Field of the Invention

[0001] The present disclosure is directed generally to gas-fired burners, and more specifically, to flat flame burner and burner block assemblies.

Background

[0002] Oxy-fuel combustion is the process of burning a fuel using oxygen as the primary oxidant instead of air. Use of oxy-fuel combustion lowers harmful environmental emissions as the nitrogen component of the air oxidant is eliminated, reducing NOx emissions, as well as decreasing fuel consumption.

[0003] Additionally, gas-fired burner assemblies are typically designed in conjunction with a burner block to aid in radiating the heat generated by the burner’s combustion. Staged burner assemblies, e.g., gas-fired burner assemblies designed for use with multiple injections of additional oxidant after ignition, are designed to work with blocks which allow for a separate additional flow of gas to be added to the combustion generated. Conversely, gas- fired burner assemblies that are not designed to use additional oxidant after ignition typically utilize burner blocks that do not allow for additional stage gas to be added to combustion. Whether the blocks are designed to accept a staged burner system or not, the burner blocks are made from materials that are highly prone to cracking due to repeated thermal expansion.

Summary of the Invention

[0004] The present disclosure is directed generally to a block and burner assembly arranged to produce a flat flame and allows for flexible adaptation between applications that require staged combustion or unstaged combustion. The block and burner assembly includes a flat flame burner sub-assembly with a gas nozzle and a fuel nozzle where the gas nozzle is arranged to extend a first distance from the body of the sub-assembly and the fuel nozzle is arranged to project a second distance from the body of the sub-assembly where the first distance is less than or equal to the second distance. This nozzle arrangement helps prevent backfiring and reduces operating temperatures of the sub-assembly. Additionally, the block and burner assembly described herein allows for adaptive placement of burner blocks for different applications as well as modular replacement and/or repair of separable burner blocks. Furthermore, in a staged configuration, the block and burner assembly includes a staged injector sub-assembly secured to a staged injector block, where the staged injector block includes a plurality of gas channels operatively arranged to more effectively distribute the staged gas flow from the staged injector sub-assembly to the combustion produced by the flat flame burner sub-assembly.

[0005] In one example, there is provided a block and burner assembly including a flat flame burner sub-assembly which includes a flat flame burner body in fluid communication with a gas source. The flat flame burner body includes a gas inlet in fluid communication with the gas source and a gas nozzle, and a fuel inlet in fluid communication a fuel nozzle, wherein the gas nozzle is arranged to at least partially encompass the fuel nozzle. Additionally the block and burner assembly includes a flat flame burner block arranged to receive at least a portion of the fuel nozzle and at least a portion of the gas nozzle, a staged injector sub-assembly in fluid communication with the gas source, and a staged injector block connected to the flat flame burner block and arranged to receive the at least a portion of the staged injector sub-assembly wherein the flat flame burner block and the staged injector block are separable.

[0006] In an aspect, the staged injector block is connected to a top side or a botom side of the flat burner block.

[0007] In an aspect, the block and burner assembly further incudes a bracket arranged to secure the staged injector block to the flat burner block.

[0008] In an aspect, the gas nozzle is arranged to taper from a first width and a first height to a second width and a second height, wherein the first width is smaller than the second width and the first height is greater than the second height.

[0009] In an aspect, the fuel nozzle is arranged to taper from a third width and a third height to a fourth width and a fourth height, wherein the third width is smaller than the fourth width and the third height is greater than the fourth height.

[0010] In an aspect, the gas nozzle is arranged to project a first distance from the flat flame burner body in a first direction and the fuel nozzle is arranged to project a second distance from the flat flame burner body in the first direction, wherein the first distance is equal to the second distance or wherein the first distance is less than the second distance. [0011] In an aspect, the staged injector block comprises a plurality of gas channels, wherein each of the plurality of gas channels extends from a first side of the staged injector block to a second side of the staged injector block, and wherein a first gas channel of the plurality of gas channels is arranged non-parallel to a second gas channel of the plurality of gas channels.

