Bulk Materials Pump for Pressurized Gasification Reactor
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Solution Overview
Problem
Existing systems for feeding particulate solid materials to pressurized gasification reactors face issues with erosion, fouling, and lack of direct flow control due to the presence of an intermediate feeder tank, which complicates maintaining the optimal oxygen-to-carbon ratio for maximizing carbon monoxide and hydrogen production.
Innovation Solution
A system using a bulk materials pump with rotatable drive disks and a scraper to transport solid materials from a lower pressure zone to a higher pressure zone, where a gaseous stream is injected to break open the compacted cake, allowing for direct control of the solids flow to the reactor, enabling a stable and efficient delivery of particulate solid carbonaceous materials to the pressurized gasification reactor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an intermediate feeder tank is used to transport solids to the pressurized reactor, then the solids can be transported, but the flow control is lost and the oxygen-to-carbon ratio cannot be directly controlled
Solution Approach 1:
The patent removes the intermediate feeder tank from the system, extracting the component that was causing the loss of flow control. By eliminating this intermediate storage vessel, the system achieves direct coupling between the solids pump and the pressurized reactor, enabling precise control of the oxygen-to-carbon ratio without compromising transport capability.
Solution Approach 2:
The patent merges the functions of solids transport and flow control into a single integrated system. The bulk materials pump with rotatable drive disks directly feeds solids to the reactor while simultaneously controlling the flow rate, combining what were previously separate functions (transport in feeder tank, control in pump) into one unified operation.
2Productivity
If a lock hopper is used to pressurize dry pulverised coal, then the coal can be pressurized, but multiple batch tanks are cycled causing disruptions and venting of pressurising gas
Solution Approach 1:
The patent implements a continuous solids pumping system that eliminates the batch cycling inherent in lock hopper operations. The bulk materials pump with rotatable drive disks provides continuous transport of solids from the lower pressure zone to the higher pressure zone, maintaining uninterrupted operation and eliminating the need to cycle multiple batch tanks, thereby preventing pressurising gas venting.
3Productivity
If a solids pump is used to continuously supply solids, then the solids can be transported, but erosion and fouling vulnerability increases
Solution Approach 1:
The patent changes the operational parameters of the solids pump by using rotatable drive disks that operate at controlled speeds. This parameter change reduces the mechanical stress and wear on the pump components, thereby minimizing erosion and fouling while maintaining continuous supply capability. The scraper mechanism also helps maintain clean operation by removing accumulated material.
4Ease of operation
If the rotational speed of the solids pump is varied to control solids flow, then flow control is achieved, but the compacted cake cannot be broken open
Solution Approach 1:
The patent introduces a gaseous stream as an intermediary substance that is injected into the compacted cake at the discharge point. This gas stream acts as a mediator that breaks open the compacted cake structure, allowing the solids to be properly discharged and transported while the rotational speed of the drive disks continues to control the overall flow rate.
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 approach allows for direct feeding of particulate solids to the reactor, improving flow control and reducing erosion and fouling risks, while maintaining a stable flow of solids and gas, thus optimizing the production of carbon monoxide and hydrogen by ensuring precise control over the oxygen-to-carbon ratio.
Implementation Method 1
injecting a gaseous stream into the cake of solid materials at the point where the cake of solid materials is discharged from the housing
Implementation Method 2
transporting the solid material and the gaseous stream in a transport conduit to the burner
Implementation Method 3
transporting the solid material from a first lower pressure zone to a higher pressure zone using a bulk materials pump
Data Source
Figure 1~1a
Figure 2~5a
Figure 3~4
AI summary
The invention is directed to a system to provide a particulate solid carbonaceous material to a pressurised gasification reactor comprising a low pressure storage vessel fluidly connected to the inlet of a bulk materials pump, a first part of a transport conduit directly connecting the outlet of the bulk materials pump to an inlet of a diverter valve, a second part of the transport conduit connecting an outlet of the diverter valve to a burner as present in a reactor vessel, wherein said diverter valve is provided with a second outlet connecting a recycle conduit with the low pressure storage vessel and which diverter valve is adjustable to either fluidly connect the bulk materials pump to the burner or alternatively fluidly connect the bulk materials pump to the low pressure storage vessel.