between the upper portion of the one side portion of the mix
chamber and the
6
CA 03047961 2019-06-20
ignition bar coupling plate and between the upper portion of the one side
portion of the mix
chamber and the flame sensing bar coupling plate.
The smoke tube boiler may further include a cooling means configured to block
transfer of the combustion heat generated from the combustion chamber (C) to
the sealing
means.
The cooling means may include an air cooling type cooling means and a water
cooling
type cooling means.
The mix chamber flange and the burner flange may be provided at the one side
portion
of the mix chamber to meet each other to seal the mixing space, the ignition
bar assembly may
pass through the mix chamber flange and the burner flange to be assembled, and
the mix
chamber flange and the burner flange may be cooled by the mixed gas introduced
into the
mixing space in the air cooling type cooling means.
The mix chamber flange and the burner flange may be provided at the one side
portion
of the mix chamber to meet each other to seal the mixing space, the ignition
bar assembly may
pass through the mix chamber flange and the burner flange to be assembled, and
an upper pipe
plate flange configured to come into contact with a heat medium of a heat
exchanger provided
under the combustion chamber may be provided to come into contact with the
burner flange to
cool the burner flange in the water cooling type cooling means.
A plurality of radiating fins may be provided on the one side portion of the
mix
chamber at which the ignition bar assembly is assembled along an edge of the
ignition bar
assembly.
The smoke tube boiler may include an outer cylinder provided at an edge of a
tube
through which the combustion gas passes the inside thereof to form an outer
wall of a water
7
CA 03047961 2019-06-20
tank in which the heat medium is accommodated at the outside of the tube, and
a lower pipe
plate having an end plate structure and formed of a horizontal portion
configured to support a
lower end portion of the tube and form a bottom surface of the water tank, a
vertical portion
coupled to an outer side surface of a lower end portion of the outer cylinder,
and a round
portion configured to connect an outer end of the horizontal portion and a
lower end portion of
the vertical portion and formed in an outwardly convexly curved shape to
disperse a water
pressure of the heat medium.
The vertical portion of the lower pipe plate may be fit-coupled to the outer
side surface
of the lower end portion of the outer cylinder.
A flange part configured to extend in an outward direction by a predetellnined
length
may be formed on the vertical portion of the lower pipe plate, and the flange
part and the outer
side surface of the outer cylinder may be coupled to each other by welding.
The smoke tube boiler may include a condensate collector provided under the
lower
pipe plate to collect condensate generated from the lower pipe plate and a
leakage prevention
member provided between an edge portion of the lower pipe plate and an edge
portion of the
condensate collector to prevent leakage of the condensate.
The leakage prevention member may be provided in a shape which surrounds a
lower
portion of each of the round portion and the vertical portion of the lower
pipe plate, and the
condensate foimed on the horizontal portion of the lower pipe plate may be
blocked from
moving in a lateral direction by a blockage of the leakage prevention member
and may drop in
a downward direction.
8
CA 03047961 2019-06-20
A sidewall of the condensate collector may be provided to be located near a
boundary
between the horizontal portion and the round portion of the lower pipe plate
to guide dropping
of the condensate.
A contact protrusion configured to protrude toward an outer side surface of
the lower
pipe plate may be formed on an inner side surface of the leakage prevention
member.
A plurality of contact protrusions may be founed at locations vertically
spaced apart
from the inner side surface of the leakage prevention member.
A first flange part configured to extend in an outward direction from an upper
end of
the sidewall of the condensate collector to support a lower portion of the
leakage prevention
member may be provided at the edge portion of the condensate collector, and a
fastening
protrusion and a fastening groove fastened to each other at corresponding
locations may be
provided at the leakage prevention member and the first flange part.
The smoke tube boiler may further include an extending portion configured to
extend
in an upward direction from an outer end of the first flange part and come
into close contact
with an outer side surface of the leakage prevention member and a second
flange part
configured to extend in an outward direction from an end of the extending
portion at the edge
portion of the condensate collector, wherein a fitting protrusion and a
fitting groove fitted to
each other at corresponding locations may be formed on an upper portion of the
leakage
prevention member and the second flange part to block the leakage of the
condensate and fix a
location of the leakage prevention member.
An exhaust guide, having a plurality of punched holes formed therein so that
the
combustion gas which passes through the heat exchanger is uniformly
distributed to the entire
area of the condensate collector to be discharged, may be provided in the
condensate collector.
9
CA 03047961 2019-06-20
A stair part configured to guide a flow of the combustion gas which passes
through the
exhaust guide to the condensate drain port may be formed on a bottom surface
of the
condensate collector so that a drainage direction of the condensate and a flow
direction of the
combustion gas may be the same in the condensate collector.
The mix chamber may include a flat-shaped mix chamber body and the flat plate
type
burner disposed on the combustion chamber in a horizontal direction.
A separation space between a lower surface of the mix chamber body and an
upper
surface the flat plate type burner may be formed in a flat disc shape.
The smoke tube boiler may further include a heat exchanger in which heat
exchange
between combustion heat of the combustion chamber and the heat medium is
performed,
wherein the heat exchanger may include an outer cylinder through which the
heat medium is
introduced and discharged and forming the outer wall of the water tank in
which the heat
medium is accommodated, an upper pipe plate having an end plate structure
coupled to an
inner side of the outer cylinder and forming the combustion chamber so that a
heat medium
path is formed between the upper pipe plate and the outer cylinder, a
plurality of tubes each
formed in a flat shape so that the combustion gas generated from the
combustion chamber is
heat-exchanged with the heat medium which flows through the outside while
flowing along
the insides of the tubes, a turbulator coupled to inner sides of the tubes to
induce generation of
turbulence in a flow of the combustion gas, a multilayer diaphragm provided
between the
outer cylinder and the tube to guide the heat medium so that a flow direction
of the heat
medium is alternately switched inward and outward in a radial direction, and a
lower pipe
plate having an end plate structure configured to support lower end portions
of the tubes and
form a bottom surface of the water tank.
CA 03047961 2019-06-20
A flange of the upper pipe plate may be formed to protrude from an upper end
of the
round portion to the outside, and a ratio of a diameter difference between an
outer diameter of
the flange of the upper pipe plate and an inner diameter of a lower end of the
round portion
may be smaller than or equal to 20%.
A height between a lower surface of the flat plate type burner inserted into
the upper
pipe plate and a bottom surface of the upper pipe plate may be set so that a
tip of a flame
generated from the flat plate type burner may be spaced apart from the bottom
surface of the
upper pipe plate by a predetermined distance, preferably, by a height of about
80 mm.
The turbulator may include an upper turbulator coupled to an inner side of an
upper
portion of the tube adjacent to the combustion chamber to come into surface
contact with the
tube to increase heat conductivity and induce generation of the turbulence in
the flow of the
combustion gas, and a lower turbulator coupled to an inner side of the tube in
a downward
direction from the upper turbulator to induce generation of the turbulence in
the flow of the
combustion gas.
[Advantageous Effects]
In a smoke tube boiler according to the present invention, when an ignition
bar
assembly is installed through one side portion of a mix chamber to apply a
flat plate type
burner which is easy to manufacture and has greater productivity in comparison
with a
cylindrical burner, leakage of a mixed gas and an exhaust gas can be
prevented.
Further, when the flat plate type burner having a combustion area foimed to be
greater
than that of the cylindrical burner is used, a cooling structure for the
ignition bar assembly
coupled through one side portion of the mix chamber is advantageous due to a
gas and air
11
CA 03047961 2019-06-20
introduced into the combustion area, and durability can be improved by
preventing damage
due to deterioration.
