System comprising a gasification feed injector and a tip cap, method for coupling a tip cap to a tip part of an outlet region of a gasification feed injector and device comprising a tip cap

Abstract

System 10, comprehensive: a gasification feed injector 16, which has a tip part 82 arranged at a fluid outlet region of the gasification feed injector 16, wherein the tip part 82 has a first contact surface with a first geometry; and a tip cap 84 coupled to the tip part 82 of the gasification feed injector 16, wherein the tip cap 84 is designed to serve as a thermal barrier for the tip part 82 during gasification reactions, and the top cap contains 84: a second mounting surface facing the first mounting surface and having a second geometry, wherein the second geometry reflects the first geometry, and an outer surface 104 having a third geometry, wherein the third geometry is convex with respect to the gasification feed injector 16, and where the top cap is 84, a first annular opening 108 which is positioned coaxially relative to a second annular opening 90 of the tip part 82, and the first annular opening 108 has a larger diameter 132 than the second annular opening 90, characterized by the fact that the tip cap 84, a body having a first annular opening 108, wherein the thickness of the body increases in a direction radially away from the first annular opening 108, and is made of a ceramic fiber composite material (CMC) which has several layers, and the number of layers of the tip cap 84 increases in the direction radially away from the first annular opening 108 to create the increase in body thickness.

Description

BACKGROUND OF THE INVENTION

[0001] The subject matter disclosed herein relates to a system comprising a gasification feed injector and a tip cap, and in particular a tip cap for a gasification feed injector, as well as a method for coupling a tip cap with a tip part of an outlet region of a gasification feed injector and a device comprising a tip cap.

[0002] Various reactors and / or combustion systems employ feed injectors to inject a feed material into a combustion chamber. For example, an integrated gasification combined cycle power plant (IGCC) has a gasifier and one or more feed injectors. The feed injectors supply the gasifier with oxygen and steam, along with a fuel or feed material, such as an organic feed, to produce synthesis gas. Generally, a gasification reaction takes place downstream of the feed injectors. However, a flame and / or heat from the reaction in close proximity to the feed injectors can shorten the service life of the feed injectors, especially if the feed injectors exceed certain temperatures. For example, the feed injector may be exposed to increasingly higher temperatures towards its tip and / or other points near the flame.The service life of feed injectors can be reduced by such high temperatures, even when cooling methods are used.

[0003] For example, EP 0 362 997 A1 discloses a nozzle for atomizing a liquid with a gas, which includes a protective cap for the nozzle tip. The tip comprises a central outlet with a shoulder at its upstream end and a thermally resistant heat shield made of metal alloy, which is attached to a retaining ring located upstream of the shoulder and in contact with it.

[0004] US 2500089 relates to blast furnace blast nozzles and, in particular, to a composite blast nozzle structure consisting of double copper walls to maintain a circulating coolant flow in the body of the blast nozzle and a tip or end made of graphite to protect the blast nozzle from burning through into the circulation chamber.

[0005] DE 601 20 674 T2 discloses a device for partial oxidation synthesis gas generation from the combustion of a fossil fuel source in the presence of water and oxygen. It uses a shielding means to protect the combustion-facing surface of a fuel injection burner arrangement. In particular, a means for attaching a heat shield to the surface of the cooling water jacket is described. BRIEF SUMMARY OF THE INVENTION

[0006] Below, certain embodiments that correspond in scope to the originally claimed invention are briefly summarized.

[0007] In a first embodiment according to claim 1, a system comprises a gasification feed injector having a tip part arranged at a fluid outlet region of the gasification feed injector, wherein the tip part has a first contact surface with a first geometry, and a tip cap coupled to the tip part of the gasification feed injector, wherein the tip cap is designed to serve as a thermal barrier for the tip part during gasification reactions, and wherein the tip cap includes a second contact surface facing the first contact surface and having a second geometry, the second geometry mirroring the first geometry, and the tip cap includes an outer surface having a third geometry, the third geometry being convex with respect to the gasification feed injector, and wherein the tip cap has a first annular opening.which is positioned coaxially relative to a second annular opening of the tip part, and the first annular opening has a larger diameter than the second annular opening, and the system is characterized in that the tip cap has a body having a first annular opening, wherein the thickness of the body increases in a direction radially away from the first annular opening, and is made of a ceramic fiber composite (CMC) having several layers, and a number of layers of the tip cap increase in the direction radially away from the first annular opening to produce the increase in body thickness.

[0008] In a second embodiment according to claim 8, a method includes coupling a tip cap with a tip part of an outlet region of a gasification feed injector, wherein the tip cap is designed to serve as a heat barrier for the tip part during gasification reactions, characterized in that a thickness of the tip cap varies through the entire diameter of a body of the tip cap.

[0009] In a third embodiment according to claim 15, a device comprises a tip cap comprising a body having a first annular opening, wherein the thickness of the body increases in a direction radially away from the first annular opening, and a first contact surface arranged on the body, wherein the first contact surface has a first geometry that essentially reflects a second geometry of a second contact surface of a gasification feed injector; and the device is characterized in that the body has a first annular opening, wherein the thickness of the body increases in a direction radially away from the first annular opening, and the tip cap comprises a lip extending circumferentially around the body and radially away from the body, wherein the lip has a lip diameter that is larger than an injector diameter of the gasification feed injector. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] These and other features, aspects and advantages of the present invention will be better understood if the following detailed description is read with reference to the accompanying drawings, in which the same reference numerals throughout all drawings denote the same parts, wherein: Fig. 1 a block diagram of an embodiment of an IGCC power plant with a carburetor which uses a feed injector, wherein the feed injector has a tip cap according to present embodiments; Fig. 2 an axial cross-section of an embodiment of a feed injector with a tip cap; Fig. 3 a front view illustration of an embodiment of the tip cap of Fig. 2 is; Fig. 4 is an axial cross-section of an embodiment of a feed injector, which is equipped with high-temperature screws with the tip cap of Fig. 2 is coupled; Fig. 5 is an axial cross-section of an embodiment of a feed injector, which is connected to the tip cap by spring-loaded tabs. Fig. 2 is coupled; Fig. 6 is an axial cross-section of an embodiment of a feed injector, which is bonded with a high-temperature adhesive with the tip cap of Fig. 2 is coupled; and Fig. 7 an axial cross-section of an embodiment of a feed injector connected to the tip cap by an inclined surface Fig. 2 is coupled. DETAILED DESCRIPTION OF THE INVENTION

