Dosing Cyclone and Lance for Dust Oxidation Wear Reduction
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Solution Overview
Problem
Existing devices for oxidizing, reducing, calcining, sintering, or melting dusts face issues with wear and irregular melting due to complex and expensive injectors, which lead to refractory problems and inefficient temperature transfer, especially when handling abrasive materials.
Innovation Solution
A device with a dosing cyclone and combustion chamber configuration that includes a height-adjustable lance for coaxial fuel and gas injection, creating an annular gap for extended flame residence time and reduced pressure, allowing for stable and adjustable flames, and eliminating the need for expensive dosing means and injectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If complex injectors are used to inject dusts into the combustion chamber, then the dust injection capability is improved, but the device complexity increases and wear problems worsen
Solution Approach 1:
The patent extracts the dust injection function from the complex injector system and relocates it to a dosing cyclone positioned before the combustion chamber. This separates the dust injection task from the fuel injection system, allowing each component to be simpler and more specialized. The cyclone uses centrifugal force to inject dust continuously without the need for complex adjustable nozzles.
Solution Approach 2:
The dosing cyclone acts as an intermediary device between the dust storage and the combustion chamber. It receives dust continuously and delivers it in a controlled manner using carrier gases and centrifugal forces, eliminating the need for complex direct injection mechanisms into the combustion chamber.
2Ease of manufacture
If complex injectors are used for dust injection, then the dust injection capability is improved, but the reliability decreases due to wear and abrasion
Solution Approach 1:
By extracting the dust injection function from the injector system and placing it in a separate dosing cyclone, the patent eliminates wear problems associated with complex injectors. The cyclone has no moving parts or adjustable components that would wear from abrasive dust, significantly improving reliability.
Solution Approach 2:
The dosing cyclone uses simple, wear-resistant components that can be easily replaced if needed, rather than complex expensive injectors that wear out. The design accepts that simple components may need replacement but avoids the high cost and complexity of wear-resistant injectors.
3Ease of operation
If pulsed operation of injectors is used, then the dust injection control is improved, but the melting regularity worsens
Solution Approach 1:
The dosing cyclone provides continuous dust injection rather than pulsed injection. Dust is continuously fed into the cyclone and delivered steadily to the combustion chamber, ensuring constant melting action without interruptions that would cause irregularities in the melting process.
4Use of energy by moving object
If coaxial fuel injection is used, then the temperature transfer speed is improved, but the flame stability worsens
Solution Approach 1:
The patent segments the fuel injection into two separate systems: liquid fuel injected coaxially for rapid temperature transfer, and dust injected via the cyclone for stable combustion. This segmentation allows each fuel type to perform its optimal function without compromising the other's stability.
Solution Approach 2:
The dosing cyclone acts as an intermediary that introduces dust in a manner that stabilizes the overall combustion process, while the coaxial liquid fuel injection provides the rapid temperature transfer. The interaction between these two systems achieves both rapid heating and flame stability.
5Productivity
If high pressure is maintained in the dosing cyclone, then the dust charging efficiency is improved, but the pressure level increases requiring expensive dosing means
Solution Approach 1:
The dosing cyclone uses pneumatic principles with carrier gases (such as air or oxygen) to transport and inject dust into the combustion chamber. The carrier gases create the necessary flow and pressure differentials to achieve efficient dust charging without requiring high overall pressure levels in the cyclone, eliminating the need for expensive high-pressure dosing equipment.
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 configuration enhances burnout and reaction efficiency, reduces refractory expenses, and enables the processing of both fine and coarse materials with improved temperature control and reduced wear, allowing for efficient sintering or melting of dusts with minimal contact with the combustion chamber walls.
Implementation Method 1
a dosing cyclone into which the dusts are charged and to which a tangential connector for feeding carrier gases is connected
Implementation Method 2
a lance is arranged in the interior of the dosing cyclone, coaxially with the discharge opening of the dosing cyclone, for the introduction of liquid substances, substances dissolved in liquids or suspended in gases, or gaseous oxidizable substances and, in particular, fuels
Implementation Method 3
The combustion chamber itself can be heated by the aid of burners to the temperatures required to melt the dusts, for instance temperatures of from 1200° C. to 1650° C.
Implementation Method 4
The rotational movement imparted on the material present in the dosing cyclone consequently results in a longer residence time in the region of the flame over an accordingly short axial length
Data Source
AI summary
In a device for oxidizing, reducing, calcining, sintering or melting dusts such as, e.g., furnace or steel dusts, marl and lime dust mixtures, shredder light fractions, mineral dusts such as, e.g., glass dusts, cement kiln bypass dusts, dry sewage sludge, paper slurries or oil-containing grinding dust suspensions, using a dosing cyclone into which the dusts are charged and to which a tangential connector for feeding carrier gases is connected, and a combustion chamber following the dosing cyclone in the axial direction, wherein fuel and optionally additional carrier gas are injected into the combustion chamber coaxially with the discharge opening of the cyclone, a lance is arranged in the interior of the dosing cyclone, coaxially with the discharge opening of the dosing cyclone, for the introduction of liquid substances, substances dissolved in liquids or suspended in gases, or gaseous oxidizable substances and, in particular, fuels. According to the proposed method, the dosing cyclone is operated at a pressure reduced relative to the pressure prevailing in the fuel lance.