In addition, since a lower pipe plate is configured to surround an outer side
surface of
an outer cylinder and a convexly curved round portion is formed at a corner
configured to
connect a horizontal portion and a vertical portion of the lower pipe plate to
disperse a water
pressure of a heat medium, the durability can be improved by improving water
pressure
resistance of the lower pipe plate to minimize defolination.
In addition, since the lower pipe plate of the smoke tube heat exchanger is
configured
to surround the outer side surface of the outer cylinder, a leakage prevention
member is
configured in a shape which surrounds a lower portion of the vertical portion
of the lower pipe
plate and the round portion, and a sidewall of a condensate collector is
disposed to be located
near a boundary between the horizontal portion and the round portion of the
lower pipe plate
to guide the dropping of condensate, the occurrence of corrosion due to
stagnation of the
condensate can be prevented.
In addition, since contact protrusions configured to protrude in a direction
toward an
outer side surface of the lower pipe plate are fonned on an inner side surface
of the leakage
prevention member, the contact protrusion of the leakage prevention member
configured to
protrude in a direction opposite to a direction in which a water pressure acts
comes into
contact with the outer side surface of the lower pipe plate to prevent leakage
of the condensate
when the water pressure is applied. In addition, when a plurality of contact
protrusions are
formed at locations vertically spaced apart from each other, the leakage of
the condensate can
be more reliably prevented.
12
CA 03047961 2019-06-20
In addition, since a flat-shaped mix chamber body and the flat plate type
burner are
provided, an upper pipe plate formed in an end plate structure is lowered to a
minimum height
at which mixed air is completely combusted and the heat exchange efficiency of
the heat
exchanger is improved, the height of the boiler can be lowered in comparison
with a
conventional boiler such that a smoke tube boiler having high efficiency and a
compact size
can be provided.
[Description of Drawings
FIG. 1 is a view schematically illustrating a configuration of a conventional
smoke
tube boiler.
FIG. 2 is a perspective view of an exterior of a smoke tube boiler according
to an
embodiment of the present invention.
FIG. 3 is a perspective view of a lower surface of a mix chamber shown in FIG.
2.
FIG. 4 is an exploded perspective view illustrating a structure in which an
ignition bar
assembly is coupled to the mix chamber.
FIG. 5 is an enlarged perspective view of an ignition bar assembly coupling
part.
FIG. 6 is a front view of FIG. 2.
FIG. 7 is a partial cross-sectional perspective view taken along line A-A in
FIG. 6.
FIG. 8 is a partial enlarged cross-sectional view taken along line A-A in FIG.
6.
FIG. 9 is a partial perspective view of a portion of a boiler having a smoke
tube heat
.. exchanger according to the embodiment of the present invention.
FIG. 10 is an exploded perspective view of a main portion of the boiler having
the
smoke tube heat exchanger according to the embodiment of the present
invention.
13
CA 03047961 2019-06-20
FIG. 11A is a plan view of a leakage prevention member, and FIG. 11B shows a
cross-
sectional view and an enlarged view taken along line B-B in FIG. 11A.
FIG. 12 is a cross-sectional view of part A in FIG. I.
FIG. 13 is a perspective view of an exterior of a smoke tube boiler according
to
another embodiment of the present invention.
FIG. 14 is a perspective view of a mix chamber.
FIG. 15 is a perspective view of a lower surface of the mix chamber.
FIG. 16 is an exploded perspective view illustrating a structure in which an
ignition
bar and a flame sensing bar are coupled to the mix chamber.
FIG. 17 is a plan view of the mix chamber and a heat exchanger.
FIG. 18 is a partial cross-sectional perspective view taken along line C-C in
FIG. 17.
FIG. 19 is a partial cross-sectional view taken along line C-C in FIG. 17.
FIG. 20 is a cross-sectional view illustrating a coupling structure between an
upper
pipe plate and a burner.
FIG. 21 is a perspective view of the heat exchanger.
FIG. 22 is an exploded perspective view of the heat exchanger.
FIG. 23 is a front view of a state in which a tube assembly and a multilayer
diaphragm
are coupled to each other.
FIG. 24A is a plan view of FIG. 23, FIG. 24B is a cross-sectional view taken
along
line D-D in FIG. 23, and FIG. 24C is a cross-sectional view taken along line E-
E in FIG. 23.
FIG. 25 is a plan view of the heat exchanger.
FIG. 26 is a cross-sectional perspective view taken along line F-F in FIG. 25.
FIG. 27 is a perspective view illustrating an embodiment of the tube assembly.
14
CA 03047961 2019-06-20
FIG. 28 is an exploded perspective view of the tube assembly.
FIG. 29 is a front view of an upper turbulator and a lower turbulator.
FIG. 30 is an enlarged perspective view of the upper turbulator shown in FIG.
29.
FIG. 31 is a plan view of FIG. 30.
FIG. 32A is a cross-sectional view taken along line G-G in FIG. 31 and FIG.
32B is a
cross-sectional perspective view taken along line G-G in FIG. 31.
FIG. 33 is a left side view of FIG. 30.
FIG. 34 is a perspective view of the smoke tube boiler according to another
embodiment of the present invention.
FIG. 35 is an exploded perspective view of the smoke tube boiler according to
another
embodiment of the present invention.
FIG. 36 A is a plan view of a leakage prevention member, and FIG. 36B shows a
cross-sectional view and an enlarged view taken along line H-H in FIG. 36A.
FIG. 37 is a cross-sectional view illustrating a sealing structure and a
condensate
draining structure of the smoke tube boiler according to another embodiment of
the present
invention.
[Reference numerals]
10: blower 11: mix chamber
12: combustion chamber cover 20: cylindrical burner
30: combustion chamber 40: heat exchanger
41: outer cylinder 42: tube
43: water tank 50: insulation material
60: ignition bar 1,1': smoke tube boilers
CA 03047961 2019-06-20
100: mix chamber 110: mixed air introduction port
120: mix chamber flange 130: flat plate type burner
131: flame hole plate 131a: flame hole
132: metal fiber 133: burner flange
140: ignition bar assembly 141: first ignition bar
142: second ignition bar 143: flame sensing bar
141a,142a,143a: insulators 141b,142b,143b: bushings
144: coupling plate 144a,144b,144c: coupling holes
150: ignition bar assembly coupling part 151: coupling plate seating part
152: second sealing member seating part 153: through port
154: radiating fin 160: first sealing member
170: insulation material 180: second sealing member
181: contact protrusion 190: sealing member
200: heat exchanger 210: outer cylinder
220: upper pipe plate 221: tube insertion hole
222: upper pipe plate flange 230: tube
240: water tank 300: condensate collector
400: air discharge duct 500: leakage prevention member
510: body 510a: inner side surface of leakage prevention member
520,521,522,523,524: contact protrusions
530: lower portion of leakage prevention member
531: fastening groove 540: upper portion of leakage prevention member
541: fitting protrusion 1000: mix chamber
16
CA 03047961 2019-06-20
1100: mix chamber body 1110: mix chamber flange
1200: mixed air introduction port 1300: flat plate type burner
1310: flame hole plate 1330: burner flange
1400: ignition bar assembly 1410: ignition bar
1420: flame sensing bar 1500: ignition bar assembly coupling part
1600: first sealing member 1700: second sealing member
1800: third sealing member 1900: sealing member
2000: heat exchanger 2100: outer cylinder
2110: heat medium introduction port 2120: heat medium discharge port
2200: upper pipe plate 2240: round portion
2300: tube 10000: tube assembly
2400: upper turbulator 2500: lower turbulator
2610: upper diaphragm 2620: middle diaphragm
2630: lower diaphragm 2640: supporter
2700: lower pipe plate 3000: condensate collector
3100: condensate drain port 3200: leakage prevention member
3300: exhaust guide 3310: punched hole
4000: air discharge duct 5000: pre-mixing chamber
6000: mixed air adjusting part 7000: blower
[Modes of the Invention]
Hereinafter, the configuration and operation of an embodiment of the present
invention will be described in detail with reference to the accompanying
drawings,
17
CA 03047961 2019-06-20
Referring to FTGS. 2 to 8, a smoke tube boiler 1 according to an embodiment of
the
present invention includes a mix chamber 100 having a mixing space S in which
a combustion
gas and air supplied through a mixed air introduction port 110 connected to a
blower are
mixed and a flat plate type burner 130 configured to burn the mixed air and
disposed on a
.. combustion chamber C, a heat exchanger 200 in which heat exchange between a
heat medium
and the combustion gas is performed, a condensate collector 300 configured to
collect
condensate generated when vapor which passes through the heat exchanger 200
and is
included in the combustion gas is condensed, and an air discharge duct 400
connected to one
side of the condensate collector 300 so that the combustion gas which passes
through the heat
exchanger 200 is discharged.