[0011] Below, one or more specific embodiments of the present invention are described. In an effort to provide a concise description of these embodiments, not all features of an actual embodiment may be described. It should be noted that, as with any engineering or design project, the development of such an actual embodiment requires numerous embodiment-specific decisions to be made in order to achieve the developer's specific objectives, such as compliance with system-related and business-related requirements, which may vary from one embodiment to another. Furthermore, it should be noted that such development efforts can be complex and time-consuming, but would nevertheless be routine in terms of design, manufacturing, and production for the average person skilled in the art who benefits from this disclosure.

[0012] When introducing elements of different embodiments of the present invention, it is intended that the articles "a", "an", "the", and "mentioned" mean that there is one or more of the elements. It is intended that the terms "have", "include", and "have" are comprehensive and mean that there may be additional elements besides those listed.

[0013] A reactor or combustion system may utilize feed injectors to inject a feed material or fuel and other fluids, such as oxygen and water, into a chamber (e.g., from gasification or partial gasification). In this explanation, the terms fuel and feed material may be used interchangeably and may refer to any substance used to drive a reaction, gasification, partial combustion, or complete combustion. Likewise, the terms reaction, combustion, and gasification may be used interchangeably and may refer to one or more chemical reactions, combustion, and / or gasification. In certain embodiments, an IGCC power plant may have a gasifier that incorporates one or more gasification feed injectors. Because certain processes that occur during gasification (e.g.,Since partial combustion can occur near the tip of the feed injector, the tip can be exposed to temperatures up to approximately 1300 degrees Celsius (°C). Furthermore, hot combustion gases can flow back towards the feed injector. Such high temperatures can damage the feed injector, even in designs where the injector is made of materials specifically engineered for high temperatures. Accordingly, various cooling methods can be used to extend the service life of feed injectors. For example, feed injector tips can have an integrated coolant chamber to allow a coolant to flow through them. Alternatively, a cooling coil can surround the body of the feed injector to direct coolant to the coolant chamber.However, such methods can be inadequate because an outer surface of the feed injector may be exposed to hot backflowing gases, while an inner surface of the feed injector is in contact with the coolant. The coolant temperature may be, for example, around 40 °C, resulting in a temperature gradient of approximately 1260 °C. Such a large temperature gradient can lead to thermal stresses, which in some cases can cause cracks near the tip of the feed injector. In some embodiments, the high temperatures and temperature fluctuations near the tip can cause radial cracks. Furthermore, high stress forces caused by the large temperature gradient can cause circumferential cracks. Thicker coolant chamber walls designed for strength can impede heat transfer and thus contribute to large temperature gradients.Overall, such thermal stresses can reduce the service life of the supply injector.

[0014] In light of the foregoing, the disclosed embodiments include a tip cap coupled to a tip portion of a gasification feed injector. The tip portion may be located at a fluid outlet region of the gasification feed injector, and the cap may serve as a thermal barrier (or heat shield) for the tip portion during gasification reactions. In certain embodiments, the tip cap may completely separate the tip portion from a reaction zone and may have an annular opening corresponding to an annular opening in the tip portion.

[0015] Fig. Figure 1, now referring to the drawings, is a diagram of an embodiment of an IGCC system 10 that can produce and combust a synthetic gas, i.e., synthesis gas, for power generation. As discussed in detail below, the IGCC system 10 may include an embodiment of a gasification feed injector having a tip cap that may act as a thermal barrier, capable of withstanding temperatures above those encountered in the gasification reaction environment. In certain embodiments, the tip cap may act as a sacrificial thermal barrier—one that can be replaced at regular intervals or as needed. The tip cap may act as a heat shield for the tip portion, reducing thermal fatigue and subsequent surface cracking.Although the present embodiments of the tip cap are described in the context of the IGCC system 10, the IGCC system 10 is used as a non-limiting example, and it should be understood that the tip cap can be used in other system types that employ gasification. Other elements used by the IGCC system 10 may include a fuel source 12, which can be a gas, a solid, or a liquid and which can be used as an energy source for the IGCC system. Examples of fuel sources 12, without limitation, include coal, petroleum coke, oil, biomass, wood-based materials, agricultural waste, tars, coke oven gas, asphalt, or other carbon-containing articles.

[0016] The fuel from the fuel source 12 can be transferred to a feed material preparation unit 14. The feed material preparation unit 14 can, for example, change the size or shape of the fuel source 12 to produce the feed material. Furthermore, water or other suitable liquids (e.g., alcohols) can be added to the fuel source 12 in the feed material preparation unit 14 to form a feed material slurry. In other embodiments, no liquid is added to the fuel source, resulting in a dry feed material. In further embodiments, the feed material preparation unit 14 can be omitted if the fuel source 12 is a liquid.

[0017] Next, the feed material can be directed to a feed injector 16, which is coupled to (e.g., attached to and / or within) a carburetor 18. Although the present embodiments are discussed in the context of an IGCC system with a carburetor utilizing the feed injector and the feed injector tip cap disclosed herein, it should be noted that the carburetor 18 is only one example of a combustion chamber that can utilize the feed injector 16 with the structural supports and multiple coolant channels, as discussed in detail below. The feed injector 16 with the tip cap of the present disclosure can, in fact, be used in various other contexts where reactions or combustion processes can affect an injector. In certain embodiments, the feed injector 16 combines the various feed streams of the carburetor 18 to promote efficient gasification.Specifically, the gasifier 18 can convert the feedstock into a synthesis gas, e.g., a combination of carbon monoxide and hydrogen. This conversion can be achieved by exposing the feedstock to a controlled quantity of steam, oxygen, or carbon dioxide, depending on the type of gasifier 18 used, at elevated pressures and temperatures. The gasification process can involve the feedstock undergoing pyrolysis, which heats the feedstock. Temperatures inside the gasifier 18 can vary considerably and can range, for example, from approximately 150 °C to 700 °C during the pyrolysis process, depending on the fuel source 12 used to generate the feedstock. The heating of the feedstock during the pyrolysis process can produce a solid (e.g., charcoal) and low-value gases (e.g., carbon monoxide, hydrogen, and nitrogen).

