Adhesive Separator for Molten Dust Separation in High Temperature Gas
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Solution Overview
Problem
Current methods for separating molten dust from high temperature gas in industries such as coal combustion, gasification, and metallurgy are inefficient, leading to low productivity, high energy consumption, and the need for cleaner fuels like oil or natural gas, which increases costs and environmental impact.
Innovation Solution
A method and equipment using an adhesive separator in conjunction with a regenerative heat exchanger to recycle heat and enhance the separation efficiency of molten dust, maintaining the gas temperature above the dust's melting point and improving the contact area with the inner sidewall for effective separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the cylindrical furnace chamber is extended to improve separation efficiency of molten dust, then the separation efficiency improves, but the heat dissipating surface increases causing temperature drop and dust solidification
Solution Approach 1:
The furnace chamber is divided into multiple independent separation zones along its length, each equipped with its own air damper and centrifugal separation section. This segmentation allows the total separation efficiency to be distributed across multiple stages while limiting the heat dissipation surface of each individual zone, preventing temperature drop that would cause dust solidification.
2Productivity
If air dampers are arranged adjacent to coal powder addition location for complete combustion, then combustion efficiency improves, but the number of air dampers is limited and they cannot be disposed freely along the length direction
Solution Approach 1:
Air dampers are arranged not only adjacent to the coal powder addition location but also distributed along the length direction of the furnace chamber at multiple positions. This spatial distribution in the longitudinal dimension enables multiple air dampers to be installed without interfering with combustion efficiency, providing flexibility in damper placement while maintaining complete combustion.
3Manufacturing precision
If multiple air dampers are introduced to improve separation efficiency, then separation efficiency improves, but the air flow must correspond to fuel quantity limiting the number of dampers
Solution Approach 1:
Each air damper is equipped with independent control mechanisms that allow dynamic adjustment of air flow rates. This enables the air flow from multiple dampers to be coordinated and optimized according to the fuel quantity being processed, allowing the system to accommodate multiple dampers without compromising air flow coordination or separation efficiency.
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
Achieves separation efficiencies of over 95% for molten dust, allowing for the use of cheaper coal, reducing energy consumption, and improving environmental conditions by effectively recycling heat and reducing dust content in gas products.
Implementation Method 1
the air driven by an air damper sprays into the cylindrical chamber of the furnace along a direction tangent to the cylindrical furnace chamber and generates a centrifugal rotary force, so that the molten dust is separated from the high temperature gas and adheres to a sidewall around the furnace chamber
Implementation Method 2
conveying the cleaned high temperature gas to a heat exchanger directly or right after further reacting with/heating materials for cooling and discharging; using the heat recycled by the heat exchanger to heat the gas supplied to the adhesive separator
Implementation Method 3
the molten dust adhering to the inner sidewall flowing down along the inner sidewall and discharging via a drain outlet defined in a bottom portion of the adhesive separator due to the gravity force
Data Source
AI summary
A method for separating out molten dust in high temperature gas includes the steps of: passing the high temperature gas carrying molten dust through an adhesive separator, the molten dust adhering to the adhesive separator and separating from the high temperature gas, the molten dust adhering to the inner sidewall flowing downwardly due to the gravity force and discharging; conveying the cleaned high temperature gas into a heat exchanger directly or after heating materials for cooling and discharging; using the heat recycled by the heat exchanger to heat the gas supplied to the adhesive separator; and supplying the gas heated by the heat exchanger into the adhesive separator directly or after further reaction, the heat absorbed from the heat exchanger and the heat generated in the reaction keeping the temperature of the gas flowing out of the adhesive separator higher than the melting point of the dust.