Further, the smoke tube boiler 1 includes an ignition bar assembly 140
configured to
pass through one side portion of the mix chamber 100 to be assembled and
extend across an
upper portion of the combustion chamber C to a lower side of the flat plate
type burner 130,
and a sealing means configured to block leakage of a mixed gas of the mixing
space S and an
exhaust gas of the combustion chamber C to the outside through a gap between
the mix
chamber 100 and the ignition bar assembly 140.
A burner applied to the present invention is the flat plate type burner 130
and includes
a flame hole plate 131 having a flat plate shape in which plurality of flame
holes 131a are
formed and a metal fiber 132 coupled to the flame hole plate 131. The flat
plate type burner
130 is provided over the entire area of the mixing space S and is thus
advantageous for an air
cooling type structure due to gas and air introduced thereinto, and since a
combustion area is
expanded to decrease load per unit area, the discharge of pollutants such as
CO, NOx, and the
like can be decreased to improve combustion performance.
18
CA 03047961 2019-06-20
The ignition bar assembly 140 passes through one side portion of the mix
chamber
100 to be assembled. The ignition bar assembly 140 may include a first
ignition bar 141, a
second ignition bar 142, and a flame sensing bar 143. Insulators 141a, 142a,
and 143a made
of an insulating material are coupled to outer side surfaces of the first
ignition bar 141, the
second ignition bar 142, and the flame sensing bar 143, respectively, and
bushings 141b, 142b,
and 143b are coupled to outer side surfaces of the insulators 141a, 142a, and
143a.
respectively, to maintain airtightness.
The first ignition bar 141, the second ignition bar 142, and the flame sensing
bar 143
and the insulators 141a, 142a, and 143a and the bushings 141b, 142b, and 143b
coupled to the
outer side surfaces of the first ignition bar 141, the second ignition bar
142, and the flame
sensing bar 143 are coupled to each other by passing through coupling holes
144a, 144b, and
144c formed in a coupling plate 144.
The insulators 141a, 142a. and 143a are insulation means configured to prevent
the
generation of sparks due to energization at the time of ignition, and the
bushings 141b, 142b,
and 143b are configurations for sealing gaps between the outer side surfaces
of the insulators
141a, 142a, and 143a and the coupling holes 144a, 144b, and 144c.
Referring to FIGS. 4 and 5, an ignition bar assembly coupling part 150
configured to
assemble the ignition bar assembly 140 is provided on one side portion of the
mix chamber
100. The ignition bar assembly coupling part 150 includes a coupling plate
seating part 151
folined in a groove shape so that the coupling plate 144 is seated thereon, a
second sealing
member seating part 152 formed inward from the coupling plate seating part 151
so that a
second sealing member 180 is seated thereon, and a through port 153 through
which the first
ignition bar 141, the second ignition bar 142, and the flame sensing bar 143
pass. Further, a
19
CA 03047961 2019-06-20
plurality of radiating fins 154 configured to radiate combustion heat are
provided around the
ignition bar assembly coupling part 150.
Referring to FIGS. 6 to 8, a mix chamber flange 120 and a burner flange 133
connected to an edge portion of the flat plate type burner 130 to support the
edge portion of
the flat plate type burner 130 are provided at one side portion of the mix
chamber 100 to meet
each other to seal the mixing space S, and the ignition bar assembly 140
passes through the
mix chamber flange 120 and the burner flange 133 to be assembled at a location
spaced apart
from the mixing space S.
The sealing means may include a first sealing member 160 provided at a portion
in
which the mix chamber flange 120 and the burner flange 133 meet each other to
prevent
leakage of the mixed gas introduced into the mixing space S to the outside,
and the first
sealing member 160 may be formed of a heat resistant graphite material.
Further, an
insulation material 170 configured to block transfer of the combustion heat
generated from the
combustion chamber C is provided on the first sealing member 160.
In addition, the sealing means may include a second sealing member 180
provided
between an upper portion of one side portion of the mix chamber 100 and the
coupling plate
144 to prevent leakage of the exhaust gas generated from the combustion
chamber C to the
outside, and the second sealing member 180 may be formed of a rubber material.
In addition,
a plurality of contact protrusions 181 formed to protrude to the outside may
be formed at
predeteimined intervals on an outer side surface of the second sealing member
180, and may
come into close contact with a lower surface of the coupling plate 144 and an
upper surface of
the second sealing member seating part 152 to further improve sealability.
CA 03047961 2019-06-20
In addition, as described above, in the ignition bar assembly 140, since the
bushings
141b, 142b, and 143b are coupled to the outer side surfaces of the insulators
141a, 142a, and
143a, respectively, the leakage of the exhaust gas or the mixed gas through
the coupling holes
144a, 144b, and 144c of the coupling plate 144 may be blocked again.
Hereinafter, the configuration and operation of a cooling means configured to
block
the transfer of the combustion heat to the sealing means and radiate the
combustion heat will
be described below with reference to FIGS 7 and 8.
The cooling means is a configuration for blocking the transfer of the
combustion heat
generated from the combustion chamber C to the sealing means configured to
prevent leakage
of the combustion heat through the gap between the mix chamber 100 and the
ignition bar
assembly 140 and may include an air cooling type cooling means and a water
cooling type
cooling means.
As described above, the mix chamber flange 120 and the burner flange 133 may
be
provided at one side portion of the mix chamber 100 to meet each other to seal
the mixing
space S, the ignition bar assembly 140 passes through the mix chamber flange
120 and the
burner flange 133 to be assembled, and the air cooling type cooling means may
be configured
so that the mix chamber flange 120 and the burner flange 133 are cooled in a
convection
manner by the mixed gas introduced into the mixing space S.
Meanwhile, the heat exchanger 200 may include a smoke tube heat exchanger and
may include an outer cylinder 210, an upper pipe plate 220 forming a bottom
surface of the
combustion chamber C and an upper surface of the heat exchanger 200, a
plurality of tubes
230 having upper end portions passing through a tube insertion hole 221 formed
in the upper
pipe plate 220 to be coupled and through which the combustion gas flows by
passing through
21
CA 03047961 2019-06-20
the inside thereof, and a water tank 240 located at outer sides of the tubes
230 and in which
the heat medium is accommodated in the outer cylinder 210. The heat medium may
be
heating water or warm water used for heating or warm water.
In the water cooling type cooling means, since an upper pipe plate flange 222
configured to come into contact with the heat medium of the heat exchanger 200
provided
under the combustion chamber C is provided to come into contact with the
burner flange 133,
the burner flange 133 and the sealing member 190 may be cooled in a conduction
manner.