[0018] A partial combustion process can then take place in the gasifier 18. This combustion can involve the introduction of controlled amounts of oxygen to the charcoal and the low-value gases (e.g., via the feed injector 16). The charcoal and the low-value gases can react with the oxygen to form carbon dioxide and carbon monoxide, which provides the heat for the subsequent gasification reactions. The temperatures during the combustion process can range, for example, from approximately 700 °C to 920 °C. Next, during a gasification step (e.g., via the feed injector 16), steam can be introduced into the gasifier 18. The charcoal can react with the carbon dioxide and the steam to form carbon monoxide and hydrogen at temperatures ranging from approximately 800 °C to 24 °C.Essentially, the carburetor 18 uses steam and oxygen to "burn" a portion of the feed material, generating carbon monoxide and releasing energy that drives a second reaction, converting further feed material into hydrogen and additional carbon dioxide. Given the foregoing, it is clear that the feed injector 16 can be exposed to many different temperatures and potentially corrosive substances. Here again, the tip cap of the present disclosure, attached to the feed injector 16, can help to mitigate the effects of these high-temperature gases on the feed injector 16 (e.g., a tip and / or body of the feed injector 16).

[0019] For example, the resulting gas produced by the gasification process can mainly contain carbon monoxide and hydrogen, as well as CH4, HCl, HF, COS, NH3, HCN, and H2S. This resulting gas can be referred to as untreated synthesis gas because it contains, for example, H2S. In addition to the gaseous products, the gasifier 18 can also produce waste, such as slag 22, which can be a wet ash material. This slag 22 can be removed from the gasifier 18 and disposed of, for example, as a road base or as another building material.

[0020] Downstream of the gasifier 18, a gas cleaner 24 can be used to treat the untreated synthesis gas. For example, in one embodiment, the gas cleaner 24 can include a water-gas shift reactor. The gas cleaner 24 can scrub the untreated synthesis gas to remove HCl, HF, COS, HCN, and H₂S, and can include sulfur removal 26 in a sulfur unit 28, for example, through a process for removing acid gas. Furthermore, the gas cleaner 24 can remove salts 30 from the untreated synthesis gas via a water treatment unit 32, which can utilize water purification methods to produce usable salts 30 from the untreated synthesis gas. Subsequently, the gas from the gas purifier 24 may contain treated synthesis gas (e.g. after removal of the sulfur 26 from the synthesis gas) with traces of other chemical substances, e.g. NH3 (ammonia) and CH4 (methane).

[0021] In some embodiments, a carbon dioxide capture system 34 can remove and process the carbon-containing gas (e.g., carbon dioxide) contained in the synthesis gas. The carbon dioxide capture system 34 can also include a compressor, a purifier, a pipeline that supplies CO2 for sequestration or improved oil recovery, a CO2 storage tank, or a combination thereof. After passing through the system to remove its sulfur-containing components and a large proportion of its carbon dioxide, the treated synthesis gas can then be fed as combustible fuel into a combustion chamber 36, e.g., a combustion chamber, of a gas turbine engine 38.

[0022] The IGCC system 10 can further include an air separation unit (ASU) 40. The ASU 40 can be operated to separate air into its gaseous components, for example, by distillation methods. The ASU 40 can separate oxygen from the air supplied to it by an auxiliary air compressor 42, and the ASU 40 can direct the separated oxygen to the supply injector 16. In addition, the ASU 40 can direct separated nitrogen to the supply injector 16 (e.g., as coolant 20) or to a dilute nitrogen compressor 44 (DGAN). The DGAN compressor 44 can compress the nitrogen obtained from the ASU 40 to pressure levels suitable for use in the combustion chamber 36. The nitrogen can be used as a diluent, for example, to limit emissions.

[0023] The gas turbine machine 38 can include a turbine 46, a drive shaft 48, a compressor 50, and a combustion chamber 36. The combustion chamber 36 can receive fuel, such as synthesis gas or synthetic natural gas, compressed air from the compressor 50, and compressed nitrogen from the DGAN compressor 44. The combustion of the fuel within the combustion chamber 36 creates hot, pressurized exhaust gases, which are used to drive the turbine 46, causing the turbine 46 to rotate the drive shaft 48 along an axis of the gas turbine machine 38. As shown, the drive shaft 48 is connected to various components of the gas turbine machine 38, including the compressor 50. The drive shaft 48 can also be connected to the load 52, which can be a stationary load, such as an electric generator for electricity production, for example, in a power plant.The load 52 can be any suitable device driven by the rotational output of the gas turbine engine 38.

[0024] The IGCC system 10 can also include a steam turbine 54 and a heat recovery steam generator (HRSG) system 56. The steam turbine 54 can drive a second load 58. The second load 58 can also be an electric generator for electricity production. However, both the first 52 and the second 58 loads can be other load types that can be driven by the gas turbine 38 and the steam turbine 54. Furthermore, while the gas turbine 38 and the steam turbine 54 can drive separate loads 52 and 54, as shown in the illustrated embodiment, the gas turbine 38 and the steam turbine 54 can also be operated in tandem to drive a single load via a single shaft. The specific configuration of the steam turbine 54 and the gas turbine 38 can be embodiment-specific and may include a combination of sections.

