Process Burner Segmented Nozzle for Carbon Monoxide Combustion
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Solution Overview
Problem
Process burners using carbon monoxide as fuel face issues with solid carbon deposits in fuel gas lines and nozzles, leading to inefficiencies and increased maintenance costs due to the Boudouard reaction, which is favored by high pressures and low temperatures.
Innovation Solution
The process burner design includes a second fuel gas nozzle for carbon monoxide injection within the auxiliary media unit, rather than the combustion zone, where it mixes with a cooler auxiliary medium before reaching the combustion zone, reducing the formation of solid carbon deposits by avoiding high-temperature combustion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If carbon monoxide is fed into the combustion zone directly, then combustion efficiency is improved, but solid carbon deposits form in fuel gas lines and nozzles
Solution Approach 1:
The fuel gas supply system is segmented into two separate nozzles: a first fuel gas nozzle for hydrocarbon fuels and a second fuel gas nozzle for carbon monoxide. This segmentation allows carbon monoxide to be introduced separately into the combustion zone, preventing it from forming solid carbon deposits in the fuel gas lines and nozzles while maintaining combustion efficiency.
Solution Approach 2:
Air is introduced as an intermediary substance through the auxiliary media unit, mixing with carbon monoxide before it reaches the combustion zone. This intermediary mixing prevents direct contact between carbon monoxide and the hot combustion zone, thereby preventing solid carbon deposit formation while still enabling efficient combustion.
2Productivity
If carbon monoxide is mixed with other fuel gases in the combustion zone, then combustion completeness is improved, but carbon deposits increase in burner components
Solution Approach 1:
The burner is divided into multiple independent fuel gas units, each with its own nozzle. The second fuel gas unit specifically handles carbon monoxide separately from hydrocarbon fuels. This segmentation ensures that carbon monoxide does not mix with other fuel gases in the combustion zone, preventing carbon deposit formation in burner components while maintaining complete combustion through proper air mixing.
Solution Approach 2:
Carbon monoxide is mixed with air in the auxiliary media unit before being introduced into the combustion zone. This preliminary mixing action ensures that carbon monoxide is properly prepared for combustion without forming solid carbon deposits, as the mixing occurs in a cooler environment rather than directly in the hot combustion zone.
3Quantity of substance
If high pressure is applied to increase CO flow rate, then fuel supply capability is improved, but solid carbon formation is favored by the Boudouard reaction
Solution Approach 1:
Air acts as an intermediary medium that mixes with carbon monoxide in the auxiliary media unit before the gas enters the combustion zone. This intermediary mixing prevents the Boudouard reaction from occurring in the fuel gas lines and nozzles, as the air-cooled mixture prevents the temperature conditions necessary for solid carbon formation, even at high CO flow rates.
Solution Approach 2:
The system changes the temperature parameter by introducing carbon monoxide through a second fuel gas nozzle that is cooled by the auxiliary media unit. This parameter change (lower temperature in the fuel gas line) prevents the Boudouard reaction from occurring, allowing high CO flow rates without solid carbon formation.
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 design significantly reduces solid carbon deposits in fuel gas nozzles and lines, enhancing combustion efficiency and reducing maintenance costs by preventing carbon formation at the nozzle and upstream areas.
Implementation Method 1
the second fuel gas nozzle for feeding the second fuel gas is arranged within the auxiliary media unit... the second fuel gas is fed into the process burner through the second fuel gas nozzle... due to the arrangement of the second fuel gas nozzle, this does not occur within the combustion zone, in the region of the hot burner tip/hot burner neck, but within the auxiliary media unit, in a much cooler region of the process burner
Implementation Method 2
During the combustion of carbon monoxide with oxygen to form carbon dioxide, the exothermic Boudouard reaction... competes with the actual combustion reaction
Implementation Method 3
the exothermic Boudouard reaction, also known as Boudouard equilibrium, competes with the actual combustion reaction
Implementation Method 4
the exothermic Boudouard reaction, also known as Boudouard equilibrium, competes with the actual combustion reaction, according to 2 CO C (solid) + CO 2 , whereby the formation of solid carbon and carbon dioxide is favored by high pressures and low temperatures according to Le Chatelier's principle
Data Source
Figure 1
AI summary
The invention relates to a process burner for the combustion of a plurality of fuel gases with a gaseous auxiliary medium, wherein one of the fuel gases comprises carbon monoxide (CO). The process burner according to the invention comprises a first fuel gas unit, a second fuel gas unit, and an auxiliary medium unit. A first fuel gas, which for example comprises natural gas, is fed into the process burner via a first fuel gas nozzle in the combustion zone. Fuel gas containing carbon monoxide is introduced into the process burner via the second fuel gas unit, with a second fuel gas nozzle for feeding the carbon monoxide-containing fuel gas being arranged in the auxiliary medium unit. Due to the lower temperatures in the auxiliary medium unit compared to the combustion zone, the coking of carbon monoxide to solid carbon is effectively reduced or completely avoided.