Further, as described above, a plurality of radiating fins 154 are provided on
one side
portion of the mix chamber 100, to which the ignition bar assembly 140 is
assembled, along
an edge of the ignition bar assembly 140, and the above also serve as a
cooling means.
As described above, according to the present invention, since the sealing
means and
the cooling means are provided when the ignition bar assembly 140 passes
through one side
portion of the mix chamber 100 having the flat plate type burner 130 to be
assembled, the
leakage of the mixed gas and the exhaust gas may be blocked and thermal loss
of the sealing
means due to the combustion heat may be prevented. Further, since the problem
of blockage
of the tube due to an insulation material installed at one side of a lower end
area of a
conventional mix chamber may be prevented, and the insulation material 170 is
used in only a
part of a lower end of the ignition bar assembly 140, use of the insulation
material may be
minimized, the ignition bar assembly 140 may be safely assembled, and the
leakage of the
mixed gas and the exhaust gas due to damage of the sealing means may be
prevented.
Referring to FIGS. 9 to 12, the smoke tube boiler 1 according to the
embodiment of
the present invention further includes a leakage prevention member 500 coupled
to a
22
CA 03047961 2019-06-20
connection portion between the above-described heat exchanger 200 and the
condensate
collector 300 to prevent leakage of the condensate.
Referring to FIG. 9, the heat exchanger 200 includes the outer cylinder 210
through
which the heat medium is introduced and discharged and forming an outer wall
of a water
tank (S, see FIG. 12) in which the heat medium is accommodated, a plurality of
tubes 220
configured to allow the combustion gas generated by ignition of the burner in
the mix
chamber 100 to flow along the inside thereof and to exchange heat with the
heat medium, an
upper pipe plate 230 configured to support upper end portions of the tubes 220
and form an
upper surface of the water tank S, a lower pipe plate 240 configured to
support lower end
portions of the tubes 220 and form a bottom surface of the water tank S, and a
supporting plate
250 coupled to locations vertically spaced apart from outer side surfaces of
the tubes 220 to
fix locations of the tube 220 and having a moving path of the heat medium
formed therein.
Referring to FIG. 10, the lower pipe plate 240 is formed in a shape in which
an upper
portion is open to be coupled while surrounding a lower outer side surface of
the outer
cylinder 210, and includes a horizontal portion 241 having a plurality of tube
insertion holes
241a formed therein through which the lower end portions of the tubes 220 pass
to support the
lower end portions of the tubes 220 and form the bottom surface of the water
tank S, a vertical
portion 242 coupled to the outer side surface of a lower end portion of the
outer cylinder 210,
and a round portion 243 configured to connect an outer end of the horizontal
portion 241 and a
lower end portion of the vertical portion 242 and formed in a shape convexly
curved toward
the outside to disperse the water pressure of the heat medium accommodated in
the water tank
S.
23
CA 03047961 2019-06-20
Referring to FIG. 12, the vertical portion 242 of the lower pipe plate 240 may
be fit-
coupled to the outer side surface of the lower end portion of the outer
cylinder 210, a flange
part 244 configured to extend in an outward direction by a predetermined
length is formed at
an upper end of the vertical portion 242 of the lower pipe plate 240, and the
flange part 244
and the outer side surface of the outer cylinder 210 may be coupled to each
other by welding.
In the heat exchanger 200, since the lower pipe plate 240 is coupled to the
outer
cylinder 210 to surround a lower outer side surface of the outer cylinder 210
and the round
portion 243 having a shape convexly curved toward the outside is formed on a
corner of the
lower pipe plate 240 which connects the horizontal portion 241 and the
vertical portion 242,
the water pressure of the heat medium may be dispersed and thus durability may
be improved
by improving the water pressure resistance of the lower pipe plate 240 to
minimize
deformation of the lower pipe plate 240.
Hereinafter. a coupling structure between the above-described heat exchanger
200,
condensate collector 300, and leakage prevention member 500 will be described
below.
Referring to FIGS. 11 and 12, the leakage prevention member 500 is provided
between an edge portion of the lower pipe plate 240 and an edge portion of the
condensate
collector 300 to prevent the leakage of the condensate. Since a body 510 of
the leakage
prevention member 500 is provided in a shape which surrounds a lower portion
of each of the
round portion 243 and the vertical portion 242 of the lower pipe plate 240,
condensate CW
formed on the horizontal portion 241 of the lower pipe plate 240 may be
blocked from moving
in a lateral direction by a blockage of a lower portion 530 of the body 510
and may drop in a
downward direction.
24
CA 03047961 2019-06-20
A sidewall 310 of the condensate collector 300 may be provided to be located
near a
boundary between the horizontal portion 241 and the round portion 243 of the
lower pipe plate
240 to guide dropping of the condensate.
As described above, since an inner end of the lower portion 530 of the leakage
.. prevention member 500 and the sidewall 310 of the condensate collector 300
are located near
the boundary between the horizontal portion 241 and the round portion 243 of
the lower pipe
plate 240, the condensate CW formed on a lower surface of the horizontal
portion 241 of the
lower pipe plate 240 may be collected in the condensate collector 300 by
flowing in a
downward direction through the inner end of the lower portion 530 of the
leakage prevention
.. member 500 and the sidewall 310 of the condensate collector 300 even while
moving in a
lateral direction, and accordingly, stagnation of the condensate CW and
corrosion of the lower
pipe plate 240 according to the above may be prevented.
Meanwhile, a contact protrusion 520 configured to protrude toward an outer
side
surface of the lower pipe plate 240 may be formed on an inner side surface
510a of the
leakage prevention member 500. A plurality of contact protrusions 521, 522,
523, and 524
may be formed at locations vertically spaced apart from the inner side surface
510a of the
leakage prevention member 500.
According to configurations of the above-described contact protrusions 520,
the
contact protrusions 520 of the leakage prevention member 500 configured to
protrude in a
direction opposite to a direction in which the water pressure acts may come
into contact with
the outer side surface of the lower pipe plate 240 to prevent a phenomenon in
which the
condensate CW permeates between the lower pipe plate 240 and the leakage
prevention
member 500 to leak. Further, when the plurality of contact protrusions 520 are
formed at
CA 03047961 2019-06-20
locations vertically spaced apart from each other, the leakage of the
condensate CW may be
more reliably prevented.
Meanwhile, since a first flange part 320 configured to extend in an outward
direction
from an upper end of the sidewall 310 of the condensate collector 300 to
support the lower
portion 530 of the leakage prevention member 500 is provided at an edge
portion of the
condensate collector 300 and a fastening protrusion 321 and a fastening groove
531 fastened
to each other at corresponding locations are provided at the lower portion 530
of the leakage
prevention member 500 and the first flange part 320, the leakage of the
condensate CW may
be blocked and the location of the leakage prevention member 500 may be fixed.
Further, since the edge portion of the condensate collector 300 includes an
extending
portion 330 configured to extend in an upward direction from an outer end of
the first flange
part 320 and come into close contact with an outer side surface of the leakage
prevention
member 500 and a second flange part 340 configured to extend in an outward
direction from
an end of the extending portion 330. A fitting protrusion 541 and a fitting
groove 341 fitted
to each other at corresponding locations are formed on an upper portion 540 of
the leakage
prevention member 500 and the second flange part 340, the leakage of the
condensate CW
may be blocked and the location of the leakage prevention member 500 may be
fixed.
In the smoke tube boiler 1 according to the embodiment of the present
invention as
described above, the pressure resistance and durability may be improved by a
coupling
structure between the lower pipe plate 240 and the outer cylinder 210 and a
structure of the
lower pipe plate 240 including the round portion 243, the stagnation of the
condensate CW
may be prevented by a location relation of the leakage prevention member 500
interposed
between the edge portion of the lower pipe plate 240 and the edge portion of
the condensate
26
CA 03047961 2019-06-20
collector 300, and the leakage of the condensate CW may be efficiently
prevented by the
configuration of the contact protrusion 520 foimed on the leakage prevention
member 500.
