Char Recycling System Blockage Detection via Differential Pressure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In char recycling systems, it is difficult to determine if the char exhausting pipe is blocked, and there is a need to reduce the frequency and amount of purge gas used to address blockages.
Innovation Solution
A char recycling system that includes a char exhausting pipe with a differential pressure gauge to measure pressure differences between upstream and downstream areas, allowing for easy detection of blockages, and a purge gas injection device controlled by a control device to inject purge gas only when necessary, along with an assist gas supply to reduce char accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the char exhausting pipe is designed to convey char efficiently, then the processing capacity is improved, but the difficulty of detecting blockages increases
Solution Approach 1:
The patent introduces a differential pressure gauge as an intermediary measurement device that indirectly detects blockages by measuring pressure differences between upstream and downstream areas of the char exhausting pipe. This allows blockage detection without directly observing the pipe interior, resolving the contradiction between efficient char conveyance and blockage detection capability.
Solution Approach 2:
The patent replaces direct mechanical inspection methods with a pressure-based detection system. Instead of physically examining the pipe interior, the system uses differential pressure measurement to infer blockage conditions, making blockage detection easier while maintaining high processing capacity through the efficient pipe design.
2Reliability
If purge gas is continuously injected to prevent blockages, then the reliability is improved, but the loss of substance increases
Solution Approach 1:
The patent implements periodic injection of purge gas based on pressure difference thresholds rather than continuous injection. The control device activates purge gas injection only when the differential pressure gauge detects pressure differences exceeding a predetermined threshold, indicating actual blockage conditions. This periodic action maintains reliability while significantly reducing purge gas consumption compared to continuous operation.
Solution Approach 2:
The patent establishes a feedback control system where the differential pressure gauge continuously monitors pressure differences and provides feedback to the control device. The control device adjusts purge gas injection based on this feedback, injecting gas only when blockages are detected. This closed-loop feedback mechanism ensures reliable blockage prevention while minimizing unnecessary purge gas consumption.
3Ease of operation
If the char exhausting pipe is inclined at a steep angle, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The patent segments the char conveying path into multiple sections with different inclination angles. The first section has a steeper angle for easy char flow from the gasifier, while the second section has a gentler angle for controlled delivery to the char bin. This segmentation allows each section to be optimized for its specific function, maintaining ease of operation while reducing overall device complexity compared to a uniformly steep inclination.
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
The system effectively determines blockages and reduces the frequency and amount of purge gas used by measuring pressure differences and controlling gas injection, thereby preventing char accumulation and minimizing operational disruptions.
Implementation Method 1
a differential pressure gauge that measures a pressure difference between the pressure in a downstream area of the powder flowpath and the pressure in an upstream area on an upstream side of the downstream area of the powder flowpath
Implementation Method 2
a purge gas injection device that injects purge gas to the inclined flowpath
Implementation Method 3
The powder flowpath may include a vertically-downwards flowpath, and an inclined flowpath connected to a downstream side of the vertically-downwards flowpath
Data Source
AI summary
A char recycling system capable of easily determining whether or not a char exhausting pipe is blocked by char. The char recycling system comprises: a stand pipe (31) forming a vertically-downwards flowpath (33) through which char is conveyed; and a differential pressure gauge (41) that measures the pressure difference between the pressure in a downstream area (45) in the vertically-downwards flowpath (33) and the pressure in an upstream area (46) in the vertically-downwards flowpath (33). The pressure difference fluctuates when char accumulates between the downstream area (45) and the upstream area (46) in the vertically-downwards flowpath (33). As a result, this kind of char recovery system is capable of easily determining whether or not the vertically-downwards flowpath (33) is blocked by char, on the basis of the measured pressure difference.