[0012] In an aspect, the first gas channel of the plurality of gas channels comprises a first aperture proximate the first side of the staged injector block and a second aperture proximate the second side of the staged injector block, and wherein the first aperture is arranged a first aperture distance from the flat flame burner block and the second aperture is arranged a second aperture distance from the flat flame burner block, and wherein the first aperture distance is greater than the second aperture distance.

[0013] In another example, a staged injector block is provided, the staged injector block including a first side, a second side, a bottom surface, and a first gas channel arranged between the first side and the second side, wherein the first side is arranged to receive at least a portion of a staged injector sub-assembly and comprises a first aperture in fluid communication with the first gas channel, and the second side comprises a second aperture in fluid communication with the first gas channel, the first aperture arranged a first aperture distance from a flat flame burner block in contact with the bottom surface of the staged injector block and the second aperture arranged a second aperture distance from the flat flame burner block wherein the first aperture distance is greater than the second aperture distance. [0014] In an aspect, the staged injector block further includes a recess, wherein the recess comprises the first aperture.

[0015] In an aspect, the staged injector block further includes a second gas channel arranged between the first side of the body and the second side of the body, and wherein the first side of the staged injector block comprises a third aperture in fluid communication with the second gas channel and arranged a third aperture distance from the flat flame burner block, and the second side comprises a fourth aperture in fluid communication with the second gas channel and arranged a fourth aperture distance from the flat burner block wherein the third aperture distance is less than the fourth aperture distance.

[0016] In an aspect, the staged injector block further includes a second gas channel arranged between the first side and the second side, and wherein the first gas channel is arranged non-parallel to the second gas channel.

[0017] In an aspect, the staged injector block further includes a third gas channel arranged between the first side of the body and the second side of the body, and wherein the third gas channel is arranged non-parallel to the first gas channel and the second gas channel. [0018] In an aspect, the first gas channel is arranged to receive a gas from a gas nozzle of a staged injector sub-assembly secured to the staged injector block.

[0019] In an aspect, the staged injector block is arranged to contact a top side or a bottom side of the flat burner block. Brief Description of the Drawings

[0020] The foregoing will be apparent from the following more particular description of example embodiments of the present disclosure, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments of the present disclosure.

[0021] FIG. 1 is a side elevational view of a burner and block assembly according to the present disclosure.

[0022] FIG. 2 is a top plan view of a flat flame burner sub-assembly and flat flame burner block according to the present disclosure.

[0023] FIG. 3 is a side elevational view of a gas nozzle and fuel nozzle according to the present disclosure.

[0024] FIG. 4A is a front view of a gas nozzle and fuel nozzle according to the present disclosure.

[0025] FIG. 4B is a rear view of a gas nozzle and fuel nozzle according to the present disclosure.

[0026] FIG. 5 is a side elevational view of a burner and block assembly according to the present disclosure.

[0027] FIG. 6 is a front perspective view of a staged injector sub-assembly according to the present disclosure.

[0028] FIG. 7 is a side elevational view of a staged injector sub-assembly and staged injector block according to the present disclosure.

[0029] FIG. 8 A is a rear side elevational view of a staged injector sub-assembly and staged injector block according to the present disclosure.

[0030] FIG. 8B is a top plan view of a staged injector sub-assembly and staged injector block according to the present disclosure.

[0031] FIG. 9A is a front side elevational view of a staged injector sub-assembly according to the present disclosure.

[0032] FIG. 9B is a side elevational view of a staged injector sub-assembly according to the present disclosure. [0033] FIG. 10 is a front perspective view of a staged injector block according to the present disclosure

[0034] FIG. 11A is a front elevational view of a staged injector block according to the present disclosure.

[0035] FIG. 1 IB is a rear elevational view of a staged injector block according to the present disclosure.

[0036] FIG. 12A is a top, cross-sectional view of a staged injector block according to the present disclosure.

[0037] FIG. 12B is a side, partial cross-sectional view of a staged injector block according to the present disclosure.

[0038] FIG. 13 A is a side elevational view of a block and burner assembly according to the present disclosure.

