Tunable Catalytic Gasifier Slurry Atomization

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Solution Overview

Problem

There is a need for efficient methods to convert solid alternative fuels like coal and biomass into syngas for energy production, as existing technologies face challenges in utilizing these fuels effectively due to their solid form and the high financial and environmental costs associated with fossil fuels.

Innovation Solution

A slurry tube with a coolant conduit and an atomizing gas conduit is used to cool and atomize a fuel slurry, which is then introduced to a reactor chamber heated by radiative heat, such as catalytic combustion, to gasify the fuel into syngas comprising hydrogen, carbon monoxide, and carbon dioxide.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If solid alternative fuels are used directly, then fuel availability is improved, but utilization efficiency deteriorates due to difficult processing

Engineering Contradiction:

Improvefuel availabilityVSAvoidutilization efficiency

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The patent changes the physical state of solid fuel by converting it into slurry form (suspending fuel particles in liquid). This parameter change from solid to slurry enables the fuel to be pumped, atomized, and combusted more efficiently while maintaining the quantity of fuel available for conversion to syngas.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes phase transition by converting solid fuel particles into a liquid slurry suspension, which can then be atomized into fine droplets. This phase transition enables better heat transfer and combustion efficiency, resolving the contradiction between fuel availability and utilization efficiency.

Inventive Principle:

Principle #36Phase transitions

2Productivity

If fossil fuels are extracted and refined, then energy production is improved, but environmental cost worsens

Engineering Contradiction:

Improveenergy productionVSAvoidenvironmental cost

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent converts harmful solid waste materials (coal, biomass) into beneficial syngas products. By gasifying these materials through slurry atomization and controlled combustion, the process transforms potentially harmful substances into useful energy carriers (hydrogen, carbon monoxide, methane) while reducing environmental impact compared to traditional fossil fuel extraction.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Manufacturing precision

If atomizing gas flow rate is increased, then atomization quality is improved, but energy consumption worsens

Engineering Contradiction:

Improveatomization qualityVSAvoidenergy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent employs dynamic adjustment of atomizing gas flow rate to optimize the balance between atomization quality and energy consumption. By controlling the gas flow to achieve sufficient atomization without excessive energy input, the system maintains manufacturing precision while minimizing energy use in the atomization process.

Inventive Principle:

Principle #15Dynamics

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 effectively converts solid fuels into syngas, enabling efficient energy production while reducing capital costs and environmental impact by utilizing scalable reactor systems and achieving high throughput at high pressures.

Implementation Method 1

a coolant conduit surrounding at least a portion of the slurry tube

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

an atomizing gas conduit in fluid communication with one or more atomizing gas apertures configured so as to contact atomizing gas with material exiting the outlet of the slurry tube

Methodology Applied

Scientific EffectAtomization: Fluid Spray

Implementation Method 3

introducing the stream of atomized fuel to a reactor chamber heated by radiative heat

Methodology Applied

Scientific EffectRadiative heat: Thermal Radiation

Implementation Method 4

heating the atomized fuel in the reactor chamber so as to gasify at least a portion of the atomized fuel to a syngas

Methodology Applied

Scientific EffectGasification: Pyrolysis

Implementation Method 5

reactor chamber heated by radiative heat, such as catalytic combustion

Methodology Applied

Scientific EffectCatalytic combustion: Combustion

Data Source

PatentUS8974557B2Tunable catalytic gasifiers and related methods

Publication Date: 2015.03.10 GOOD EARTH POWER CORP

AI summary

The present disclosure provides tunable catalytic gasifier systems suitable for gasifying coal, biomass, and other fuel sources. The gasifier reactors of the disclosed systems may be heated by, e.g., a catalytic tube or other jacket that generates heat by catalytically combusting syngas, which syngas may be syngas produced by the gasifier system.