Carbon fiber production method
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Solution Overview
Problem
Existing carbon fiber production methods face challenges in efficiently processing exhaust gases, leading to energy loss and unstable combustion processes due to the lack of distinction between exhaust gases from different production steps and improper positioning of gas introduction in the exhaust gas combustion apparatus.
Innovation Solution
A carbon fiber production method that involves an exhaust gas processing step where high and low heating value exhaust gases are separately introduced into the exhaust gas combustion apparatus, with heat exchange and mixed external air supply to optimize combustion efficiency and reduce fuel consumption, utilizing a specific configuration to stabilize the flame and recover waste heat effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If exhaust gas is introduced into the combustion apparatus without optimizing the introduction position, then the combustion processing can be carried out, but the combustion stability becomes unstable
Solution Approach 1:
The exhaust gas introduction is segmented into multiple positions (inlet side and outlet side of the combustion apparatus) to optimize combustion stability. Different introduction positions allow for better control of combustion conditions and stability.
Solution Approach 2:
Different regions of the combustion apparatus are utilized for gas introduction, with specific positions (inlet side and outlet side) assigned for optimized combustion. This local differentiation improves combustion stability.
2Loss of energy
If waste heat from processed gas is not recovered, then the system is simpler, but heat energy is unnecessarily wasted
Solution Approach 1:
The waste heat from processed exhaust gas is converted into a useful resource by using it to heat external air for the oxidation step. This transforms energy loss into energy recovery, reducing overall energy consumption.
Solution Approach 2:
Instead of discarding the heat energy in processed exhaust gas, it is recovered and reused to heat external air. This recovery process reduces energy waste and improves overall system efficiency.
3Use of energy by moving object
If all exhaust gases are treated together without differentiation, then the processing is simpler, but combustion efficiency decreases
Solution Approach 1:
Exhaust gases are segmented into different categories based on heating value (high heating value and low heating value gases). This segmentation allows for optimized combustion efficiency by treating different gas types appropriately.
Solution Approach 2:
Different exhaust gases with different heating values are introduced at different positions (inlet side for high heating value, outlet side for low heating value) to optimize combustion efficiency. This local differentiation based on gas properties improves overall combustion performance.
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 the economical production of carbon fibers by minimizing fuel consumption and ensuring stable combustion, thereby reducing energy loss and maintaining consistent quality of the produced carbon fibers.
Implementation Method 1
an exhaust gas is subjected to combustion processing in an exhaust gas combustion apparatus
Implementation Method 2
combustion processing in which a flame is applied directly to the exhaust gas in a chamber partitioned by, for example, bricks, to thereby decompose the exhaust gas
Implementation Method 3
heat exchanging in which a processed exhaust gas discharged from the exhaust gas combustion apparatus is allowed to exchange heat with an untreated external air
Data Source
AI summary
A carbon fiber production method includes a carbon fiber production step including an oxidation step and a carbonization step; and an exhaust gas processing step including a heat exchange step; an external air mixing step; and a mixed external air supplying step in which the mixed external air is supplied to at least one step that uses heated gas in the steps in the carbon fiber production step; and among the exhaust gases, a high heating value exhaust gas having a heating value of 250 kcal/Nm3 or higher is supplied to an inlet side of an exhaust gas combustion apparatus and a low heating value exhaust gas having a heating value lower than 150 kcal/Nm3 is supplied to an outlet side of the exhaust gas combustion apparatus, respectively.