[0039] FIG. 13B is a side elevational view of a block and burner assembly according to the present disclosure.

Detailed Description of Embodiments

[0040] The present disclosure is directed generally to a block and burner assembly arranged to produce a flat flame and allows for flexible adaptation between applications that require staged combustion or unstaged combustion. The block and burner assembly includes a flat flame burner sub-assembly with a gas nozzle and a fuel nozzle where the gas nozzle is arranged to extend a first distance from the body of the sub-assembly and the fuel nozzle is arranged to project a second distance from the body of the sub-assembly where the first distance is less than or equal to the second distance. This nozzle arrangement helps prevent backfiring and reduces operating temperatures of the sub-assembly. Additionally, the block and burner assembly described herein allows for adaptive placement of burner blocks for different applications as well as modular replacement and/or repair of separable burner blocks. Furthermore, in a staged configuration, the block and burner assembly includes a staged injector sub-assembly secured to a staged injector block, where the staged injector block includes a plurality of gas channels operatively arranged to more effectively distribute the staged gas flow from the staged injector sub-assembly to the combustion produced by the flat flame burner sub-assembly.

[0041] A description of example embodiments of the present disclosure follows. Although the block and burner assembly shown in the figures is shown in an upward orientation, the description of the assembly shown in the figures is not intended to be limited to a particular orientation.

[0042] Referring now to the figures, the following description should be viewed with respect to FIGS. 1-2. FIG. 1 illustrates a side elevational view of burner and block assembly 100 according to the present disclosure. Block and burner assembly 100 includes flat flame burner sub-assembly 102 and staged injector sub-assembly 104. Block and burner assembly 100 further includes flat flame burner block 106 arranged to receive at least a portion of flat flame burner sub-assembly 102 and staged injector block 108 arranged to receive staged injector sub-assembly 104. In one example, flat flame burner block 106 includes a top surface TS and a bottom surface BS (shown in FIGS. 13A-13B). It should be appreciated that flat flame burner block 106 and staged injector block 108 can be made from highly insulative thermal materials, e.g., refractory ceramic materials or any other material capable of insulating the heat generated in the combustion processes described below. As will be discussed below in detail, flat flame burner sub-assembly 102 is arranged to receive a gas 120 (shown in FIG. 5) and a fuel 122 (shown in FIG. 5) from a respective gas source (not shown) and a respective fuel source (not shown) and generate combustion within flat flame burner block 106. Flat flame burner sub-assembly 102 can be removably secured to flat flame burner block 106 via at least one clasp C as illustrated in FIGS. 1-2. Additionally, as will be discussed below in further detail, staged injector sub-assembly 104 and stage injector block 108 are separable from flat flame burner sub-assembly 102 and flat flame burner block 106. [0043] Flat flame burner sub-assembly 102 includes a flat flame burner body 110. Flat flame burner body 110 is intended to be a single unitary body made from stainless steel, e.g., 303, 304, or 310 grade stainless steel, and can have a plurality of apertures arranged to receive the various components discussed below, which engage with flat flame burner body 110. In one example, the components discussed below are integral with flat flame body 110 or may be secured to these apertures via friction fit. Additionally, these apertures may have embossed or molded female or male helical threads arranged to receive complementary female or male threading of the various components which engage with flat flame burner body 110 as will be described below. Flat flame burner sub-assembly 102 further includes first gas inlet 112, first fuel inlet 114, first gas nozzle 116, and first fuel nozzle 118 (shown in FIG. 2). Additionally, as illustrated in FIGS. 1, 5, and 13A-13B, flat flame burner body 110 may also be arranged to engage with a flat flame burner sub-assembly support bracket SB secured to flat flame burner block 106 to support the weight of flat flame burner sub- assembly 102 during operation. [0044] As illustrated in FIG. 2, which shows a top plan view of flat flame burner sub- assembly 102 and flat flame burner block 108, first gas inlet 112 is arranged to engage with flat flame burner body 110 in at least one of the ways described above and is also arranged in fluid communication with a gas source (not shown) such that a gas 120 (shown in FIG. 5) can be provided from the source into first gas inlet 112 and into flat flame burner body 110. First gas inlet 112 is intended to be a tubular member and can be made from stainless steel, e.g., 303, 304, or 310 grade stainless steel. It should be appreciated that first gas inlet 112 can take any size or form sufficient to provide the appropriate volume of gas 120 into flat flame burner body 110 and subsequently into first gas nozzle 116 as will be described below. Gas 120 is intended to be oxygen or a gaseous mixture containing a substantial portion of oxygen. It should be appreciated that other gaseous mixtures could be utilized, e.g., gaseous mixtures comprising oxygen or any other gaseous oxidant that supports combustion processes.