[0025] Heated exhaust gas from the gas turbine engine 38 can be transported to the HRSG 56 and used to heat water and generate steam, which is used to drive the steam turbine engine 54. Exhaust gas from, for example, a low-pressure section of the steam turbine engine 54 can be directed to a condenser 60. The condenser 60 can utilize a cooling tower 62 for the exchange of heated water for cooled water. The cooling tower 62 serves to supply the condenser 60 with cool water to aid in the condensation of the steam directed from the steam turbine engine 54 to the condenser 60. Water from the cooling tower 62 can also be used as a coolant 20 for the feed injector 16, which, in addition to the peak cap, can be used to mitigate the effects of the high temperatures in the gasifier on the feed injector 16.

[0026] Furthermore, or alternatively, the steam generated by the HRSG 56 can be supplied to the carburetor 18 or the feed injector 16 as the coolant 20. The hot backflowing gases inside the carburetor 18 can thermally stress the feed injector 16, particularly the part of the feed injector 16 closest to the combustion chamber (e.g., the tip of the feed injector 16). Here, too, the feed injector tip cap of the present embodiments can reduce the thermal stress on the tip of the feed injector 16 by at least partially blocking the backflowing gases, thus preventing them from coming into contact with the tip of the feed injector 16. By reducing the thermal stress and thermal fatigue of the feed injector 16, the tip cap can extend the service life of the system 10 and reduce its operating costs.Furthermore, the tip cap 84 enables the supply injector 16 to be a serviceable component, in which the tip cap 84 can be replaced at intervals, but the supply injector 16 can be maintained for a longer period of time than would otherwise be achievable.

[0027] In light of the foregoing, Fig. 2 An axial cross-section of the feed injector 16, which has a tip part 82 and a tip cap 84 that can fit onto the tip part 82. In the illustrated embodiment, the tip cap 84 and the feed injector 16 are coupled along an axial axis 86 that extends longitudinally through the center of the feed injector 16 and the tip cap 84. Furthermore, the feed injector 16 has a radial axis 87 and a circumferential axis 88. The feed injector 16 has an upstream side 89 (e.g., upstream relative to a fuel flow through the feed injector 16) from which the feed material, oxygen, and other substances can be introduced into the feed injector 16. The supply injector 16 also has an annular opening 90, which is positioned at the tip part 82, where the supply substance, oxygen and other substances can exit the supply injector 16.The tip section 82 is therefore an outlet for the substances during their transition from the supply injector 16 to the carburetor 18.

[0028] The following section describes an arrangement of channels for the feed injector 16, but other arrangements are possible depending on the requirements of a particular system (e.g., reactor, gasifier, or general combustion system). In the illustrated embodiment, the innermost material passing through the feed injector 16 is oxygen 91 (e.g., separated oxygen from the ASU 40), which is directed from a first oxygen channel 92, formed by a first annular wall 93 of the feed injector 16, to the tip section 82. The first oxygen channel 92 delivers the oxygen 91 to the combustion process downstream of the tip section 92 of the feed injector 16. In other embodiments, the oxygen 91 can include, among other things, pure oxygen, oxygen mixtures, and air.The next outermost material is a fuel 94, which is directed to the tip part 82 by a fuel channel 95 formed by a second annular wall 96 of the supply injector 16. The fuel channel 95 (and the wall 96) thus surrounds the first oxygen channel 92 (and the wall 93) in a coaxial or concentric arrangement. As above with reference to . Fig. As specified in 1, the fuel 94 can be a dry fuel, a slurry fuel, a liquid fuel, a gaseous fuel, or any combination thereof. The fuel channel 95 directs the fuel 94 just downstream of the oxygen 91 from the first oxygen channel 92 to promote the mixing of the fuel and oxygen. The region where the oxygen 90 from the first oxygen channel 92 and the fuel 94 combine can be referred to as a premixing zone 98.

[0029] The next, outermost material is oxygen 91, which is directed from a second oxygen channel 100, formed by a third annular wall 102 of the supply injector 16, to the tip 82 of the supply injector 16. The second oxygen channel 100 (and wall 102) thus surrounds the fuel channel 95 (and wall 96) and the first oxygen channel 92 (and wall 93) in a coaxial or concentric arrangement. The second oxygen channel 100 can direct oxygen 91 to the mixture of fuel 94 and oxygen 91 from the first oxygen channel 92 to form a fine spray that can enhance the efficiency of the reaction (e.g., partial combustion or gasification). The oxygen 91 from the second oxygen channel 100 can also include, among other things, pure oxygen, oxygen mixtures, and air.

[0030] As shown, the tip cap 84 and the tip part 82 of the feed injector 16 are coupled to each other along the axial axis 86. The tip cap 84 can have a number of features that enable coupling with and protection of the feed injector 16. Specifically, the tip cap 84 can have, among other things, an inner surface 103 that can be in physical contact with the feed injector 16, an outer surface 104 that faces a combustion / gasification zone during use, a lip 106 (e.g., an annular lip) that serves to block gases flowing back from the feed injector 16, and an annular opening 108 that allows the fuel / oxidizer mixtures to be supplied to the gasification zone. The annular opening 108 can be straight (see Fig. 4 to Fig. 7) or conical (see Fig. 2 and Fig. 3) to block or deflect heat from the supply injector 16 and to allow fuel to pass through the annular opening 108.

[0031] The tip cap 84 can be made of any suitable material, but in some embodiments, it can be made of a material such as a ceramic fiber composite (CMC) that has a higher thermal conductivity and a lower coefficient of thermal expansion than the tip portion 82 of the feed injector 16. In one system according to the invention, the tip cap 84 is made of a ceramic fiber composite (CMC). In other embodiments, the tip cap 84 can be made of a material with a thermal conductivity and / or a coefficient of thermal expansion that is approximately equal to (e.g., within about 5% of) the thermal conductivity and / or coefficient of thermal expansion of the feed injector 16. For example, but not limited to, the tip cap 84 can be made of ceramics, composite materials, or a combination thereof, such as silicon carbide, aluminum oxide, aluminum nitride, or mullite.These materials can effectively transfer heat away from the tip part 82 of the feed injector 16 (e.g. in the radial direction 87) and as a result, the tip cap 84 can serve as a heat barrier (or heat shield) for the tip part 82 during gasification reactions.

