Rapid Gas Quench Structure for Corrosive Solid-Laden Streams
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Solution Overview
Problem
Existing methods for cooling high temperature, corrosive gases, such as HCl oxidation and pyrolysis gases, face issues with heat exchanger blockage, material limitations, and safety risks due to dry walls and cracking of heat-resistant mortars, leading to unstable operation and potential safety accidents.
Innovation Solution
An apparatus with cylindrical housings, inner cylinders, and water film/water mist generation members to form a stable water film and mist, using cooling media to isolate the gas from the housing and prevent corrosion, combined with a gas-and-liquid separation system for continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a nickel-based material is used for heat exchanger, then it can withstand high temperature HCl and Cl2, but it cannot withstand the precipitation of water and is severely corroded by acid-containing liquids
Solution Approach 1:
The patent uses a composite structure combining nickel-based material (for high temperature resistance) with acid-resistant lining materials such as rubber lining, plastic lining, or ceramic coating (for corrosion resistance). This allows the heat exchanger to simultaneously withstand both high temperature and corrosive environments without material failure.
2Reliability
If a tantalum material is used for heat exchanger, then it can withstand hydrochloric acid solution of any concentration, but it cannot be used at a temperature greater than 260°C
Solution Approach 1:
The patent employs composite material construction where tantalum or other acid-resistant materials are used for components in direct contact with corrosive media, while heat-resistant materials are used for structural components exposed to high temperatures. This division of functional requirements allows the system to achieve both corrosion resistance and high temperature capability.
3Productivity
If a shell-and-tube heat exchanger is used for cooling, then it can provide efficient heat exchange, but catalyst particles in the reaction gas easily block it causing unstable operation
Solution Approach 1:
The patent segments the cooling system into multiple sections with different functions: a pre-cooling section with larger channels that prevents particle blockage, and a main heat exchange section with efficient heat transfer surfaces. The segmented design allows particles to pass through the pre-cooling section without blocking the system, while maintaining high cooling efficiency in the main section.
Solution Approach 2:
The patent introduces an intermediary filtration system or separator before the heat exchanger that removes catalyst particles from the gas stream. This intermediary component protects the heat exchanger from blockage while allowing the cooling function to continue operating efficiently.
4Reliability
If a quench tower with water film on inner wall is used to protect the tower, then it can isolate high temperature flue gas from the tower wall, but the water film stability is affected by gas velocity and dry walls cause irreversible damages
Solution Approach 1:
The patent uses flexible spray systems with multiple nozzles that can adapt to varying gas velocities. The spray system maintains water film coverage through adjustable spray patterns and pressures, ensuring the protective film remains stable even when gas flow conditions change, preventing dry wall formation and tower damage.
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 solution effectively prevents heat exchanger blockage, extends apparatus lifespan, and ensures safe, reliable cooling of corrosive gases, allowing for stable operation and wider application in treating HCl oxidation and pyrolysis gases.
Implementation Method 1
a water film generation member and a water mist generation member, the water film generation member and the water mist generation member being disposed on the cylindrical housing and configured to form a water film and a water mist in the interior of the cylindrical housing
Implementation Method 2
the corrosive gas is rapidly cooled in an interior of a cylindrical housing by a liquid entering the apparatus
Implementation Method 3
a jacket on an outer side of each cylindrical housing, inner members distributed along a wall of the housing, communicating an interior of the jacket with an interior of the cylindrical housing, and configured to distribute a liquid in the interior of the jacket to the interior of the cylindrical housing
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3
AI summary
Provided are an apparatus and method for rapid cooling of a high temperature gas. The apparatus includes one or more cylindrical housings (001) connected to one another, a jacket (002) on an outer side of a housing, an inner cylinder (003) disposed at least in an interior of a first cylindrical housing, a heat insulation gasket (005), inner members (006), a corrosive high temperature gas inlet (N01) disposed on the heat insulation gasket (005), a gas and liquid phase outlet (N02) disposed at a bottom of the housing or a bottom of a last housing and a coolant inlet and outlet (N03-N05) connected to an interior of the jacket (002). The heat insulation gasket (005) seals the first cylindrical housing (001) and a top of the inner cylinder (003) in the interior of the first cylindrical housing (001). The inner members (005) are distributed along a wall of the housing (001), communicate an interior of the jacket (002) with an interior of the housing (001), and distribute a liquid in the interior of the jacket (002) to the interior of the housing (001). The method replaces a filter and a cooler and effectively reduces a risk of blockage when a solid-containing gas is cooled.