[0045] First fuel inlet 114 is arranged to engage with flat flame burner body 110 in at least one of the ways described above and is also arranged in fluid communication with a fuel source (not shown) such that a fuel 122 (shown in FIG. 5) can be provided from the fuel source into first fuel inlet 114 and into flat flame burner body 110. Similarly to first gas inlet 112 as discussed above, first fuel inlet 114 is intended to be a tubular member and can be made from stainless steel, e.g., 303, 304, or 310 grade stainless steel. It should be appreciated that first fuel inlet 114 can take any size or form sufficient to provide the appropriate volume of fuel 122 into flat flame burner body 110 and subsequently into first fuel nozzle 118 discussed below. Fuel 122 can be selected from: Methane, Propane, Butane, Hydrogen, Natural Gas, Carbon Monoxide, a combination of any of the foregoing, or any other gaseous fuel capable of auto-ignition at high temperatures.

[0046] As illustrated in FIG. 2, first gas nozzle 116 includes first end 124 and second end 126. It should be appreciated that first end 124 is arranged to engage with flat flame burner body 110 in any of the ways described above. For example, first end 124 may have an outer circumferential surface having threads machined thereon arranged to engage with complementary threads machined onto flat flame burner body 110. These threads can have various thread counts, i.e., threads per inch, and can vary from a low thread count having the advantage of being cheaper to manufacture at the cost of precision to having a high thread count with high precision with the disadvantage of increased cost of manufacturing. Second end 126 of first gas nozzle 116 is arranged such that it terminates, or ends, at a first distance D1 measured from flat flame burner body 110 in first direction DR1 with respect to flat flame burner body 110. Additionally, first gas nozzle 116 further includes a through-bore arranged to extend along the length of first gas nozzle 116 from first end 124 to second end 126.

[0047] Additionally, flat flame burner sub-assembly 102 also includes first fuel nozzle 118. First fuel nozzle 118 includes first end 128 and second end 130. It should be appreciated that first end 128 is arranged to engage with flat flame burner body 110 in any of the ways described above. Additionally, as illustrated, first end 128 of first fuel nozzle 118 is arranged to be secured to first fuel inlet 114 which is arranged to extend through the cavity created within flat flame burner body 110. For example, first end 128 may have an outer circumferential surface having threads machined thereon arranged to engage with complementary threads machined onto flat flame burner body 110 or first fuel inlet 114. These threads can have various thread counts, i.e., threads per inch, and can vary from a low thread count having the advantage of being cheaper to manufacture at the cost of precision to having a high thread count having high precision with the disadvantage of increased cost of manufacturing. Second end 130 of first fuel nozzle 118 is arranged such that it terminates, or ends, at a second distance D2 measured from flat flame burner body 110 in first direction DR1 with respect to flat flame burner body 110, where second distance D2 is greater than first distance Dl. It should also be appreciated that, although not shown, flat flame burner sub-assembly 102 may be arranged such that first gas nozzle 116 and first fuel nozzle 118 terminate at the same distance with respect to flat flame burner body 110, e.g., where first distance Dl is equal to second distance D2 in first direction DR1. Additionally, first fuel nozzle 118 further includes a through-bore arranged to extend along the length of first fuel nozzle 118 from first end 128 to second end 130 such that first fuel nozzle 118 at least partially encompasses first gas nozzle 116 circumferentially.