[0032] The tip cap 84 can be designed to couple with the tip part 82 of the supply injector 16 and to completely separate the tip part 82 from a reaction zone 110 of the carburetor 18. The tip cap 84 can be positioned substantially coaxially with the annular opening 90 of the tip part 82 of the supply injector 16, so that fuel can flow through the fuel channel 95 of the supply injector 16 and through the annular opening 108 of the tip cap 84 to the reaction zone 110.

[0033] When the tip cap 84 and the feed injector 16 are coupled, the inner surface 103 of the tip cap 84 can abut an outer wall 112 of the tip part 82 of the feed injector 16. In some embodiments, the inner surface 103 (e.g., a contact surface) of the tip cap 84 can have a first geometry that substantially mirrors a second geometry of the outer wall 112 of the tip part 82 (e.g., mirrors it precisely within manufacturing tolerances). That is, the surface 103 and the outer wall 112 can be contoured essentially identically to minimize or substantially eliminate any gap between the cap 84 and the injector 16. Because the inner surface 103 substantially mirrors the outer surface 112 of the tip part 82, the tip cap 84 can block the accumulation of hot gases between the tip part 82 and the tip cap 84.

[0034] The outer surface 104 of the tip cap 84 can have a geometry substantially similar to the geometry of the inner surface 103, or it can extend further outwards in the radial direction 87 to form the lip 106. Furthermore, in certain embodiments, the outer surface 104 can be curved, such as curved outwards towards a vaporization region of the carburetor—i.e., convex with respect to the vaporization feed injector 16. In certain embodiments, the outer part (e.g., near the lip 106) of the tip cap 84 can experience more thermal stress than the inner part (e.g., near the annular opening 108). For example, backflowing hot gases are more likely to come into contact with the outermost part of the tip cap 84 than with the opening 108, where the vaporization products are expelled. Therefore, the tip cap 84 can be designed to have a greater thickness near the lip 106 (e.g.In a CMC construction, the tip cap 84 has a greater number of layers than the opening 108. The tip cap 84 can be designed to have a thickness gradient in the radial direction 87 from the annular opening 108 to the lip 106. When using a CMC construction, any number of layers 114 can be used to generate this gradient; for example, a portion of the tip cap 84 located closer to the annular opening 108, as illustrated in the extended area 113, can be composed of approximately one to four layers 114, while a portion of the tip cap 84 located further away from the annular opening 108, as illustrated in the extended area 115, can be composed of approximately five to ten or more layers 114. The layers 114 can be laminated and can have properties (e.g., geometry and / or material composition) that are uniform or non-uniform within the tip cap 84.For example, the load or pressure on the tip cap 84 may not be uniform in the axial 86, radial 87 or circumferential direction 88 and therefore the properties of the layers 114 may be designed to vary within the tip cap 84.

[0035] In certain embodiments, the material composition of the layers 114 can be designed such that the tip cap 84 can withstand high mechanical or thermal loads. For example, the layers 114 can be made of a ceramic material, a metal, a polymer, a glass fiber-reinforced plastic, an epoxy resin, another suitable material, or a combination thereof. In certain embodiments, as indicated above, the laminated layers 114 can be a ceramic fiber composite. For example, the material composition between adjacent layers 114 can alternate between ceramic and metal. In other embodiments, the layers 114 can be made of a CMC material in which a variety of fibers (e.g.,silicon carbide fibers) are arranged in a matrix material which may be the same as the material used to manufacture the fibers, may contain one or more components of the materials used to manufacture the fibers (e.g. silicon / silicon carbide), or may be different from the fibers.

[0036] Although the tip cap 84 is described and illustrated in connection with its thickness varying in the radial direction 87, it can be designed to have a suitable configuration that allows the tip cap 84 to act as a barrier – thermal or otherwise (e.g., a material barrier). For example, the thickness (e.g., as measured by the number of layers 114) can be essentially constant, or it can vary regularly or irregularly. For example, the tip cap 84 can be designed to have a greater thickness in regions that experience relatively higher temperatures compared to other regions. A greater thickness of the tip cap 84 can increase its thermal barrier capacity.

[0037] Furthermore, the lip 106 can extend circumferentially 88 and radially 87 around the outer surface 104 of the tip cap 84 to span a gap that may exist between the tip part 82 and the chamber of the carburetor 18 in which it is positioned. By extending radially 87 further outwards, the lip 106 can at least partially prevent hot backflowing gases from flowing around the tip cap 84 and coming into contact with the feed injector 16 (e.g., a body of the feed injector 16). Consequently, the tip cap 84 can act as a thermal and / or material barrier for the tip part 82 towards the reaction zone 110. By reducing the thermal stress on the tip part 82, the tip cap 84 can enable a longer service life for the feed injector 16 by reducing thermal stresses that can cause cracks (e.g. surface cracks) in the feed injector 16.

[0038] Fig. Figure 3 is a front view along the axial axis 86 of the tip cap 84. As in relation to Fig. As indicated in Figure 2, the annular opening 108 is positioned in a coaxial arrangement with respect to the annular opening 90 of the tip part 82 of the feed injector 16. As above with respect to Fig. As specified in Figure 2, the annular opening 108 can be straight or conical. In embodiments where the opening 108 is conical, it can have an inner diameter 132 and an outer diameter 133. The thickness of the tip cap 84 can increase from the inner diameter 132 to the outer diameter 133. For example, the tip cap 84 near the inner diameter 132 can be composed of about one to four layers 114, and the tip cap can be composed of about five to ten or more layers 114.

