Dynamic Opening Area Control for Gasification Slag Blockage Prevention
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Solution Overview
Problem
Gasification melting systems face challenges in predicting and preventing sudden blockages at slag outlets, which can lead to operational inefficiencies and potential damage due to fluctuating ash component properties and temperature changes.
Innovation Solution
A blocking prevention device that adjusts the slag adhesion prevention capabilities based on the change rate and area of the opening part, utilizing a combination of secondary combustion chamber air supply, basicity modifier supply, and burner devices to control slag flow and prevent adhesion, while also providing imaging and display systems for operator awareness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a fixed threshold α is used to determine blocking, then the system is simple to operate, but it cannot respond to sudden blockages that proceed rapidly
Solution Approach 1:
The patent transitions from a fixed static threshold α to a dynamic threshold system that adapts based on the rate of change of opening area. The determination standard changes from a single fixed value to a combination of absolute threshold and rate-of-change threshold, enabling the system to respond differently to gradual versus rapid blockages.
Solution Approach 2:
The patent introduces a new parameter (rate of change of opening area) alongside the existing opening area parameter. By monitoring both the absolute opening area and its rate of change, the system can distinguish between normal fluctuations and sudden blockages, improving detection reliability without sacrificing operational simplicity.
2Reliability
If the opening area becomes very small before triggering prevention, then false alarms are reduced, but the risk of sudden complete blockage increases
Solution Approach 1:
The patent enables preliminary action by detecting rapid changes in opening area before the opening becomes completely blocked. By monitoring the rate of change, the system can trigger prevention measures earlier in sudden blockage scenarios, preventing complete blockage and its associated losses.
Solution Approach 2:
The system uses feedback from both the opening area measurement and its rate of change to dynamically adjust the determination standard. This dual-feedback mechanism allows the system to maintain appropriate sensitivity across different blocking scenarios, reducing false alarms while catching sudden blockages.
3Adaptability or versatility
If operator experience determines threshold settings, then the system adapts to specific conditions, but human error and inconsistency increase
Solution Approach 1:
The patent implements a self-service mechanism where the system automatically determines appropriate thresholds based on real-time monitoring of opening area and its rate of change. This eliminates dependence on operator experience and subjective judgment, providing consistent, objective blocking determination across different operators and conditions.
Solution Approach 2:
The patent replaces the human operator's subjective judgment mechanism with an automated computational system. The control device calculates and applies determination standards based on objective measurements, substituting human decision-making with a reliable automated process that eliminates human error and inconsistency.
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
Enables early prediction and prevention of blockages, ensuring continuous operation by adapting to varying conditions and reducing human error, regardless of operator experience, and allows for cost-effective installation of imaging devices.
Implementation Method 1
an imaging device that images the opening part
Implementation Method 2
a calculation unit that calculates an opening area of the opening part and a change rate of the opening area on the basis of the image
Implementation Method 3
a control device that controls the plurality of slag adhesion prevention devices 13 on the basis of the opening area and the change rate of the opening area
Data Source
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AI summary
A blocking prevention device for a gasification melting system (1) that combusts and melts an object to be treated into a slag in a melting furnace (4) after the object to be treated is converted into pyrolysis gas in a gasification furnace (2) is provided, the blocking prevention device including: a slag adhesion prevention device (13) that has a slag adhesion prevention capability for preventing adhesion of the slag at an opening part (16, 20) that may be blocked due to the adhesion of the slag; an imaging device (39, 40) that images the opening part; and a control device (50) including a calculation unit that calculates a change rate of an opening area of the opening part using a plurality of images with different capturing times or a video, captured by the imaging device, and a prevention device control unit that changes the slag adhesion prevention capabilities of a plurality of the slag adhesion prevention devices in accordance with the change rate.