Flow Splitter for Coal Gasification Reactor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional gasification systems face issues with pulverized coal plugging and non-uniform flow due to its behavior as a Bingham plastic at low shear stress, limiting the use of high void fraction coal with high velocity, multi-element injectors, and resulting in poor mixing and efficiency.
Innovation Solution
A flow splitter design with specific inside diameters for secondary tubes, satisfying Equations (I) and (II), ensures uniform division of the fuel mixture without plugging, allowing operation in a previously unavailable hydrodynamic regime, reducing wear, and enabling lower velocity operation while maintaining uniform flow splitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high void fraction coal is used to prevent plugging, then plugging is avoided, but non-uniform flow and poor mixing occur
Solution Approach 1:
The flow splitter divides the single fuel mixture stream into multiple separate streams through multiple outlet passages. This segmentation allows each stream to maintain stable, uniform flow characteristics while collectively handling the full fuel mixture flow, thus preventing plugging without sacrificing flow uniformity.
2Productivity
If high velocity multi-element injectors are used to improve mixing, then mixing capability increases, but plugging occurs due to low shear stress
Solution Approach 1:
The flow splitter performs preliminary flow division and stabilization before the fuel mixture enters the injector. By pre-establishing uniform flow through multiple outlet passages with specific diameter ratios, the system prepares the fuel mixture for effective injection without requiring excessively high velocities that would cause plugging.
3Object-generated harmful factors
If lower velocity operation is used to reduce wear, then wear is reduced, but flow uniformity and mixing performance deteriorate
Solution Approach 1:
Instead of relying solely on high velocity in a single dimension to achieve flow uniformity, the invention introduces a spatial dimension by using multiple outlet passages arranged in specific configurations. The diameter ratios and spatial arrangement of these passages create uniform flow distribution through geometric design rather than velocity alone, allowing lower operating velocities.
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 flow splitter achieves uniform flow division, preventing plugging, and enhances gasification reactor system performance by enabling plug flow, increasing reaction conversion, and reducing system costs and reactor vessel size.
Implementation Method 1
a first tube that has an outlet end and a plurality of second tubes that are coupled at the outlet end of the first tube to divide flow from the first tube
Implementation Method 2
the inside diameters of the plurality of second tubes satisfy at least one of Equation (I) and Equation (II), wherein Equation (I) is a uniform flow splitting equation and Equation (II) is a plugging prevention equation
Implementation Method 3
an ultra-dense phase, pulverized coal stream behaves as a Bingham plastic (at void fractions below 57%), which will plug in the gasification system if the shear stress on the coal falls below its Bingham fluid yield stress
Data Source
Figure 1~2
Figure 3
AI summary
A flow splitter is operable to divide flow of a fuel mixture. The flow splitter includes a first tube having an outlet end and a plurality of second tubes that are coupled at the outlet end to divide flow from the first tube. Each of the plurality of second tubes has a respective inside diameter that satisfies Equation (I) and Equation (II) disclosed herein.