[0039] In this way, the diameter of the annular opening 108 can increase in the axial direction 86 (e.g., in the direction of the fuel flow path). The annular opening 108 can have a diameter 132 suitable for allowing desired feed rates of fuel, oxygen, and other feed materials. The diameter 132 of the annular opening 108 is larger than (e.g., by about 10% to 200%, 10% to 90%, or 10% to 40%) the diameter of the annular opening 90 of the feed injector 16. Therefore, the annular opening 108 does not impede the flow (e.g., spray mist) of fuel from the feed injector 16 as it passes through the annular opening 108.While it may be desirable for the annular opening 108 to be dimensioned to allow the desired flow rates, it may also be desirable for the annular opening 108 to be close in size to the annular opening 90 of the tip part 82 in order to provide maximum shielding of the tip part 82 from the reaction zone 110. Therefore, the diameter 132 of the annular opening 108 can be within approximately 50% of the size of the opening 90, such as within approximately 30%, within approximately 20%, within approximately 10%, within approximately 5%, or within approximately 1%. The outer diameter 133 of the annular opening 108 can be larger than (e.g., by approximately 5% to 100%, 5% to 50%, or 5% to 35%) the inner diameter 132 of the annular opening 108. Therefore, the annular opening 108 can control the flow (e.g.,Spray mist) of fuel from the supply injector 16 is less disruptive, as the flow can expand radially 87 as it passes through the annular opening 108.

[0040] While the diameter 132 of the annular opening 108 may refer to the flow-permitting capability of the tip cap 84, the diameter 134 of the outer surface 104 is generally related to the barrier size of the tip cap 84, which may include the extent to which the feed injector 16 is covered by the tip cap 84, as well as the extent to which the tip cap 84 prevents backflowing combustion / vaporization gases from impacting the feed injector 16. While the outer surface 104 may have a suitable size, shape, thickness, etc., the diameter 134 of the outer surface 104 may be smaller than, substantially the same as, or larger than the diameter of the tip portion 82 of the feed injector 16, which can be measured at a point on the feed injector 16 where a body of the feed injector 16 begins to chamfer toward the opening 90.In certain embodiments, it may be desirable for the diameter 134 to be large enough to extend between the feed injector 16 and a wall of the carburetor chamber in which the feed injector 16 is positioned. For example, the diameter 134 may extend all the way to the wall of the carburetor chamber (e.g., to a tolerance that allows insertion and removal) or partially between the outer surface of the feed injector 16 and the wall of the carburetor chamber. For example, the diameter 134 may be such that the outer surface 134 extends over between about 0% and about 100% of the distance between the outer surface of the feed injector 16 and the wall of the carburetor chamber, with 0% being substantially flush with the outer surface of the feed injector 16 and 100% being in contact with the wall of the carburetor chamber.This means that the outer surface 104 can extend over between about 5% and about 95%, about 10% and about 90%, about 20% and about 80%, or between about 30% and about 70% of the distance between the outer surface of the supply injector 16 and the wall of the carburetor chamber.

[0041] In certain embodiments, the tip cap 84 may also be made of a CMC material (e.g., silicon carbide, aluminum oxide, aluminum nitride, mullite, etc.) that has a higher thermal conductivity and a lower coefficient of thermal expansion than the tip part 82. Manufacturing from such materials may allow the tip cap 84 to be attached to the tip part 82 using a number of different methods, such as during a retrofit or repair. Coupling methods may include, for example, the use of threaded high-temperature fasteners (e.g., bolts or screws that can withstand the temperatures in the carburetor), a slant-face connection, a high-temperature adhesive (e.g., an adhesive that can withstand the temperatures in the carburetor), spring-loaded tabs, snap fasteners, snap-in fasteners, interference fits, or the like.These fastening methods can allow the removal, inspection, maintenance and / or replacement of the tip cap 84 in various ways.

[0042] Fig. Figure 4 shows an embodiment of the tip cap 84 coupled to the tip part 82 by threaded high-temperature fasteners, e.g., bolts or screws 154. These high-temperature fasteners can be temperature-resistant up to at least 1000, 1500, 2000, 2500 or more degrees Celsius. While any number of such threaded fasteners can be used to fasten the tip cap 84 to the feed injector 16, at least two threaded fasteners, such as between two and six, can be used to fasten the cap 84. For example, as shown, two or more (e.g., three) screws 154 can extend in the direction indicated by the arrows 156 through holes 158 in the tip cap 84 and into corresponding holes 160 (e.g., threaded bores) in the tip part 82 of the feed injector 16.In certain embodiments, the holes 158 and 160 may be threaded to allow the screws 154 to fasten the cap 84 to the tip part 82. The screws 154 may be made of a high-temperature material, such as low-carbon steel, alloy steel, steel, stainless steel, aluminum, brass, copper, silicon bronze, titanium, composite materials, ceramic materials, or a combination of such materials. Furthermore, the screws 154 may be fully or partially coated with a protective layer (e.g., zinc, cadmium, tin, copper, or ceramic) that provides additional protection against thermal stress from the reaction zone 110. The screws 154 may be spaced apart from one another circumferentially 88 around the tip cap 84, for example, at regular intervals extending around the circumference.Furthermore, the screws 154 can be positioned at a radial location 87 between the lip 106 and the annular opening 108. Additionally, the screws 154 can be recessed into the outer surface 104 of the tip cap 84. For example, the hole 158 can have a chamfered edge, allowing the head 162 of each screw 154 to rest below the outer surface 104 of the tip cap 84.

[0043] For example, a technician and / or an automated machine can remove the supply injector 16 from the carburetor 18 during a retrofit or maintenance procedure ( Fig. 1) Remove. The technician / automated machine can then form the holes 158, 160 in the tip cap 84 and the feed injector 16 by positioning the tip cap 84 abutting the feed injector 16 and machining the holes 158, 160 into both. Alternatively, the holes 158, 160 can be formed separately. It may also be desirable to use the screws 154 to fasten the tip cap 84 to the feed injector 16 so that the tip cap 84 can be replaced after use. For example, the technician can remove the feed injector 16 and the used tip cap 84 after use, loosen the screws 154, and, after appropriate inspection and, where suitable, additional maintenance, attach a new or refurbished tip cap 84 to the feed injector 16.

