Gasification Fuel Injector Tip Cooling Design
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Solution Overview
Problem
Fuel injectors in gasification systems face premature wear and corrosion due to high temperatures and temperature fluctuations, leading to radial and circumferential cracks, despite the use of high-temperature materials and cooling techniques, as sulfur compounds deposit on coolant chamber walls, accelerating corrosion.
Innovation Solution
A gasification fuel injector design featuring a tip portion with an inner and outer wall surrounding a coolant chamber, where the outer wall includes a curved section to reduce strain and buckling, and a progressively increasing and decreasing diameter, along with a coolant inlet and outlet to manage heat and pressure, enhancing flexibility and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling techniques are used to manage high temperatures, then temperature control is improved, but sulfur compounds deposit on coolant chamber walls accelerating corrosion
Solution Approach 1:
The patent extracts the harmful sulfur compounds from the coolant chamber by incorporating a sacrificial coating on the inner wall that preferentially reacts with and removes sulfur compounds from the environment, preventing their deposition on the coolant chamber walls
Solution Approach 2:
The patent introduces a sacrificial coating as an intermediary layer between the sulfur compound-laden environment and the coolant chamber walls. This coating acts as a mediator that reacts with sulfur compounds first, protecting the underlying metal surfaces from corrosion
2Productivity
If the fuel injector is placed close to the flame for efficient combustion, then combustion efficiency is improved, but the life of the fuel injector is reduced due to high temperatures
Solution Approach 1:
The patent applies preliminary protective action by coating the fuel injector tip with a thermally protective material before exposure to high temperatures. This pre-applied coating provides immediate protection against thermal degradation, allowing the injector to maintain structural integrity while operating close to the flame
Solution Approach 2:
The patent changes the thermal properties of the fuel injector tip by applying a coating with different thermal characteristics. This coating modifies the temperature distribution and thermal stress parameters, enabling the injector to withstand high-temperature environments closer to the flame
3Strength
If the outer wall is made rigid to withstand pressure, then structural strength is improved, but strain and buckling increase under thermal and pressure differentials
Solution Approach 1:
The patent applies curvature to the outer wall surface, transitioning from a flat or angular design to a curved, spherical-like geometry. This curvature distributes thermal and mechanical stresses more evenly across the surface, reducing localized strain and buckling while maintaining structural strength under pressure differentials
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 design significantly reduces the likelihood of cracks and corrosion, extends the life of the fuel injector, and improves heat transfer efficiency by managing thermal stress and pressure differentials, while preventing sulfur compound deposition.
Implementation Method 1
a coolant chamber between the inner and outer walls
Implementation Method 2
managing thermal stress and pressure differentials
Implementation Method 3
the outer wall includes a curved wall portion extending in the downstream direction away from the rim
Data Source
AI summary
A system includes a gasification fuel injector. The gasification fuel injector includes a tip portion surrounding an injection passage configured to inject a fluid in a downstream direction. The tip portion includes an inner wall surrounding the injection passage and extending in the downstream direction from a neck to a rim, an outer wall surrounding the inner wall and extending from the neck to the rim, and a coolant chamber between the inner and outer walls. The outer wall includes a curved wall portion extending in the downstream direction away from the rim.