Flameless Thermal Oxidizer Mixing for Flashback-Safe Oxidation

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Solution Overview

Problem

Flameless thermal oxidizers face challenges in achieving complete oxidation of fume streams with reduced risk of flashback while minimizing operational costs and maximizing vessel capacity, as existing technologies often require excessive fuel consumption and conservative vessel sizing due to limitations in controlling reaction wave location and stability.

Innovation Solution

The implementation of a flameless thermal oxidizer with a diptube apparatus and mixing conduits that distribute vent gas streams and oxidizing agents at optimized equivalence ratios, using a programmable control system to manage flow rates and prevent flashback, and incorporating apertures in mixing conduits for uniform distribution and increased local velocity of the reactable process gas stream.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional flameless thermal oxidizers are used to treat organic vent gases, then oxidation reaction occurs, but fuel consumption is excessive and vessel capacity is reduced due to conservative sizing

Engineering Contradiction:

Improvefuel consumptionVSAvoidvessel capacity

Core Design Contradiction:

Loss of energyVSProductivity

Solution Approach 1:

The patent applies parameter changes by optimizing the equivalence ratio of the gas stream to maintain combustion stability at lower fuel consumption. By precisely controlling the air-to-fuel ratio and using a reaction wave propagation mechanism, the system achieves complete oxidation with reduced energy input, resolving the contradiction between fuel efficiency and oxidation effectiveness

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent implements dynamics through the moving reaction wave that propagates through the vessel. Unlike static combustion chambers, the reaction wave dynamically moves through the gas stream, allowing adaptive combustion that maintains efficiency while maximizing vessel utilization. This dynamic approach enables higher productivity without proportionally increasing fuel consumption

Inventive Principle:

Principle #15Dynamics

2Reliability

If higher equivalence ratios are used to improve oxidation completeness, then oxidation efficiency increases, but flashback risk increases

Engineering Contradiction:

Improveoxidization completenessVSAvoidflashback risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent employs feedback control through sensors that monitor the reaction wave position and gas stream conditions. This feedback mechanism allows real-time adjustment of the equivalence ratio, maintaining oxidation completeness while preventing flashback by detecting and responding to conditions that could lead to flame propagation back into the mixing zone

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent uses an intermediary approach by introducing a controlled amount of air through specific nozzles that act as a buffer between the fuel injection point and the combustion zone. This intermediary air stream stabilizes the reaction wave and prevents direct contact between high-equivalence ratio mixtures and ignition sources, eliminating flashback risk while maintaining oxidation efficiency

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enhances the efficiency of oxidation reactions, reduces the risk of flashback, and lowers operational costs by maintaining the mixture at or near the lower flammability limit, thereby maximizing the available capacity of the vessel and minimizing fuel consumption.

Implementation Method 1

combining the vent gas stream and the oxidizing agents in the mixing conduit

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

distributing the vent gas stream through the vent gas stream conduit; distributing the oxidizing agents through a mixing conduit

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

Thermal oxidation is a process whereby solvents and other hydrocarbons combine with oxygen to form water and carbon dioxide

Methodology Applied

Scientific EffectOxidation: Oxidation

Implementation Method 4

The reaction is referred to as 'flameless' because the FTO permits the reaction of the process gas stream to occur in the absence of a flame

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 5

a vessel configured to contain a matrix bed of media

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10234174B2Apparatus and method for flameless thermal oxidation at optimized equivalence ratios

Publication Date: 2019.03.19 LINDE ENGINEERING NORTH AMERICA INC

AI summary

In a flameless thermal oxidizer including a vessel configured to contain a matrix bed of media, and a vent gas stream conduit and an oxidizing agent conduit each extending into an interior of the vessel at least partially within the matrix bed of media, a method of delivering a vent gas stream and oxidizing agents into the vessel includes the steps of distributing the vent gas stream through the vent gas stream conduit; distributing the oxidizing agents through a mixing conduit; and combining the vent gas stream and the oxidizing agents in the mixing conduit.