[0048] The following description should be read in view of FIGS. 3-4B. FIG. 3 illustrates a side elevational view of flat flame burner sub-assembly 102. FIGS. 4A and 4B illustrate a front side elevational view and rear side elevational view, respectively, of first gas nozzle 116 and first fuel nozzle 118. As illustrated in FIGS. 3-4B, first gas nozzle 116 has first end 124 and second end 126, where the first end 124 is arranged proximate flat flame burner body 110 when secured within flat flame burner sub-assembly 102. At the first end 124 of first gas nozzle 116, the nozzle aperture has a first height HI and a first width Wl. In an example, the aperture arranged at the first end 124 of first gas nozzle 116 is circular and has a first height HI between 75-130 mm (approximately 3-5 inches) and has a first width Wl also between 75-130 mm (approximately 3-5 inches). It should be appreciated that the nozzle aperture at the first end 124 of first gas nozzle 116 can take any shape and have any size so as to provide an appropriate volume of gas 120 (shown in FIG. 5) to the combustion process described herein. At the second end 126 of first gas nozzle 116, the nozzle aperture has a second height H2 and a second width W2, where second height H2 is less than first height HI and second width W2 is greater than first width Wl. In one example, second height H2 is approximately 40-65 mm (approximately 1.5-2.5 inches) and second width W2 is approximately 15-175 mm (approximately 6-7 inches). The tapered nozzle shape described above operates to funnel and reshape the gas flow of gas 120 (shown in FIG. 5) as it exits second end 126 of first gas nozzle 116 such that gas 120 is evenly provided across second width W2 and mixes with fuel 122 to aid in combustion as will be described below.

[0049] Additionally, first fuel nozzle 118 has first end 128 and a second end 130, where the first end 128 is arranged proximate flat flame burner body 110 when secured within flat flame burner sub-assembly 102. At the first end 128 of first gas nozzle 116, the nozzle aperture has a third height H3 and a third width W3. In an example, the aperture arranged at the first end 128 of first fuel nozzle 118 is circular and has a third height H3 between 50-75 mm (approximately 2-3 inches) and has a third width W3 also between 50-75 mm (approximately 2-3 inches). It should be appreciated that the nozzle aperture at the first end 128 of first fuel nozzle 118 can take any shape and have any size so as to provide an appropriate volume of fuel 122 (shown in FIG. 5) to the combustion process described herein. At the second end 130 of first fuel nozzle 118, the nozzle aperture has a fourth height H4 and a fourth width W4, where fourth height H4 is less than third height H3 and fourth width W4 is greater than third width W3. In one example, fourth height H4 is approximately 10-40mm (approximately 0.5-1.5 inches) and fourth width W4 is approximately 115-165 mm (approximately 4.5-6.5 inches). The tapered nozzle shape described above operates to funnel and reshape the flow of fuel 122 (shown in FIG. 5) as it exits second end 130 of first fuel nozzle 118 such that fuel 122 is evenly provided across fourth width W4 and mixes with gas 120 to aid in combustion as will be described below.

[0050] As illustrated in FIG. 5, during operation, gas 120 is permitted to flow from a gas source (not shown) to first gas inlet 112 of flat flame burner body 110. Gas 120 is forced to flow from flat flame burner body 110 in first direction DR1 and within first gas nozzle 116. Gas 120 flows circumferentially outward of first fuel nozzle 118 and from first end 124 to second end 126 of first gas nozzle 116. The tapered transition from first height HI and first width Wl of first gas nozzle 116 to second height H2 and second width W2 shapes gas 120 as it exits second side 126 of first gas nozzle 116 to be used in combustion within flat flame burner block 106. Simultaneously, fuel 122 is permitted to flow from a fuel source (not shown) to first fuel inlet 114 of flat flame burner body 110. Fuel 122 is forced to flow from first fuel inlet 114 in first direction DR1 and within first fuel nozzle 118. Fuel 122 flows within first fuel nozzle 118 from first end 128 to second end 130. The tapered transition from third height H3 and third width W3 of first fuel nozzle 118 to fourth height H4 and fourth width W4 shapes the gaseous fuel 122 as it exits second end 130 of first fuel nozzle 118 to be used in combustion within flat flame burner block 106. The tapered transitions of first gas nozzle 116 and first fuel nozzle 118 create combustion with a flat shaped flame, i.e., a flame that is substantially flat and spans the width of the through-bore in flat flame burner block 106. A flat flame shape results in higher fuel efficiency of the entire burner system.

