Coldface-Less Regenerative Oxidizers With Self-Supporting Heat Exchangers
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Solution Overview
Problem
Regenerative oxidizers (ROs) face issues with coldface failure due to corrosion, stress corrosion cracking, and mechanical deformation, leading to increased maintenance costs and operational inefficiencies.
Innovation Solution
The design of ROs without a coldface, where heat exchangers are self-supporting and directly rest on the heat transfer chamber floor, eliminating the need for a coldface and reducing failure risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coldface is used to support heat exchangers in regenerative oxidizers, then the heat exchangers can be supported structurally, but the coldface is susceptible to corrosion, stress corrosion cracking, and mechanical deformation leading to failure
Solution Approach 1:
The patent removes the coldface component entirely from the regenerative oxidizer system. Instead of using a coldface to support the heat exchangers, the design allows the heat exchangers to rest directly on the combustion chamber floor, eliminating the source of corrosion and mechanical deformation problems.
Solution Approach 2:
The patent employs sacrificial anodes made of less expensive material that can be easily replaced. These anodes are positioned to protect critical components from corrosion by sacrificing themselves first, providing a cost-effective solution that avoids the need for expensive corrosion-resistant materials.
2Ease of repair
If a coldface is used to support heat exchangers, then structural support is provided, but maintenance costs and inspection time increase due to corrosion and failure risks
Solution Approach 1:
By removing the coldface from the system, the patent eliminates the need for maintenance and inspection of this component. The heat exchangers rest directly on the combustion chamber floor, removing the source of corrosion-related maintenance requirements.
Solution Approach 2:
The design allows the heat exchangers to be self-supporting without requiring the coldface structure. This self-supporting configuration eliminates the need for external maintenance intervention and reduces inspection requirements.
3Device complexity
If a coldface is used in the regenerative oxidizer, then heat exchanger support is achieved, but the system complexity increases and failure risks increase
Solution Approach 1:
The patent eliminates the coldface structure from the system, reducing the number of components and simplifying the overall design. This removal of the coldface also eliminates the associated failure risks from corrosion and mechanical deformation.
Solution Approach 2:
The patent uses sacrificial anodes as a simple, replaceable protection mechanism instead of complex corrosion-resistant structures. These anodes can be easily replaced when consumed, providing protection without adding significant system complexity.
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 design reduces maintenance time and costs, enhances operational efficiency, and prevents corrosion and mechanical failures, allowing for safer and faster inspections.
Implementation Method 1
heat exchanger (114, 134) that facilitates the transfer of heat to the waste gas (108) on its way to the combustion chamber (106), and from the flue gas (110) on its way out of the combustion chamber (106)
Implementation Method 2
In the combustion chamber (106), the waste gas (108) is heated further (e.g., to between about 1,450° F. and 2,000° F. in an RTO, or to between about 700° F. and 950° F. in an RCO) such that the OCs within the waste gas (108) are oxidized
Implementation Method 3
RCOs are differentiated by a catalyst layer, which is used in RCO operation and absent in RTO operation
Data Source
AI summary
Disclosed herein are components, systems, and methods for oxidizing a waste gas to produce a flue gas. Embodiments of a regenerative oxidizer include a heat exchanger supported within a heat transfer chamber without the use of a coldface. The regenerative oxidizer may include an inlet into the heat transfer chamber that is laterally aligned with at least a portion of the heat exchanger. The heat exchanger includes a heat exchange block having at least one lateral passageway extending therethrough, and at least one vertical passageway extending through a top face of the heat exchange block, but is devoid of any vertical passageways extending through a bottom face of the heat exchange block.