Burner Tip Catalyst Coating for Coke Fouling Reduction
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Solution Overview
Problem
Coke fouling at burner tips during the combustion of waste gas streams containing unsaturated or aromatic hydrocarbons reduces efficiency and leads to plugging, necessitating the use of high-value, non-fouling fuel gases to mitigate this issue, which is costly and inefficient.
Innovation Solution
Coating the interior surface of the burner tip with a catalyst that promotes hydrogen saturation of unsaturated hydrocarbons, either as a coating or impregnated within the burner tip body, to prevent coke formation by converting unsaturated hydrocarbons into saturated forms or facilitating their combustion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If waste gas streams containing unsaturated or aromatic hydrocarbons are burned in the burner tip, then low-cost fuel utilization is improved, but coke fouling increases causing efficiency reduction and plugging
Solution Approach 1:
A catalyst coating is applied to the burner tip surface to act as an intermediary that promotes hydrogenation of unsaturated hydrocarbons. The catalyst (such as nickel, palladium, or platinum) facilitates the conversion of coke-forming unsaturated hydrocarbons into saturated hydrocarbons or combustibles, preventing coke deposition while enabling the use of waste gas streams containing these problematic components.
Solution Approach 2:
The chemical state of unsaturated hydrocarbons is changed through catalytic hydrogenation. The catalyst modifies the chemical parameters by adding hydrogen to unsaturated bonds, converting them from coke-prone unsaturated forms to stable saturated forms that do not form coke under combustion conditions.
2Object-affected harmful factors
If non-fouling fuel gas is mixed with fouling waste gas streams to minimize coke formation, then coke fouling is reduced, but combustibility characteristics are degraded
Solution Approach 1:
The catalyst coating serves as a mediator that enables the direct use of fouling waste gas streams without requiring mixing with clean fuel gas. By promoting in-situ hydrogenation, the catalyst eliminates the need for dilution, thereby maintaining the combustibility characteristics of the original fuel gas while preventing coke formation.
3Power
If high temperatures (2,000 F) are used for combustion at the burner tip, then combustion efficiency is improved, but coke formation from unsaturated hydrocarbons increases
Solution Approach 1:
The catalyst performs preliminary hydrogenation of unsaturated hydrocarbons before they reach the high-temperature combustion zone. This pre-treatment converts coke-forming compounds into stable saturated hydrocarbons, preventing coke formation even at high combustion temperatures of 2,000 F, thereby allowing efficient combustion without the harmful side effect of coke deposition.
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 effectively reduces coke formation at the burner tips, allowing for the more efficient use of low-cost, fouling waste gas streams without degrading combustibility, thereby enhancing burner tip efficiency and extending its operational life.
Implementation Method 1
coating the interior wall of the burner tip and/or impregnating the burner tip body with at least one catalyst that promotes the hydrogen saturation of unsaturated hydrocarbons
Implementation Method 2
at least one catalyst that promotes the hydrogen saturation of unsaturated hydrocarbons
Data Source
AI summary
A method for reducing coke fouling in a burner tip when a waste gas stream containing unsaturated hydrocarbons is combusted by coating the interior of the burner tip and/or impregnating the body of the burner tip with a hydrocarbon hydrogenation promoting catalyst and/or a combustion catalyst.