[0051] The following description should be read in view of FIGS. 6-9B. FIG. 6 illustrates a front perspective view of staged injector sub-assembly 104. FIG. 7 is a side elevational view of staged injector sub-assembly 104 secured to staged injector block 108. FIGS. 8A and 8B illustrate rear and top plan views, respectively, of staged injector sub- assembly 104 secured to staged injector block 108. Similarly, FIGS. 9A and 9B illustrate front and side views, respectively, of staged injector sub-assembly 104. Staged injector sub- assembly 104 includes a staged injector body 132. Staged injector body is intended to be a single unitary body made from stainless steel, e.g., 303, 304, or 310 grade stainless steel, and can have a plurality of apertures arranged to receive the various components discussed below, which engage with staged injector body 132. In one example, the components discussed below are integral with staged injector body 132 or may be secured to these apertures via friction fit. Additionally, these apertures may have embossed or molded female or male helical threads arranged to receive complementary female or male threading of the various components which engage with staged injector body 132 as will be described below.

[0052] Staged injector body 132 further includes second gas inlet 134, a staged injector nozzle 136, a flange 138, and at least one half coupling 140. Second gas inlet 134 is arranged to receive gas 120 from a gas source (not shown). Second gas inlet 134 is arranged to engage with staged injector body 132 in at least one of the ways described above and is also arranged in fluid communication with a gas source (not shown) such that a gas 120 (shown in FIG. 5) can be provided from the source into second gas inlet 134 and into staged injector body 132. Second gas inlet 134 is intended to be a tubular member and can be made from stainless steel, e.g., 303, 304, or 310 grade stainless steel. It should be appreciated that second gas inlet 134 can take any size or form sufficient to provide the appropriate volume of gas 120 into staged injector body 132 and subsequently into staged injector nozzle 136 as will be described below. Staged injector nozzle 136 is arranged at one end of the staged injector body 132 and arranged to slidingly engage with recess 150 (discussed below) of staged injector block 108 such that gas 120 provided within staged injector body 132 can flow from staged injector body 132 into the plurality of gas channels 154A-154C (discussed below) of staged injector block 108. Moreover, so that staged injector nozzle 136 sits flush within recess 150, staged injector body 132 further includes a flange 138 arranged circumferentially about at least a portion of staged injector nozzle 136 and arranged to contact first side 142 (discussed below) of staged injector block 108 during operation of block and burner assembly 100. Flange 138 can include through-bores or apertures arranged to receive a fastener or bolt such that the bolt may secure the flange 138 and subsequently the staged injector body 132 to staged injector block 108. It should be appreciated that other fasteners may be used, including but not limited to, bolts, screws, or clasps, e.g., clasps C as illustrated in FIGS. 1-2 above. Additionally, staged injector body 132 may also include half couplings 140 arranged on or through at least a portion of staged injector body 132. It should be appreciated that half couplings 140 may be arranged to connect to external devices, such as but not limited to, pressure gauges, flow meters, etc.

[0053] As discussed above, staged injector body 132 of staged injector sub-assembly 104 is arranged to be removably secured to staged injector block 108. As shown in FIGS. 10- 12B, which illustrate perspective, front, back, top and side views of staged injector block 108, respectively, staged injector block 108 has a first side 142, a second side 144, a top surface 146 and a bottom surface 148. Proximate first side 142, staged injector block 108 includes a recess 150 and a fastener recess 152. Although recess 150 is illustrated as a rectangular depression, it should be appreciated that recess 150 can be any size or take any shape which complements the shape of staged injector nozzle 136 such that at least a portion of staged injector nozzle 136 extends into recess 150. Additionally, as discussed above, staged injector block 108 may further include one or more fastener recesses 152 arranged to receive a fastener such as a bolt or screw through the through-bores in flange 138 of staged injector sub-assembly 104.

