Gasification Feed Injector for Low Flow Rate Startup
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Solution Overview
Problem
Existing fuel feed systems and feed injector systems are inadequate for use with liquid slurry fuels and at low fuel flow rates, leading to issues such as plugging, oxidation, and coking, and are not effective in reducing emissions during startup or standby operations in integrated gasification combined cycle (IGCC) power plants.
Innovation Solution
A gasification feed injector system with multiple injector portions for low and high flow rates, a fuel circulation system to prevent stagnation, and a controller to transition between flow rates based on downstream pressure, along with cleaning and purge systems to maintain flow path integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single feed injector is used for normal or high flow rates, then the injector can supply fuel at adequate rates for normal operation, but the injector cannot operate at low flow rates during startup or standby, leading to high emissions and inability to reduce emissions during initial stages
Solution Approach 1:
The feed injector is divided into multiple independent injector portions (first injector portion and second injector portion), each capable of operating at different flow rates. This segmentation allows the system to select appropriate flow rates for different operational phases, enabling low flow rate operation during startup and standby while maintaining high flow rate capability for normal operation, thereby resolving the contradiction between productivity and adaptability
2Ease of operation
If liquid slurry fuel is stored in flow paths, then the fuel can be supplied to the injector, but the flow paths become plugged due to settling and are susceptible to oxidation and coking when not in use
Solution Approach 1:
The system implements continuous circulation of liquid slurry fuel through the flow paths via the fuel circulation system, even when the feed injector is not actively injecting fuel. This continuous motion prevents settling and plugging of the fuel in the flow paths, maintains fuel fluidity, and reduces susceptibility to oxidation and coking, thereby ensuring flow path integrity while maintaining fuel supply capability
Solution Approach 2:
The fuel circulation system acts as an intermediary mechanism that continuously moves fuel through the flow paths. This intermediary circulation function separates the storage function from the injection function, allowing fuel to be stored in the tank while being continuously circulated through the flow paths to prevent degradation and plugging, thus maintaining reliability without compromising ease of operation
3Productivity
If the feed injector operates at high flow rates only, then fuel can be supplied adequately for normal operation, but emissions cannot be reduced during startup or standby operations
Solution Approach 1:
The feed injector system is designed with dynamic flow rate adjustment capability through multiple injector portions that can be selectively activated. The system can transition from high flow rate operation during normal operation to low flow rate operation during startup or standby, enabling emissions reduction during initial stages while maintaining adequate productivity during normal operation, thus resolving the contradiction between productivity and harmful emissions
Data Source
AI summary
A system includes a gasification feed injector. The gasification feed injector includes a first injector portion configured to inject a first fuel at a first flow rate and a second injector portion configured to inject a second fuel at a second flow rate. The system also includes a fuel circulation system configured to circulate at least one fuel and supply the at least one fuel to the gasification feed injector and a controller configured to transition the gasification feed injector from injecting the first fuel to injecting the second fuel based at least on a pressure downstream of the gasification feed injector.