Acoustic Fuel Pulverizer Eliminates Metal Contamination
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Solution Overview
Problem
Traditional mechanical grinding processes for fuel feedstock preparation in gasification power plants lead to metal contamination and require significant power and maintenance, while also being inefficient in pulverizing fuels like coal.
Innovation Solution
An acoustic pulverizer system that uses sonic pulse generators to fragment and pulverize fuels, such as coal, into a uniform mixture using acoustic waves, reducing the need for heavy machinery and minimizing power and maintenance requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mechanical grinding processes (rod mill or ball mill) are used to pulverize fuel feedstock, then the fuel can be ground into a useable form, but metal contamination of the feedstock occurs and significant power and maintenance requirements arise
Solution Approach 1:
The patent replaces traditional mechanical grinding systems (rod mills, ball mills) with an acoustic field-based pulverization system. Acoustic waves are generated within a chamber to create standing wave patterns that produce high-intensity vibration and cavitation effects, breaking down fuel particles without mechanical contact. This substitution eliminates metal contamination from grinding media while achieving the required pulverization quality.
Solution Approach 2:
The patent utilizes acoustic waves to generate intense mechanical vibration within the pulverization chamber. The acoustic field creates resonant vibrations that cause fuel particles to collide and fragment. This vibration-based mechanism achieves effective pulverization without requiring heavy mechanical grinding equipment, thereby eliminating metal contamination while maintaining pulverization quality.
2Manufacturing precision
If traditional mechanical grinding processes are used to pulverize fuel feedstock, then the fuel can be ground into a useable form, but large amounts of power and significant maintenance requirements are needed
Solution Approach 1:
The patent replaces energy-intensive mechanical grinding systems with an acoustic field-based pulverization system. The acoustic waves are generated using transducers that convert electrical energy directly into acoustic energy, creating a more efficient pulverization process. This substitution reduces power consumption by eliminating the need for heavy mechanical drives, motors, and gear systems while maintaining effective fuel pulverization quality.
3Manufacturing precision
If traditional mechanical grinding processes are used to pulverize fuel feedstock, then the fuel can be ground into a useable form, but robust foundation systems and independent lubrication systems are required
Solution Approach 1:
The patent replaces complex mechanical grinding systems with a simplified acoustic field-based pulverization system. The acoustic chamber with transducers eliminates the need for robust foundation systems, heavy mechanical structures, and independent lubrication systems. This substitution dramatically reduces device complexity while achieving the required fuel pulverization quality through acoustic wave-induced particle fragmentation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The acoustic pulverizer system effectively pulverizes fuels with lower power consumption and maintenance needs compared to traditional methods, producing a uniform feedstock suitable for gasification processes without metal contamination, and can handle both dry and wet feedstocks.
Implementation Method 1
at least one acoustic wave generator configured to generate acoustic waves to at least partially break up the fuel in the acoustic chamber
Implementation Method 2
acoustic waves are configured to at least partially break up the fuel
Data Source
AI summary
Embodiments of the present disclosure are directed to a fuel preparation system. The feedstock preparation system includes an acoustic chamber configured to receive a fuel and at least one acoustic wave generator configured to generate acoustic waves to at least partially break up the fuel in the acoustic chamber.