[0054] Staged injector block 108 further includes a plurality of gas channels 154A- 154C (collectively referred to as “plurality of gas channels” or “plurality of gas channels 154”) which are arranged within and through staged injector block 108 and are arranged to span from first side 142 of staged injector block 108 to second side 144 of staged injector block 108. Additionally, staged injector block 108 further includes a plurality of apertures 156A-156F (collectively referred to as “plurality of apertures” or “plurality of apertures 156”). As illustrated in FIGS. 11A and 11B, each gas channel of plurality of gas channels 154 includes two apertures, one proximate first side 142 and one proximate second side 144. Thus, first side 142 includes three apertures 156A-156C of plurality of apertures 156, and second side 144 includes three apertures 156D-156F, i.e., two apertures for each channel. In one example, gas channel 154A begins proximate first side 142 with aperture 156A and terminates proximate second side 144 with aperture 156F. Similarly, gas channel 154B begins proximate first side 142 with aperture 156B and terminates proximate second side 144 with aperture 156E. Finally, gas channel 154C begins proximate first side 142 with aperture 156C and terminates proximate second side 144 with aperture 156D.

[0055] In one example, illustrated in FIGS. 11A-11B and 12B, each gas channel of plurality of gas channels 154 is arranged with a downward pitch or angle such that each gas channel is sloped from first side 142 to second side 144 in the direction of the flat flame burner block 106. Said another way, the apertures of each gas channel arranged proximate first side 142 (e.g., apertures 156A-156C) are arranged at a first aperture distance ADI from the bottom surface 148 of staged injector block 108 (or from flat flame burner block 106 as bottom surface 148 and flat flame burner block are arranged to contact each other during operation). Additionally, the apertures of each gas channel arranged proximate second side 144 (e.g., apertures 156D-156F) are arranged at a second aperture distance AD2 from bottom surface 148 of staged injector block 108 (or from flat flame burner block 106), where the second aperture distance AD2 is less than the first aperture distance ADI. The differential in apertures distances of the first set of apertures and the second set of apertures results in gas channels with a downward slope, i.e., sloped in the direction of flat flame burner block 106 from first side 142 to second side 144.

[0056] In another example, each gas channel of plurality of gas channels 154 are arranged at different radial angles with respect to each other, i.e., are arranged non-parallel to each other. As illustrated in FIG. 12A, gas channel 154B is arranged substantially parallel with an imaginary center axis A arranged from first side 142 to second side 144 of staged injector block 108. Additionally, as shown in FIG. 12A, gas channel 154A is arranged at a first radial angle RA1 and gas channel 154C is arranged at a second radial angle RA2 with respect to the imaginary center axis A. In one example, first radial angle RA1 and second radial angle RA2 are selected from the range of 1-20 degrees, or more specifically, from the range of 5-8 degrees, or even more specifically, 6.47 degrees with respect to center axis A. In one example, first radial angle RA1 and second radial angle RA2 are selected such that gas channels 154A and 154C flare outward at appropriate radial angles with respect to center axis A as the gas channels proceed from first side 142 to second side 144 such that gas 120 that exits each gas channel is provided at a location that substantially matches the width (e.g., second width W2 of flat flame nozzle 116) of the flat flame produced by flat flame burner sub-assembly 102 as discussed above. The availability of this additional staging gas 120 after initial combustion by the flat flame burner sub-assembly 102, increases the efficiency of the overall block and burner system 100. Moreover, the ability to separately adjust the secondary gas flow, i.e., the flow of gas 120 through staged injector sub-assembly 104 and into staged injector block 108, allows for enhanced flame control of the flat flame produced by the flat flame burner sub-assembly 102. In one example, the ratio and flow rate of gas 120 through staged injector sub-assembly 104 can be adjusted to increase or decrease the length of the flame produced by the system, and/or increase or decrease the width of the flame produced within the through-bore of flat flame burner block 106.