Hereinafter, the configuration and operation of a smoke tube boiler 1'
according to
another embodiment of the present invention will be described below with
reference to FIGS
13 to 37.
The smoke tube boiler 1' according to another embodiment of the present
invention
includes: a mix chamber 1000 having a mixing space S in which a combustion gas
and air are
mixed, a mix chamber body 1100 formed in a flat shape, and a flat plate type
burner 1300
disposed on a combustion chamber C in a horizontal direction; a heat exchanger
2000,
wherein the heat exchanger 2000 includes an outer cylinder 2100 through which
a heat
medium is introduced and discharged and forming an outer wall of a water tank
B in which
the heat medium is accommodated, an upper pipe plate 2200 having an end plate
structure
coupled to an inner side of the outer cylinder 2100 and forming the combustion
chamber C so
that a heat medium path is formed between the upper pipe plate 2200 and the
outer cylinder
2100, a plurality of tubes 2300 each formed in a flat shape so that the
combustion gas
generated from the combustion chamber C is heat-exchanged with the heat medium
which
flows through the outside while flowing along the insides of the tubes 2300,
turbulators 2400
and 2500 coupled to inner sides of the tubes 2300 to cause turbulence in a
flow of the
combustion gas, multilayer diaphragms 2610, 2620, and 2630 provided between
the outer
cylinder 2100 and the tubes 2300 to guide the heat medium so that the flow
direction of the
heat medium is alternately switched inward and outward in a radial direction,
and a lower pipe
plate 2700 having an end plate structure configured to support lower end
portions of the tubes
2300 and form a bottom surface of the water tank B; and a condensate collector
3000
27
CA 03047961 2019-06-20
configured to collect condensate CW generated from the lower pipe plate 2700
to guide the
condensate CW to a condensate drain port 3100 fainted at one side thereof and
guide the
combustion gas which passes through the tubes 2300 to an air discharge duet
4000 connected
to an upper side of the condensate drain port 3100 and provided at one side of
the outer
.. cylinder 2100.
Further, the present invention further includes a pre-mixing chamber 5000 in
which
the combustion gas and the air supplied to the mix chamber 1000 are pre-mixed
and a mixed
air adjusting part 6000 configured to open and close a flow path of the air
and gas which
passes through the pre-mixing chamber 5000 to adjust a supply flow rate of the
mixed air.
Referring to FIGS. 13 to 19, the mix chamber 1000 includes the mix chamber
body
1100 which is convex in an upward direction and formed in a flat shape, an
ignition bar
assembly 1400 configured to pass through one side portion of the mix chamber
body 1100 to
be assembled and extend in a downward direction from the flat plate type
burner 1300 across
an upper portion of the combustion chamber C, and sealing means 1600, 1700,
and 1800
configured to block leakage of a mixed gas of the mixing space S and an
exhaust gas of the
combustion chamber C to the outside through a gap between the mix chamber 1000
and the
ignition bar assembly 1400.
A burner applied to the present invention is the flat plate type burner 1300
and
includes a flame hole plate 1310 having a flat plate shape in which plurality
of flame holes
1310a are formed and a metal fiber 1320 is coupled to the flame hole plate
1310. A
separation mixing space S between a lower surface of the mix chamber body 1100
and an
upper surface the flat plate type burner 1300 may be formed in a flat disc
shape to form the
mix chamber 1000 at a low height.
28
CA 03047961 2019-06-20
Further, unlike a conventional cylindrical burner, since the flat plate type
burner 1300
is provided in the entire area of the mixing space S and thus the gas and air
introduced
thereinto are supplied to an edge portion thereof, that is, a location
adjacent to locations at
which the sealing means 1600, 1700, and 1800 are provided, the sealing means
1600, 1700,
and 1800 may be cooled in an air cooling type manner by the gas and air, and
since a
combustion area is expanded to decrease load per unit area, the discharge of
pollutants such as
CO, NOx, and the like can be decreased to improve combustion performance.
The ignition bar assembly 1400 configured to pass through one side portion of
the
mix chamber 1000 to be assembled may include an ignition bar 1410 and a flame
sensing bar
1420, and the ignition bar 1410 may include a first ignition bar 1410-1 and a
second ignition
bar 1410-2. Insulators 1410a and 1420a made of an insulating material are
coupled to outer
side surfaces of the ignition bar 1410 and the flame sensing bar 1420,
respectively, and
bushings 1410b and 1420b are coupled to outer side surfaces of the insulators
1410a and
1420a, respectively, to maintain airtightness.
The ignition bar 1410, the insulator 1410a, and the bushing 1410b are fixed to
an
ignition bar coupling plate 1430, and the flame sensing bar 1420, the
insulator 1420a, and the
bushing 1420b are fixed to a flame sensing bar coupling plate 1440. The
insulators 1410a
and 1420a are insulation means configured to prevent the generation of sparks
due to
energization when ignition is performed, and the bushings 1410b and 1420b are
configurations for sealing gaps between the outer surfaces of the insulators
1410a and 1420a,
the ignition bar coupling plate 1430 and the flame sensing bar coupling plate
1440.
Referring to FIG. 16, an ignition bar assembly coupling part 1500 configured
to
assemble the ignition bar assembly 1400 is provided on one side portion of the
mix chamber
29
CA 03047961 2019-06-20
1000. The ignition bar assembly coupling part 1500 includes a second scaling
member
seating part 1510 formed in a groove shape so that the ignition bar coupling
plate 1430 and the
second sealing member 1700 coupled to a lower side of the ignition bar
coupling plate 1430
are seated thereon and a third sealing member seating part 1520 formed in a
groove shape so
that the flame sensing bar coupling plate 1440 and a third sealing member 1800
coupled to a
lower side of the flame sensing bar coupling plate 1440 are seated thereon.
Further, a
plurality of radiating fins 1530 configured to radiate combustion heat are
provided on an edge
of the ignition bar assembly coupling part 1500.
Referring to FIGS. 17 to 19, a mix chamber flange 1110 and a burner flange
1330
connected to an edge portion of the flat plate type burner 1300 to support the
edge portion of
the flat plate type burner 1300 are provided at one side portion of the mix
chamber 1000 to
meet each other to seal the mixing space S, and the ignition bar assembly 1400
passes through
the mix chamber flange 1110 and the burner flange 1330 to be assembled at a
location spaced
apart from the mixing space S.
The sealing means may include a first sealing member 1600 provided at a
portion in
which the mix chamber flange 1110 and the burner flange 1330 meet each other
to prevent
leakage of the mixed gas introduced into the mixing space S to the outsidc,
and the first
sealing member 1600 may be formed of a heat resistant graphite material.
Further, the sealing means may include a second sealing member 1700 provided
between mix chamber flange 1110 and the ignition bar coupling plate 1430 to
prevent leakage
of the exhaust gas generated from the combustion chamber C to the outside, and
a third
sealing member 1800 provided between the mix chamber flange 1110 and the flame
sensing
bar coupling plate 1440 to prevent the leakage of the exhaust gas generated
from the
CA 03047961 2019-06-20
combustion chamber C to the outside. In addition, the second sealing member
1700 and the
third sealing member 1800 may be formed of a rubber material and may be
separately
manufactured as separate components and then assembled to minimize deformation
of the
rubber material due to a high temperature.