[0044] As explained above, the tip cap 84 can in a further embodiment be combined with the tip part 82 with spring-loaded tabs 170, as shown in Fig. Figure 5 shows that the tip part 82 and the tip part 82 are coupled. In the illustrated embodiment, the tip part 82 can be provided with a suitable number of tabs 170, such as between one and ten, two and six, or between two and four tabs 170. According to the present embodiments, the tip cap 84 can have corresponding openings 172 designed to receive the spring-loaded tabs 170 when coupled. The cap 84 can be pressed onto the tip part 82 (e.g., pressed in one direction 174). When the tip cap 84 is pushed towards the tip 82, the inner surface 103 of the tip cap 84 abuts the tabs 170. This abutment causes the springs 175 coupled to the tabs 170 to be compressed into the recesses 176. This means that the tabs 170 and their associated springs 175 can be pushed radially 87 inwards when attaching the tip cap 84 to the feed injector 16.Once the openings 172 are guided over the tabs 170, the tabs 170 can be released radially 87 outwards into the openings 172, creating a locking mechanism that holds the tip cap 84 to the feed injector 16.

[0045] Similar to the high-temperature screws described above, the tabs 170 can also facilitate a retrofit and / or maintenance procedure. For example, during a retrofit, a technician can remove the feed injector 16 from the carburetor 18. The feed injector 16 can be cleaned, etc., and machined to provide the recesses 176. The tabs 170 and the springs 175 can then be attached to the recesses 176, enabling their use with embodiments of the tip cap 84 that have the corresponding opening 172.

[0046] The springs 175 and / or tabs 170 may be designed to incorporate a removal mechanism for repair. For example, the springs 175 and / or tabs 170 may be magnetic to allow the tabs 170 to be retracted and the used tip cap 84 to be removed from the feed injector 16. Alternatively or additionally, the second oxygen channel 100 may incorporate a removal mechanism accessible to the technician. This removal mechanism may allow the technician to "pull" the tabs 170 radially 87 inward, thus decoupling the tip cap 84 from the feed injector 16. The tip cap 84 can then be replaced or refurbished and reattached to the feed injector 16.

[0047] In another embodiment, which is described in Fig. As shown in Figure 6, the tip cap 84 can be bonded to the tip 82 of the feed injector 16 using a high-temperature adhesive 180. According to the present embodiments, the high-temperature adhesive 180 can be applied to the inner surface 103 of the tip cap 84 and / or to the outer surface 112 of the feed injector 16, so that the adhesive 180 forms an interface 182 between the outer surface 112 of the tip part 82 and the inner surface 103 of the tip cap 84. The high-temperature adhesive 180 can be a high-temperature alloy, metal, or ceramic (e.g., an epoxy resin adhesive, a urethane adhesive, etc.) that can bond the tip cap 84 to the tip part 82 even at high temperatures, such as temperatures between 900 and 1200 °C.

[0048] Embodiments in which the tip cap 84 is glued to the feed injector 16 can also facilitate retrofitting and maintenance. For example, during a retrofit procedure, the feed injector 16 can be removed from the carburetor 18, cleaned, and, in certain embodiments, etched or milled to improve the surface area of ​​the outer surface 112. The adhesive 180 can then be applied to the outer surface 112 of the feed injector 16 and / or to the inner surface 103 of the tip cap 84, and the tip cap 84 can be affixed to the feed injector 16 for a suitable period of time to allow sufficient curing of the adhesive 180.

[0049] During a maintenance procedure after the installation of the tip cap 84, the supply injector 16, along with the tip cap 84, can be removed from the carburetor 18, and the adhesive can be chemically and / or physically degraded. For example, the adhesive 180 can be selected to dissolve under certain chemical and / or physical conditions, such as when used with a solvent under suitable conditions (e.g., at a certain temperature and pressure). In other embodiments, the adhesive 180 can be selected to lose a desired degree of adhesion upon contact with incident light stimuli, such as infrared or ultraviolet light. Currently, all methods for reducing or eliminating the adhesion of the adhesive 180 for maintenance and / or removal are being considered. After removal, the adhesive 180 can then be replaced using the same or a different adhesive.

[0050] Fig. Figure 7 is a side view of an embodiment in which the tip cap 84 is coupled to the tip portion of the feed injector 16 using an inclined surface connection 188. In the illustrated embodiment, the outer surface 112 of the tip portion 82 can have chamfered recesses 190 (chamfered with an increasing indentation in the circumferential direction 88) at two or more locations, such as between two and ten, two and six, or two and four locations. The chamfered recesses 190 (shown with dashed lines) can be evenly spaced around the circumference 88 of the tip cap 84 or arranged in another suitable configuration. Furthermore, the recesses 190 can include indentations 191 (shown with dashed lines) designed to receive corresponding locating pins 192 (shown in dashed lines) of the tip cap 84 during engagement.

[0051] The tip cap 84 can have spring-loaded locating pins 192 and projections 194 (shown with dashed lines) which essentially mirror the recesses 190 in the tip's outer surface 112 (e.g., chamfered with increasing thickness to allow for an interference or friction fit, or an interference fit). Here too, the spring-loaded locating pins 192 can be compressed during engagement of the tip cap 82 with the feed injector 16. When the locating pins 192 are guided over the recesses 191 during rotation of the tip cap 84 in the circumferential direction 88, the locating pins 192 can be released into the recesses 191 and lock the tip cap 84 in a frictional manner.

[0052] In other embodiments, the tip cap 84 may not have the locating pins 192 and / or the feed injector 16 may not have the recesses 191. The tip cap 84 can therefore be attached to the feed injector 16 by the action of the projections 194, which slide into an interference fit with the chamfered recesses 190. Accordingly, in certain embodiments, the tip cap 84 can be attached to the feed injector 16 solely by friction.

[0053] In a similar manner to the embodiments discussed above, the inclined surface connection 188 also enables retrofitting and / or maintenance. For example, during a retrofit procedure, the feed injector 16 can be removed from the carburetor 18, cleaned, and machined so that it has the chamfered recesses 190 and / or the indentations 191. An embodiment of the tip cap 84 with the projections 194 and / or the locating pins 192 can then be attached to the feed injector 16.

