Catalytic Liquid Fuel Gasification System
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Solution Overview
Problem
Existing gasification methods for liquid fuels face challenges such as limited vaporization rates, fuel decomposition, coke formation, and the need for large amounts of superheated steam, which complicate the process and lead to inefficient conversion and clogging issues.
Innovation Solution
A system that eliminates the need for a vaporizer by spraying cold liquid fuel directly into a catalyst bed, using a nozzle with a heat exchanger to generate steam and a catalyst bed with a substrate having random voids for efficient mixing and partial oxidation, producing a hydrogen-rich gas without external pre-heating or steam addition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a vaporizer is used to gasify liquid fuels by indirect heat supply, then fuel vaporization can be achieved, but the vaporization rate is limited by heat transfer rate requiring large surface area
Solution Approach 1:
The invention extracts the vaporization function from the traditional heat exchanger and relocates it to the catalyst bed where partial oxidation occurs. Liquid fuel is sprayed directly into the catalyst bed and vaporized through the exothermic oxidation reactions, eliminating the need for a separate vaporizer and its large heat exchange surface area.
Solution Approach 2:
The invention merges the vaporization process with the partial oxidation process in a single catalyst bed. The heat generated from partial oxidation of fuel simultaneously provides the energy needed for vaporization of liquid fuel, combining two previously separate functions into one integrated system.
2Temperature
If liquid fuel is heated to vaporization temperature in fuel passages, then fuel can be vaporized, but fuel decomposition and coke formation occur
Solution Approach 1:
The invention applies preliminary oxidation to the liquid fuel droplets as they are being vaporized in the catalyst bed. By introducing oxidizer into the catalyst bed along with liquid fuel, partial oxidation occurs during the vaporization process, converting fuel before it can decompose into coke, thus preventing harmful deposits.
Solution Approach 2:
The invention changes the chemical environment parameters within the catalyst bed by introducing oxidizer, transforming the atmosphere from purely thermal (which causes decomposition) to chemically reactive (partial oxidation), thereby converting fuel molecules into oxidized products before they can form coke.
3Object-generated harmful factors
If superheated steam is used to prevent coke formation and supply heat for vaporization, then coke formation is reduced, but large amounts of steam are required creating large heat load
Solution Approach 1:
The system makes the catalyst bed self-sufficient by using the heat generated from partial oxidation reactions within the bed itself to vaporize the liquid fuel. This eliminates the need for external steam injection and the associated large heat load for steam production, as the system serves its own vaporization needs through internal chemical reactions.
Solution Approach 2:
The invention introduces oxidizer directly into the catalyst bed to accelerate partial oxidation of liquid fuel droplets. This accelerated oxidation provides both the heat for vaporization and the chemical conversion that prevents coke formation, replacing the need for large amounts of superheated steam.
4Reliability
If fine and uniform droplet size with homogeneous fuel-air distribution is achieved, then coke formation is avoided and temperature uniformity is obtained, but it is difficult to achieve in practical systems
Solution Approach 1:
The invention uses a porous catalyst bed structure that provides large surface area and uniform distribution of liquid fuel droplets as they are sprayed in. The porous structure facilitates homogeneous contact between fuel, oxidizer, and catalyst, achieving reliable partial oxidation without requiring complex atomization systems, as the porous medium itself promotes uniform distribution.
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 enables efficient conversion of liquid fuels to syngas with reduced coke formation, lower temperatures, and simplified system design, allowing for effective de-sulfurization and operation without external heat or steam, enhancing fuel conversion rates and system robustness.
Implementation Method 1
The heat exchanger is in close proximity with the catalyst bed and the nozzle. The hot catalyst bed is used to vaporize the liquid fuel and generate steam.
Implementation Method 2
converting the liquid fuel into a gas by partial oxidation and steam reforming
Implementation Method 3
converting the liquid fuel into a gas by partial oxidation and steam reforming
Implementation Method 4
spraying cold liquid fuel directly into a catalyst bed, using a nozzle
Data Source
AI summary
The present invention provides a system for the gasification of a liquid fuel and includes providing a supply of a liquid fuel and an oxidant, atomizing the liquid fuel and mixing it with the oxidant, catalytically reacting the fuel oxidant mixture, providing an ignition source for initiating the catalytic reaction, positioning a heat exchanger in proximity with the catalytic bed, and producing steam which can be fed back into the system thereby eliminating the need for a vaporizer. A hydrocarbon fuel can be mixed with oxygen, as a constituent of air, preferably forming a fuel rich fuel air mixture that passes through a catalytic reactor having an ultra-short channel length metal monolith substrate.