Claus Reactor Flame Stability via Segmented Combustion Zones

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Solution Overview

Problem

Integrated gasification combined cycle (IGCC) power plants face challenges in simultaneously removing sulfur and ammonia from syngas due to differing combustion temperatures, necessitating efficient cleaning processes that can handle both impurities effectively.

Innovation Solution

A system incorporating a sulfur recovery unit that utilizes a high energy fuel, such as syngas, to maintain stable combustion temperatures in a Claus thermal reactor, ensuring efficient thermal recovery of sulfur and ammonia by adjusting fuel amounts and combustion zones to achieve temperatures above 2300 degrees Fahrenheit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional combustion processes are used for sulfur removal, then sulfur recovery is achieved, but flame stability and temperature control become problematic when simultaneously removing ammonia

Engineering Contradiction:

Improvecapability to remove both sulfur and ammoniaVSAvoidcombustion temperature control

Core Design Contradiction:

Adaptability or versatilityVSTemperature

Solution Approach 1:

The thermal reactor is divided into multiple zones with different functions: a first combustion zone for sulfur removal at lower temperatures, and a second combustion zone for ammonia removal at higher temperatures. This segmentation allows each zone to operate at its optimal temperature range, resolving the contradiction between removing both impurities and controlling temperature.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the reactor are provided with different local conditions - the first combustion zone has conditions optimized for sulfur combustion, while the second combustion zone has conditions optimized for ammonia combustion. This includes different fuel injection strategies and oxygen supply rates in different zones, enabling simultaneous removal of both impurities with proper temperature control.

Inventive Principle:

Principle #3Local quality

2Productivity

If high temperature combustion is used for ammonia removal, then ammonia is effectively removed, but flame stability decreases and heat output becomes insufficient for sulfur recovery

Engineering Contradiction:

Improveammonia removal efficiencyVSAvoidflame stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Sulfur combustion is performed first in the first combustion zone to generate heat and establish a stable flame. This preliminary action creates the thermal foundation necessary for subsequent ammonia combustion in the second zone, ensuring flame stability is maintained while achieving high temperature for ammonia removal.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The first combustion zone acts as an intermediary that prepares the thermal environment for the second combustion zone. The heat and stable flame from sulfur combustion serve as a mediator that enables the high-temperature ammonia combustion to proceed reliably, resolving the contradiction between productivity and reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Temperature

If fuel amount is increased to maintain temperature, then heat output is sufficient, but combustion efficiency decreases and operating cost increases

Engineering Contradiction:

Improvecombustion temperatureVSAvoidfuel consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The system maintains continuous useful action by having the first combustion zone continuously generate heat through sulfur combustion, which then sustains the second combustion zone. This continuous heat generation reduces the need for additional fuel to maintain temperature, improving energy efficiency while keeping combustion temperature adequate for ammonia removal.

Inventive Principle:

Principle #20Continuity of useful action

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 stabilizes the flame and maintains sufficient heat output for effective removal of hydrogen sulfide and ammonia, enhancing the efficiency of sulfur recovery and reducing pollutant emissions.

Implementation Method 1

a thermal reaction zone configured to thermally recover sulfur from the acid gas by combustion of the fuel and the acid gas with the oxygen

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 2

reaction of the acid gas with combustion products arising from the combustion

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS8597581B2System for maintaining flame stability and temperature in a Claus thermal reactor

Publication Date: 2013.12.03 AIR PROD & CHEM INC

AI summary

A system may include a sulfur recovery unit. The sulfur recovery unit may include an acid gas supply, which may supply acid gas, an oxygen supply, which may supply oxygen, a fuel supply, which may supply fuel. The fuel may have a higher heating value than the acid gas. Also, the sulfur recovery unit may include a thermal reaction zone, which may thermally recover sulfur from the acid gas by combustion of the fuel and the acid gas with the oxygen and through reaction of the acid gas with combustion products arising from the combustion.