ATR Start-Up Process Using Main Burner for Autoignition
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Solution Overview
Problem
Traditional ATR and POX systems require a labor-intensive and time-consuming start-up process involving a dedicated start-up burner, which needs to be removed and replaced, and leak testing is conducted in hot conditions, making the process inefficient and unsafe.
Innovation Solution
A process where the ATR or POX reactor is heated by a process stream containing combustible components, such as a hydrocarbon and steam mixture, to above autoignition temperature using a main burner, eliminating the need for a dedicated start-up burner and allowing safe leak testing in cold conditions, with controlled ignition parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a dedicated start-up burner is used to heat the ATR reactor to high temperature, then the reactor reaches the required temperature for autoignition, but the process becomes labor-intensive and time-consuming due to burner removal and replacement
Solution Approach 1:
The patent extracts the heating function from a separate dedicated start-up burner and integrates it into the main process burner. The main burner is designed to perform both heating during start-up and combustion during normal operation, eliminating the need for burner removal and replacement while achieving the required reactor temperature for autoignition
Solution Approach 2:
The main process burner is designed with multi-functionality to serve dual purposes: heating the reactor during start-up phase and enabling combustion during normal operation. This universal design eliminates the need for separate start-up and main burners, reducing labor-intensive work and time consumption
2Reliability
If the main process burner is installed and leak testing is performed in hot conditions, then the system can be ensured to be leak-tight, but the process becomes more dangerous and complex
Solution Approach 1:
The patent performs leak testing of the main process burner installation in cold conditions before introducing hydrocarbon and oxygen feeds. This preliminary action ensures the system is leak-tight while avoiding the safety risks associated with hot condition testing, allowing sufficient time for thorough inspection without dangerous operating conditions
3Adaptability or versatility
If the dedicated start-up burner is removed before feed introduction, then the main process burner can be installed, but temperature control becomes less optimal as temperature may decrease below autoignition temperature
Solution Approach 1:
The main process burner is designed to perform both heating and combustion functions continuously without removal. This multi-functional design maintains optimal temperature control throughout the process, preventing temperature drops below autoignition temperature that would occur during burner replacement
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
This method enables faster, safer, and more efficient start-up of ATR/POX systems by maintaining optimal temperature control and reducing soot formation, while minimizing equipment changes and ensuring leak-tightness, thus improving operational efficiency and safety.
Implementation Method 1
heating a process stream by at least one heating means
Implementation Method 2
heating the ATR or POX reactor to or above autoignition temperature via the heated process stream
Implementation Method 3
above the autoignition temperature at atmospheric pressure before introduction of the hydrocarbon containing feed stream
Data Source
AI summary
The present invention relates to a process for heating an ATR or POX comprising the steps of heating a process stream by at least one heating means, admitting the heated process stream to an ATR or POX reactor through a main burner, and heating the ATR or POX reactor to or above autoignition temperature of the process stream via the heated process stream.