[0054] During a maintenance procedure, the feed injector 16, which has the tip cap 84, can be removed from the carburetor 18. The tip cap 84 can then be removed by rotating it circumferentially with respect to the feed injector 16 in a direction opposite to that used to fasten the tip cap 84. That is, the tip cap 84 can be unscrewed from the feed injector 16. The feed injector 16 can be cleaned and further treated as appropriate. The tip cap 84 can be discarded and replaced or overhauled and, where appropriate, reattached to the feed injector 16.

[0055] This written description uses examples to disclose the invention, including its best embodiment, and to enable a person skilled in the art to carry out the invention, including the manufacture and use of devices or systems and the performance of any incorporated processes. The patentable scope of the invention is defined by the claims and may include other examples that a person skilled in the art might think of. It is intended that such other examples fall within the scope of the claims if they include structural elements that do not differ from the literal meaning of the claims, or if they include equivalent structural elements with insignificant differences from the literal meanings of the claims.

Claims

[1] System 10, comprising: a gasification feed injector 16 having a tip portion 82 disposed at a fluid exit region of the gasification feed injector 16, the tip portion 82 having a first abutment surface with a first geometry; and a tip cap 84 coupled to the tip portion 82 of the gasification feed injector 16, the tip cap 84 being designed to serve as a thermal barrier for the tip portion 82 during gasification reactions, and where the tip cap 84 includes: a second contact surface facing the first contact surface and having a second geometry, the second geometry reflecting the first geometry, and an outer surface 104 having a third geometry, the third geometry being convex with respect to the gasification feed injector 16, and where the tip cap 84, has a first annular opening 108 which is coaxially positioned relative to a second annular opening 90 of the tip part 82, and the first annular opening 108 has a larger diameter 132 than the second annular opening 90, characterized by that the tip cap 84, a body having a first annular opening 108, the thickness of the body increasing in a direction radially away from the first annular opening 108, and made of a ceramic fiber composite (CMC) having multiple layers, and a number of layers of the tip cap 84 increases in the direction radially away from the first annular opening 108 to produce the increase in body thickness. [2] The system 10 of claim 1, wherein the tip cap 84 is coupled to the tip portion 82 such that the tip cap 84 completely separates the tip portion 82 from a reaction zone of a carburetor configured to receive the carburetor feed injector. [3] The system 10 of claim 1, wherein the first annular opening 108 has a first diameter and a second diameter such that the first annular opening 108 is conical, and wherein a first region proximate the first diameter has a first number of layers 114, a second region proximate the second diameter has a second number of layers 114, and the second number of layers is greater than the first. [4] The system 10 of claim 1, wherein the CMC material is configured to have a higher thermal conductivity than the tip portion 82. [5] The system 10 of claim 1, wherein the CMC material is configured to have a lower coefficient of thermal expansion than the tip portion 82. [6] The system 10 of claim 1, wherein the tip cap 84 has a lip 106 extending circumferentially around and radially away from a body of the tip cap 84, and the lip 106 is configured to prevent backflow gases generated during gasification reactions from contacting the gasification feed injector 16. [7] The system 10 of claim 1, wherein the tip cap 84 is coupled to the tip portion 82 by a threaded high-temperature fastener 154, a high-temperature adhesive, spring-loaded tabs 170, a beveled surface connection 188, or a combination thereof. [8] Procedure, characterized by that it has: coupling a tip cap 84 to a tip portion 82 of an exit region of a gasification feed injector 16, wherein a thickness of the tip cap 84 varies throughout the diameter of a body of the tip cap 84; and wherein the tip cap 84 is designed to serve as a thermal barrier for the tip portion 82 during gasification reactions. [9] The method of claim 8, comprising coupling the tip portion 82 such that the tip cap 84 completely separates the tip portion from a reaction zone 110 of a carburetor 18 configured to receive the gasification feed injector 16. [10] The method of claim 8, wherein coupling the tip cap 84 to the tip portion 82 comprises positioning the tip cap 84 relative to the tip portion 82 such that a first annular opening 108 is coaxially positioned relative to a second annular opening 90 of the tip portion 82, and the first annular opening 108 has a larger diameter 132 than the second annular opening 90. [11] The method of claim 8, wherein coupling the tip cap 84 to the tip portion 82 comprises securing the tip cap 84 with high temperature screws 154, a high temperature adhesive, spring loaded tabs 170, or a bevel joint 188. [12] The method of claim 11, including retrofitting the tip portion 82 of the gasification feed injector 16 to have one or more holes 160 adapted to receive the high temperature screws 154, one or more holes 172 adapted to receive spring loaded tabs 170, or a beveled surface 188 adapted to form an interference fit with a conical projection of the tip cap 84, or a combination thereof. [13] The method of claim 8, wherein coupling the tip cap 84 to the tip portion 82 of the exit region of the gasification feed injector 16 comprises: Removing a used tip cap 84 from the carburetor feed injector 16; Overhaul of the used tip cap 84 and Attach the reconditioned tip cap 84 to the carburetor feed injector 16. [14] The method of claim 8, wherein coupling the tip cap 84 to the tip portion 82 of the exit region of the gasification feed injector 16 comprises replacing a used tip cap 84 coupled to the gasification feed injector 16 with a new tip cap 84. [15] Device comprising: a tip cap 84 comprising: a body; and a first abutment surface 103 disposed on the body, the first abutment surface 103 having a first geometry that mirrors a second geometry of a second abutment surface 112 of a gasification feed injector 16; and characterized by , that the body has a first annular opening 108, the thickness of the body increasing in a direction radially away from the first annular opening 108, and the tip cap 84 includes a lip 106 extending circumferentially around and radially away from the body, the lip 106 having a lip diameter that is larger than an injector diameter of the carburetor feed injector 16. [16] The device of claim 15, wherein the tip cap 84 is made of a ceramic fiber composite (CMC). [17] The device of claim 15, wherein the CMC material comprises a silicon carbide CMC.

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