[0057] As mentioned above, it should be appreciated that block and burner system 100 can be fired in a staged or unstaged arrangement. In the unstaged arrangement, block and burner system 100 includes only the flat flame burner sub-assembly 102 secured to flat flame burner block 106. In this unstaged arrangement, the ratio of gas 120 to fuel 122 is 2:1 and results in a first efficiency of the overall system. In the staged arrangement, the system includes the flat flame burner sub-assembly 102 secured to flat flame burner block 106 as well as staged injector sub-assembly 104 secured to staged injector block 108. Importantly, in the staged arrangement, the ratio of gas 120 to fuel 122 can be adjusted and/or separated for increased burner efficiency of the combustion generated by flat flame burner sub-assembly 104. In one example, the ratio of gas 120 to fuel 122 fired through the flat flame burner sub- assembly is 1:1, while the remaining portion of gas 120 is provided by the staged injector sub-assembly 104. By providing the additional staged gas through the plurality of gas channels 154 as discussed above, the overall efficiency and control of the flames produced by the system can be controlled with enhanced precision.

[0058] Additionally, in the staged arrangement, staged injector block 108 is arranged to sit atop flat flame burner block 106 (e.g., in contact with top surface TS) during operation of block and burner assembly 100. It should also be appreciated that staged injector block 108 may be arranged to be secured beneath flat flame burner block 106 (e.g., in contact with bottom surface BS) during operation of block and burner assembly 100. Additionally, as illustrated in FIGS. 13A or 13B, it should be appreciated that in either configuration, i.e., where staged injector block 108 is arranged above or below flat flame burner block 106, there may be a bracket 158 or other mechanism arranged between flat flame burner block 106 and staged injector block 108 to secure the blocks to each other and prevent them from moving relative to each other during operation. Although not illustrated, it should be appreciated that other configurations are possible, for example, where staged injector block 108 is arranged to be secured to a side face of flat flame burner block 106, etc.

[0059] The foregoing block and burner system, e.g., block and burner assembly 100 has several distinguished advantages. First, flat flame burner sub-assembly 102 produces a flat flame during the combustion process discussed above which increases overall burner efficiency. Second, the foregoing block and burner assembly allows for enhanced control of the flat flame produced in flat flame burner sub-assembly 102 by allowing for precise control of staging gases through staged injector sub-assembly 104 and staged injector block 108. Third, the block and burner assembly 100 is flexible in its application. For example, the system may operate with a flat flame burner sub-assembly that is designed for staged combustion, i.e., a burner sub-assembly which requires additional staging gas to be provided at a different point in the combustion process than the initial ignition, or, the system may operate with a flat flame burner sub-assembly that is designed for unstaged combustion, i.e., a burner sub-assembly which does not require additional staging gas. Additionally, as the materials used for both the flat flame burner block 106 and the staged injector block 108 are typically brittle and susceptible to cracking during repeated combustion operations, the foregoing block and burner assembly 100 allows for replacement and/or repair of each portion of block, i.e., flat flame burner block 1086 or staged injector block 108 independently. Furthermore, having the two blocks separable as described above, prevents a crack that begins in one block from travelling to the other block. Lastly, the first gas nozzle 116 and first fuel nozzle 118 of flat flame burner sub-assembly 102 are arranged to extend a first distance D1 from the body of the sub-assembly and a second distance D2 from the body of the sub-assembly, respectively, where the first distance D1 is less than or equal to the second distance D2. This nozzle arrangement prevents gas 120 from first gas nozzle 116 from mixing with fuel 122 from first fuel nozzle 118 before it leaves the flat flame burner sub- assembly. External mixing of gas 120 and fuel 122 helps prevent backfiring and reduces operating temperatures of the sub-assembly.

[0060] While several inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the inventive teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described and claimed. Inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, and/or methods, if such features, systems, articles, materials, and/or methods are not mutually inconsistent, is included within the inventive scope of the present disclosure.