In addition, a plurality of contact protrusions 1710 formed to protrude to the
outside
may be formed at a predetermined interval on an outer side surface of each of
the second
sealing member 1700 and the third sealing member 1800, and may come into close
contact
with a lower surface of the ignition bar coupling plate 1430, an upper surface
of the second
sealing member 1700, a lower surface of the coupling plate 1440, and an upper
surface of the
.. third sealing member 1800 to further improve sealability.
In addition, as described above, in the ignition bar assembly 1400, since the
bushings
1410b and 1420b are coupled to the outer side surfaces of the insulators 1410a
and 1420a,
respectively, the leakage of the exhaust gas or the mixed gas to the outside
of the mix chamber
1000 may be blocked again.
Hereinafter, the configuration and operation of a cooling means configured to
block
the transfer of the combustion heat to the sealing means and radiate the
combustion heat will
be described below with reference to FIGS 18 and 19.
The cooling means is a configuration for blocking the transfer of the
combustion heat
generated from the combustion chamber C to the sealing means configured to
prevent leakage
of the combustion heat through the gap between the mix chamber 1000 and the
ignition bar
assembly 1400 and may include an air cooling type cooling means and a water
cooling type
cooling means.
31
CA 03047961 2019-06-20
As described above, the mix chamber flange 1110 and the burner flange 1330 may
be
provided at one side portion of the mix chamber 1000 to meet each other to
seal the mixing
space S, the ignition bar assembly 1400 passes through the mix chamber flange
1110 and the
burner flange 1330 to be assembled, and the air cooling type cooling means may
be
configured so that the mix chamber flange 1110 and the burner flange 1330 are
cooled in a
convection manner by the mixed gas introduced into the mixing space S.
Meanwhile, the heat exchanger 2000 may include a smoke tube heat exchanger and
may include an outer cylinder 2100, an upper pipe plate 2200 forming a bottom
surface of a
combustion chamber C and an upper surface of a heat exchanger 2000, a
plurality of tubes
2300 having upper end portions coupled through a tube insertion port 2210a
fointed in the
upper pipe plate 2200 and through which the combustion gas flows through the
inside thereof,
and a water tank B located at outer sides of the tubes 2300 and in which the
heat medium is
accommodated in the outer cylinder 2100. The heat medium may be heating water
or \Vann
water used for heating or warm water.
In the water cooling type cooling means, an upper pipe plate flange 2230
configured
to come into contact with the heat medium of the heat exchanger 2000 provided
under the
combustion chamber C is provided to come into surface contact with the burner
flange 1330,
and the burner flange 1330 and the scaling means 1600, 1700, and 1800 may be
cooled by the
heat medium stored in the water tank B in a conduction manner.
Further, as described above, a plurality of radiating fins 1530 are provided
on one side
portion of the mix chamber body 1100, to which the ignition bar assembly 1400
is assembled,
along an edge of the ignition bar assembly 140, and the above also serve as a
cooling means.
32
CA 03047961 2019-06-20
As described above, according to the present invention, since the mix chamber
1000
includes the flat shaped mix chamber body 1100 and the flat plate type burner
1300, the height
of the mix chamber 1000 may be significantly decreased in comparison with the
structure
having a conventional cylindrical burner.
Further, since the sealing means and the cooling means are provided to allow
the
ignition bar assembly 1400 to pass through one side portion of the mix chamber
1100 having
the flat plate type burner 1300 to be assembled, the leakage of the mixed gas
and the exhaust
gas may be blocked and thernial damage of the sealing means due to the
combustion heat may
be prevented. Accordingly, since an insulation material is not used in the mix
chamber 1000
having the flat plate type burner 1300, the ignition bar assembly 1400 may be
safely
assembled and the leakage of the mixed gas and the exhaust gas may be blocked
by
preventing the thermal damage of the sealing means.
Meanwhile, referring to FIG. 20, the upper pipe plate 2200 includes a bottom
portion
2210 forming a lower surface of the combustion chamber C, a sidewall portion
2220 forming
a sidewall of the combustion chamber C, a round portion 2240 including the
upper pipe plate
flange 2230 on which the burner flange 1330 is seated and configured to
connect an upper end
of the sidewall portion 2220 and an inner end of the upper pipe plate flange
2230, and a round
portion 2250 configured to connect an outer end of the bottom portion 2210 and
a lower end
of the sidewall portion 2220.
As described above, since the upper pipe plate 2200 includes the round
portions 2240
and 2250, the water pressure of the heat medium stored in the water tank B may
be dispersed
to improve the durability of the upper pipe plate 2000. The ratio of the
diameter difference
between an outer diameter dl of the upper pipe plate flange 2230 and an inner
diameter d2 of
33
CA 03047961 2019-06-20
a lower end of the round portion 2240 may be smaller than or equal to 20%.
When the upper
pipe plate flange 2230 and the round portion 2240 are configured in the ratio
of the diameter
difference as described above, the flow rate and temperature of water
accommodated in the
water tank B may be uniformly controlled.
Further, a height h between a lower surface of the flat plate type burner 1300
inserted
into the upper pipe plate 2200 and a bottom surface of the upper pipe plate
2200 may be set so
that the tip of a flame generated from the flat plate type burner 1300 may be
spaced apart from
the bottom surface of the upper pipe plate 2200 by a predetermined distance,
and the height h
may be set to a size of about 80 mm in consideration of the length of the
flame from the flat
plate type burner 1300. As described above, the tip of the flame is set to be
spaced apart
from the bottom surface of the upper pipe plate 2200 by the predetermined
distance because a
condition in which nitrogen oxide (N0x) and carbon monoxide (CO) are
experimentally
minimized may be secured when a predetelmined space between the tip of a flame
generated
from the flat plate type burner 1300 and the bottom surface of the upper pipe
plate 2200 is
secured.
Further, as described above, since the height h of the upper pipe plate 2200
is
designed to be low, the height of the combustion chamber C becomes low and
thus the overall
height of the smoke tube boiler 1' may be decreased. That is, when the
conventional
cylindrical burner is applied, the height between a lower surface of the
burner and a bottom
surface of the upper pipe plate is about 190mm, but in the case of the present
invention, since
the height may be decreased to about 80 mm, the height may accordingly be
decreased by
about 40% in comparison with the conventional art.
34
CA 03047961 2019-06-20
Meanwhile, in the embodiment, the electrode bar assembly 1400 is formed at a
location adjacent to one side of the mixed air introduction port 1200
connected to a blower
7000 configured to supply the mixed air to the mix chamber 1000. In this case,
since a
worker may easily access the electrode bar assembly 1400 through the mixed air
introduction
port 1200, convenience of maintenance may be improved.
In another embodiment, as shown in the above-described FIG. 2, the electrode
bar
assembly 1400 may be disposed at a side opposite to the mixed air introduction
port 1200.
In this case, since the mixed air supplied from the blower 7000 is directly
supplied to the
electrode bar assembly 1400, delayed ignition may be prevented.
Referring to FIGS. 21 to 26, the heat exchanger 2000 includes an outer
cylinder 2100
having a heat medium introduction port 2110 and a heat medium discharge port
2120 and
through which the heat medium is introduced and discharged, an upper pipe
plate 2200
coupled to an inner side of the outer cylinder 2100 and forming a combustion
chamber C by
the flat plate type burner 1300 seated thereon so that a heat medium path is
formed between
.. the upper pipe plate 2200 and the outer cylinder 2100, a plurality of tubes
2300 each formed
in a flat shape so that the combustion gas generated from the combustion
chamber C is heat-
exchanged with the heat medium while flows along the insides of the tubes
2300, a tube
assembly 10000 having turbulators 2400 and 2500 coupled to inner sides of the
tubes 2300 to
cause the turbulence in the flow of the combustion gas and configured to
support the tubes
.. 2300, and a lower pipe plate 2700 configured to support the tube assembly
10000 and coupled
to a condensate collector 3000.
