Refractory material retention device

Abstract

A combustion burner refractory material retention system is provided. The system may include a tubular enclosure having a first section and a second section, wherein the first section has an internal cross-sectional area that is less than an internal cross-sectional area of the second section. A refractory material body may be disposed within the tubular enclosure second section. A first support layer may be disposed on a surface of the refractory material body, and at least one outer support layer may be disposed between the refractory material body and a wall of the tubular enclosure second section. The first support layer may form an insulating barrier between the refractory material body and the outer support layer, and a cross-sectional area of the combined refractory material body and first support layer may be at least as large as the internal cross-sectional area of the tubular enclosure first section.

1 . A combustion burner refractory material retention system, comprising: 
 a tubular enclosure having a first section and a second section, wherein the first section has an internal cross-sectional area that is less than an internal cross-sectional area of the second section;    a refractory material body disposed within the tubular enclosure second section;    a first support layer disposed on a surface of the refractory material body; and    at least one outer support layer disposed between the refractory material body and a wall of the tubular enclosure second section, wherein the first support layer forms an insulating barrier between the refractory material body and the outer support layer, and a cross-sectional area of the combined refractory material body and first support layer is at least as large as the internal cross-sectional area of the tubular enclosure first section.    
   
   
       2 . The system of  claim 1 , wherein the refractory material body includes a ceramic.  
   
   
       3 . The system of  claim 2 , wherein the ceramic includes silicon carbide.  
   
   
       4 . The system of  claim 2 , wherein the ceramic includes cordierite.  
   
   
       5 . The system of  claim 2 , wherein the ceramic includes yittria-stabilized zirconia alumina.  
   
   
       6 . The system of  claim 1 , wherein the refractory material body is configured to withstand temperatures up to 1200° Celsius.  
   
   
       7 . The system of  claim 1 , wherein the refractory material body is configured to withstand temperatures up to 1400° Celsius.  
   
   
       8 . The system of  claim 2 , wherein the first support layer includes a ceramic.  
   
   
       9 . The system of  claim 8 , wherein the first support layer has a porosity which is less than a porosity of the refractory material body.  
   
   
       10 . The system of  claim 9 , wherein the first support layer has a porosity of less than 10% by volume.  
   
   
       11 . The system of  claim 9 , wherein the refractory material body has a porosity of at least 80% by volume.  
   
   
       12 . The system of  claim 8 , wherein the first support layer includes silicon carbide.  
   
   
       13 . The system of  claim 1 , wherein the tubular enclosure includes one or more surface openings.  
   
   
       14 . The system of  claim 1 , further including a retention ring configured to secure the refractory material body within the tubular enclosure.  
   
   
       15 . The system of  claim 1 , wherein the first section includes an indentation in a wall of the tubular enclosure.  
   
   
       16 . The system of  claim 15 , wherein the indentation is configured to deflect hot gases away from the at least one outer support layer.  
   
   
       17 . The system of  claim 1 , wherein the first section includes a retention ring.  
   
   
       18 . A method for securing a refractory material within an exhaust system burner unit, comprising: 
 selecting a refractory material body;    applying a first support layer to a surface of the refractory material body;    applying at least one outer support layer to a surface of the first support layer; and    positioning the refractory material body, first support layer, and at least one outer support layer within a burner tubular enclosure, wherein the tubular enclosure has a first section which has a first internal cross-sectional area and a second section which has a second internal cross-sectional area, wherein the first internal cross-sectional area is less than the second internal cross-sectional area and a cross-sectional area of the combined refractory material body and first support layer is at least as large as the first internal cross-sectional area.    
   
   
       19 . The method of  claim 18 , wherein the refractory material body includes a ceramic.  
   
   
       20 . The method of  claim 19 , wherein applying the first support layer includes applying a slurry to a section of the refractory material body and heat treating the refractory material body and slurry.  
   
   
       21 . The method of  claim 20 , wherein the slurry includes silicon carbide.  
   
   
       22 . The method of  claim 18 , wherein applying the first support layer includes applying at least one of a high-temperature adhesive, a casting material, and a high-temperature paint to a surface of the refractory material body.  
   
   
       23 . The method of  claim 18 , wherein applying the first support layer includes producing one or more strips of a first support layer material, contacting the first support layer material with a surface of the refractory material body, and heat treating the first support layer and refractory material body.  
   
   
       24 . The method of  claim 23 , wherein the one or more strips of first support layer material are produced by at least one of tape casting and tape calendaring.  
   
   
       25 . A work machine, comprising: 
 an engine;    an exhaust system configured to receive an exhaust gas stream produced by the engine; and    a burner unit configured to heat the exhaust gas stream and including:    a tubular enclosure having a first section and a second section, wherein the first section has an internal cross-sectional area that is less than an internal cross-sectional area of the second section;    a refractory material body disposed within the tubular enclosure second section;    a first support layer disposed on a surface of the refractory material body; and    at least one outer support layer disposed between the refractory material body and a wall of the tubular enclosure second section, wherein the first support layer forms an insulating barrier between the refractory material body and the outer support layer, and a cross-sectional area of the combined refractory material body and first support layer is at least as large as the internal cross-sectional area of the tubular enclosure first section.    
   
   
       26 . The work machine of  claim 25 , wherein the burner unit is disposed upstream of a diesel particulate filter.  
   
   
       27 . The work machine of  claim 25 , wherein the burner unit is disposed upstream of at least one catalyst.  
   
   
       28 . A work machine, comprising: 
 an engine;    an exhaust system configured to receive an exhaust gas stream produced by the engine; and    a burner unit configured to heat the exhaust gas stream and including:    a tubular enclosure having a first section and a second section;    a refractory material body disposed within the tubular enclosure second section;    a first support layer disposed on a surface of the refractory material body; and    at least one outer support layer disposed between the refractory material body and a wall of the tubular enclosure second section, wherein the outer support layer is insulated from the refractory material body and an interior of the tubular enclosure.    
   
   
       29 . The work machine of  claim 28 , wherein the first section has an internal cross-sectional area that is less than an internal cross-sectional area of the second section and further including a retention ring configured to secure the refractory material body within the tubular enclosure.