Gasification Burner Cooling Device Truncated Cone Rings
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Solution Overview
Problem
Existing burner muffles in gasification reactors are vulnerable to slag ingress, leading to corrosion and reduced lifespan due to inadequate protection against thick slag layers, which disrupt combustion and reduce the protective slag layer's effectiveness.
Innovation Solution
A cooling device with concentric rings forming a truncated cone shape, featuring at least one part-circular outer ring with an interruption, allowing the slag to flow downward and providing increased protection and improved heat flux resistance, enabling the rings to withstand higher temperatures and reducing corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional burner muffle design is used, then the structure is simple and easy to manufacture, but the protection against slag ingress is inadequate leading to corrosion and reduced lifespan
Solution Approach 1:
The burner muffle is divided into multiple concentric rings (typically 3-5 rings) with increasing diameters, forming a truncated cone shape. Each ring is a separate component that can be individually manufactured and assembled. This segmentation allows the structure to better resist slag ingress while maintaining manufacturability, as each ring can be produced using standard fabrication processes and then welded or bolted together to form the complete protective structure.
2Temperature
If the burner muffle is designed to withstand high temperatures, then heat flux resistance is improved, but corrosion from slag accumulation increases
Solution Approach 1:
The design intentionally allows a controlled slag layer to form on the outer surface of the burner muffle rings. This slag layer, while potentially harmful, actually serves as an insulating barrier that protects the metal structure from direct exposure to high heat flux and corrosive combustion products. The concentric ring structure with interruptions facilitates proper slag distribution and drainage, converting the harmful slag accumulation into a protective thermal barrier that extends component life.
3Reliability
If the burner muffle is made robust to prevent slag ingress, then protection is improved, but repair difficulty increases
Solution Approach 1:
The burner muffle is constructed from multiple discrete concentric rings that can be independently removed and replaced. If corrosion or damage occurs in one section, only the affected ring needs to be replaced rather than the entire muffle structure. This modular design significantly reduces repair time and cost while maintaining the overall protective function of the multi-ring configuration against slag ingress.
4Strength
If concentric rings are used to improve heat flux resistance, then temperature withstand capability is improved, but device complexity increases
Solution Approach 1:
The concentric ring structure serves multiple functions simultaneously: it provides mechanical strength to withstand high heat flux, creates a truncated cone shape that directs slag flow away from the burner head, forms cooling channels for circulating coolant, and creates a modular assembly that is relatively simple to manufacture and maintain. This multi-functionality justifies the increased structural complexity by delivering comprehensive protection and operational benefits.
Data Source
AI summary
A gasification reactor comprises a pressure shell; a reaction zone partly bounded by a tubular membrane wall enclosed by the pressure shell; at least one burner having a burner head, said burner head protruding the membrane wall; at least one cooling device arranged in the membrane wall and enclosing the burner head of at least one burner, the at least one cooling device comprising several concentric rings of increasing diameter, forming a truncated cone shape having a largest diameter opening facing the reaction zone and a smallest diameter opening facing the burner head, each ring being a conduit having an inlet and an outlet for a cooling medium, the smallest diameter opening for the burner head being located between the pressure shell and the membrane wall; the cooling device comprising at least one part-circular outer ring having an interruption.