Multilayer diaphragms 2610, 2620. and 2630 are provided on outer side surfaces
of
the tubes 2300 to be vertically spaced apart from each other to guide the flow
of the heat
CA 03047961 2019-06-20
medium so that the flow direction of the heat medium is alternately switched
inward and
outward in the radial direction, and the multilayer diaphragms 2610, 2620, and
2630 are fixed
and supported by a supporter 2640. The plurality of tubes 2300 are installed
in a vertical
direction so that the combustion gas generated from the combustion chamber C
flows in a
downward direction, and the plurality of tubes 2300 are spaced apart from each
other in a
circumferential direction to be disposed in a radial shape.
In the embodiment, the multilayer diaphragms include an upper diaphragm 2610,
a
middle diaphragm 2620, and a lower diaphragm 2630 each having a plate shape.
Referring
to FIG. 24A, in the upper diaphragm 2610, a tube insertion port 2610a into
which the tubes
are inserted is formed, and an opening portion 2610b through which the heat
medium passes is
formed at a center. Referring to FIG. 24B, in the middle diaphragm 2620, since
a tube
insertion port 2620a is formed with a gap from outer side surfaces of the
tubes 2300, the heat
medium flows through the gap between the tube insertion port 2620a and the
tubes 2300. A
center portion 2620b of the middle diaphragm 2620 is formed in a blocked
structure. In the
embodiment, the tube insertion port 2620a may be configured in a structure in
which the two
tubes 2300 are spaced apart from each other toward both sides to be inserted
into the tube
insertion port 2620a. Referring to FIG. 24C, in the lower diaphragm 2630, a
tube insertion
port 2630a having the same structure as that of the upper diaphragm 2610 is
formed, and an
opening portion 2630b is formed at a center.
According to structures of the above-described multilayer diaphragms 2610,
2620,
and 2630, as shown by arrows in FIGS. 25 and 26, the heat medium introduced
into the outer
cylinder 2100 through the heat medium introduction port 2110 flows toward the
opening
portion 2630b formed at the center of the lower diaphragm 2630 inward in the
radial direction,
36
CA 03047961 2019-06-20
the heat medium which passes through the opening portion 2630b to flow in an
upward
direction from the lower diaphragm 2630 is dispersed to a separation space of
the tube
insertion port 2620a formed in a radial shape in the middle diaphragm 2620 to
flow outward
in the radial direction, and the heat medium which passes through the tube
insertion port
2620a to flow in an upward direction from the middle diaphragm 2620 toward the
opening
portion 2610b formed at the center of the upper diaphragm 2610 inward in the
radial direction,
and then passes through the opening portion 2610b to be discharged through the
heat medium
discharge port 2120 formed in one side of an upper portion of the outer
cylinder 2100.
As described above, since the flow direction of the heat medium is alternately
switched inward and outward in the radial direction, the flow distance of the
heat medium
increases, and thus the heat-exchange efficiency of the heat exchanger 2000
may be improved,
and since a high-efficiency heat exchange performance may be obtained even
when the height
of the heat exchanger 2000 is decreased in comparison with a conventional heat
exchanger,
the height of the heat exchanger 2000 may be decreased. Further, the flow
velocity of the
heat medium may be increased to prevent a boiling phenomenon due to partial
overheating
caused by stagnation of the heat medium.
Hereinafter, the configuration and operation of the tube assembly 10000 will
be
described below with reference to FIGS 27 to 33.
The tube assembly 10000 according to the embodiment of the present invention
includes a tube 2300 formed in a flat shape so that the combustion gas
generated from a
combustion chamber C flows through the inside of the tube 2300 to be heat
exchanged with a
heat medium which flows through the outside, an upper turbulator 2400 coupled
to an inner
side of an upper portion of the tube 2300 adjacent to the combustion chamber
to come into
37
CA 03047961 2019-06-20
surface contact with the tube 2300, so as to increase heat conductivity and
cause the
turbulence in the flow of the combustion gas, and a lower turbulator 2500
coupled to an inner
side of the tube 2300 in a downward direction from the upper turbulator 2400
to cause the
turbulence in the flow of the combustion gas.
The upper turbulator 2400 includes tube contact surfaces 2410a and 2410b
(2410) that
come into close contact with inner side surfaces of the tube 2300 and pressure
supporting parts
2420a and 2420b (2420) formed to be bent from incised portions 2430a and 2430b
(2430) in
the tube contact surfaces 2410a and 2410b (2410).
The tube contact surface 2410 includes a structure in which a first tube
contact
surface 2410a configured to come into surface contact with the inner side
surface of one side
portion of the tube 2300 and a second tube contact surface 2410b configured to
come into
surface contact with the inner side surface of the other side portion of the
tube 2300 are
symmetric.
The pressure supporting part 2420 is a configuration for preventing
deformation and
damage of the tube 2300 due to the water pressure of the heat medium and
includes a first
pressure supporting part 2420a in which a part of a first incised portion
2430a of the first tube
contact surface 2410a is bent to protrude toward the second tube contact
surface 2410b and a
second pressure supporting part 2420b in which a part of a second incised
portion 2430b of
the second tube contact surface 2410b is bent to protrude toward the first
tube contact surface
2410a.
The incised area of the first incised portion 2430a is formed to be greater
than the
incised area of the second incised portion 2430b, a protruding end portion of
the first pressure
supporting part 2420a comes into contact with the second tube contact surface
2410b, and
38
CA 03047961 2019-06-20
when the pressure supporting part 2420 is inserted into the tube 2300, a
protruding end portion
of the second pressure supporting part 2420b is provided to come into contact
with the inner
side surface of the tube 2300 through the first incised portion 2430a.
According to the above, the first pressure supporting part 2420a supports the
first tube
contact surface 2410a and the second tube contact surface 2410b to solidly
maintain the
shapes thereof when the water pressure is provided, and the second pressure
supporting part
2420b more solidly supports the tube 2300 supported by the first tube contact
surface 2410a
and the second tube contact surface 2410b.
Further, as shown in FIG. 33, a plurality of first pressure supporting parts
2420a and a
plurality of second pressure supporting parts 2420b are provided to be spaced
apart from each
other in frontward and backward directions and a vertical direction, a first
pressure supporting
part 2420a' located at an upper side and a first pressure supporting part
2420a" located at a
lower side are provided in the vertical direction at locations not overlapping
each other, and a
second pressure supporting part 2420b' located at an upper side and a second
pressure
supporting part 2420b" located at a lower side are provided in the vertical
direction at
locations not overlapping each other. According to the above, since the water
pressure
which acts to the tube 2300 due to the first pressure supporting parts 2420a
and the second
pressure supporting parts 2420b provided in a zigzag shape in the frontward
and backward
directions and the vertical direction throughout the entire area of the upper
turbulator 2400 is
uniformly dispersed, deformation and damage of the tube 2300 may be
efficiently prevented.
Further, since each of the first pressure supporting part 2420a and the second
pressure
supporting part 2420b is foimed in a plate shape and in a structure in which
both side surfaces
having broad areas are disposed to be parallel to a flow direction of the
combustion gas, as
39
CA 03047961 2019-06-20
shown by arrows in FIG. 32A, flow resistance may be minimized in a process in
which the
combustion gas passes through the first pressure supporting parts 2420a and
the second
pressure supporting parts 2420b while flowing.
Referring to FIG. 29, the lower turbulator 2500 includes a flat surface
portion 2510
configured to divide an inner space of the tube 2300 into both sides and
disposed in a
longitudinal direction of the tube 2300, and a first guide piece 2520 and a
second guide piece
2530 spaced apart in a longitudinal direction from both side surfaces of the
flat surface portion
2510 and formed to protrude to be alternately inclined.
The first guide piece 2520 is disposed on one side surface of the flat surface
portion
.. 2510 to be inclined to one side and the second guide piece 2530 is disposed
on the other side
surface of the flat surface portion 2510 to be inclined to the other side.
Accordingly, the heat
media introduced into the first guide piece 2520 and the second guide piece
2530 are
sequentially transferred to the second guide piece 2530 and the first guide
piece 2520 disposed
to be adjacent to the opposite surfaces of the flat surface portion 2510 to
alternately flow
through both spaces in the flat surface portion 2510.
In a heat medium introduction end of the first guide piece 2520, a first
communication
port 2520b connected to one side end of the flat surface portion 2510 by the
first connection
piece 2520a and in which the fluid communicates through both spaces in the
flat surface
portion 2510 between one side end of the flat surface portion 2510, the first
connection piece
2520a, and the first guide piece 2520 is provided.
In a heat medium introduction end of the first guide piece 2530, a second
communication port 2530b connected to the other side end of the flat surface
portion 2510 by
the second connection piece 2530a and in which the fluid communicates through
both spaces
CA 03047961 2019-06-20
in the flat surface portion 2510 between the other side end of the flat
surface portion 2510, the
second connection piece 2530a, and the second guide piece 2530 is provided.
The first guide piece 2520 and the second guide piece 2530 may be configured
so that
portions of the flat surface portion 2510 may be incised to be bent to both
sides of the flat
surface portion 2510 and the fluid may communicate through both spaces in the
flat surface
portion 2510 through the incised portions of the flat surface portion 2510.
Further,
supporters 2530a and 2530b (2530) configured to protrude in outward directions
to come into
contact with the facing inner side surfaces of the tube 2300 are formed on
both side surfaces
of the lower turbulator 2500. In addition, a first supporting part 2550 and a
second
supporting part 2560 vertically spaced apart from each other to come into
contact with both
side surfaces of the tube 2300 and protrude in frontward and backward
directions are formed
on an upper end portion and a lower end portion, respectively, of the lower
turbulator 2500.
Meanwhile, referring to FIGS. 34 to 37, the smoke tube boiler 1' includes a
condensate collector 3000 in which the condensate generated when vapor which
passes
through a heat exchanger 2000 and is included in the combustion gas is
condensed is collected
and drained and a leakage prevention member 3200 coupled to a lower pipe plate
2700 of the
heat exchanger 2000 and a connection part of the condensate collector 3000 to
prevent
leakage of the condensate.
Referring to FIG. 22, the lower pipe plate 2700 is formed in an end plate
structure and
includes a horizontal portion 2710 having a plurality of tube insertion holes
2710a through
which a lower end portion of the tube 2300 passes formed therein to support
the lower end
portion of the tube 2300 and form the bottom surface of the water tank B, a
vertical portion
2720 coupled to a lower end portion of the outer cylinder 2100, and a round
portion 2730
41
CA 03047961 2019-06-20
configured to connect an outer end of the horizontal portion 2710 and a lower
end portion of
the vertical portion 2720 and formed in a shape convexly curved toward the
outside to
disperse the water pressure of the heat medium.
As described above, since the round portion 2730 formed in the shape convexly
.. curved toward the outside is formed on a corner connecting the horizontal
portion 2710 and
the vertical portion 2720 of the lower pipe plate 2700, the water pressure of
the heat medium
may be dispersed, and thus durability may be improved by improving the water
pressure
resistance of the lower pipe plate 2700 to minimize deformation of the lower
pipe plate 2700.
Hereinafter, a coupling structure between the condensate collector 3000 and
the
leakage prevention member 3200 will be described.
Referring to FIGS. 36 and 37, the leakage prevention member 3200 is provided
between an edge portion of the lower pipe plate 2700 and an edge portion of
the condensate
collector 3000 to prevent the leakage of the condensate. Since a body 3210 of
the leakage
prevention member 3200 is provided in a shape which surrounds a lower portion
of each of
the round portion 2730 and the vertical portion 2720 of the lower pipe plate
2700, the
condensate CW formed on the horizontal portion 2710 of the lower pipe plate
2700 may be
blocked from moving in a lateral direction by a blockage of a bottom portion
2330 formed to
extend to one side from a lower portion of the body 32] 0 and may drop in a
downward
direction.
Meanwhile, a contact protrusion 3220 configured to protrude toward an outer
side
surface of the lower pipe plate 2700 may be formed on an inner side surface
3210a of the
leakage prevention member 3200. A plurality of contact protrusion 3220a,
3220b, 3220c,
42
CA 03047961 2019-06-20
3220d, 3220e, and 3220f may be formed at locations vertically spaced apart
from the inner
side surface 3210a of the leakage prevention member 3200.
According to configuration of the above-described contact protrusions 3220,
when the
water pressure acts, the contact protrusions 3220 of the leakage prevention
member 3200
configured to protrude in a direction opposite to a direction in which the
water pressure acts
may come into contact with the outer side surface of the lower pipe plate 2700
to effectively
prevent a phenomenon in which the condensate CW is infiltrated into the gap
between the
lower pipe plate 2700 and the leakage prevention member 3200 to leak. Further,
when the
plurality of contact protrusions 3220 are foimed at locations vertically
spaced apart from each
other, the leakage of the condensate CW may be more reliably prevented.
A first flange part 3010 configured to support the leakage prevention member
3200 is
provided at an edge portion of the condensate collector 3000, and a fastening
protrusion 3010a
and a fastening groove 3230a fastened to each other at corresponding locations
are provided at
the leakage prevention member 3200 and the first flange part 3010. Further,
the edge portion
of the condensate collector 300 further includes an extending portion 3020
configured to
extend in an upward direction from an outer end of the first flange part 3010
and come into
close contact with an outer side surface of the leakage prevention member
3200, and a second
flange part 3030 configured to extend in an outward direction from an end of
the extending
portion 3020, and a fitting protrusion 3240a and a fitting groove 3240b fitted
to each other at
corresponding locations are formed on an upper portion of the leakage
prevention member
3200 and the second flange part 3030. According to the above, the leakage of
the condensate
CW may be blocked, and the location of the leakage prevention member 3200 may
be solidly
fixed.
43
CA 03047961 2019-06-20
Meanwhile, referring to FIG. 35, an exhaust guide 3300 in which a plurality of
punched holes 3310a and 3310b (3310) are formed so that the combustion gas
which passes
through the heat exchanger 2000 is uniformly distributed to the entire area of
the condensate
collector 3000 to be discharged is provided in the condensate collector 3000.
The punched
holes 3310 may be formed to have different sizes in consideration of the flow
direction of the
combustion gas.
Further, since a stair part 3040 configured to guide the flow of the
combustion gas
which passes through the exhaust guide 3300 to the condensate drain port 3100
formed under
one side of the condensate collector 3000 may be formed on a bottom surface of
the
condensate collector 3000, as shown by a dotted line arrow which is the
drainage direction of
the condensate and a solid line arrow which is the flow direction of the
combustion gas in FIG.
37, the drainage direction of the condensate and the flow direction of the
combustion gas may
be the same in the condensate collector 3000. According to the above
configuration, since
the condensate is guided in the flow direction of the exhaust gas, corrosion
of the lower pipe
plate 2700 due to stagnation of the condensate may be prevented and the
condensate may be
guided to the condensate drain port 3100 to be smoothly drained.
As described above, the present invention is not limited to the above-
described
embodiments, it will be apparent to those skilled in the art that the present
invention may be
modified without departing from the spirit of the present invention in the
claims, and such a
modification is included in the scope of the present invention.
44
