Gasifier Additives Forming Protective Spinel Layers

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Solution Overview

Problem

The existing refractory linings in gasifiers degrade quickly due to slag infiltration, requiring frequent and costly replacements, as the liquid slag byproduct penetrates the porous materials, causing cracking, spalling, and dissolution.

Innovation Solution

Incorporating ferric oxide, magnesium oxide, or manganese oxide additives in the hydrocarbon feed to form a liquid slag with at least 15% by weight of these oxides, which reacts with the refractory material to form protective spinel layers that prevent deeper slag penetration and reduce degradation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If porous refractory material is used to line the gasifier walls, then heat containment is improved, but slag infiltration causes rapid degradation

Engineering Contradiction:

Improveheat containmentVSAvoidrefractory material durability

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The invention converts the harmful liquid slag into a beneficial protective layer by controlling its composition to form spinel phases. The slag, which initially causes degradation through infiltration, is modified to react with the refractory material and form a protective spinel layer that prevents further slag penetration, thus converting the harmful infiltration process into a protective mechanism.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention changes the chemical composition parameters of the slag by adding specific oxides (Fe2O3, MgO, MnO) to alter its reactivity and phase formation behavior. By adjusting the slag composition to contain at least 15% by weight of these oxides, the slag transforms from a degrading agent into a material that forms protective spinel layers, fundamentally changing its interaction with the refractory lining.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If refractory material is replaced frequently, then operational reliability is maintained, but production time and costs increase

Engineering Contradiction:

Improvegasifier operational reliabilityVSAvoidgasifier production time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention performs preliminary action by modifying the slag composition before it contacts the refractory material. By pre-adjusting the chemical composition of the slag to contain sufficient spinel-forming oxides (Fe2O3, MgO, MnO), the protective layer formation is initiated in advance, preventing degradation before it occurs and eliminating the need for frequent refractory replacements.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention enables the system to self-protect by allowing the modified slag to automatically form protective spinel layers on the refractory surface. This self-service mechanism continuously regenerates the protective barrier during operation, maintaining refractory integrity without external intervention or shutdowns for maintenance.

Inventive Principle:

Principle #25Self-service

3Productivity

If liquid slag flows along the gasifier walls, then gasification reaction proceeds, but refractory degradation occurs through infiltration

Engineering Contradiction:

Improvegasification reaction efficiencyVSAvoidslag infiltration damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The invention converts the harmful infiltration action of liquid slag into a beneficial protective process. By modifying the slag composition to form spinel layers, the same flowing liquid slag that previously caused degradation now deposits protective layers on the refractory surface, transforming the harmful infiltration process into a self-healing protective mechanism.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention introduces spinel-forming oxides (Fe2O3, MgO, MnO) as intermediary substances that mediate between the liquid slag and the refractory material. These intermediaries facilitate the formation of protective spinel phases at the slag-refractory interface, acting as a buffer that prevents direct harmful interaction between the slag and refractory while maintaining the gasification process.

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

The formation of protective spinel layers significantly reduces the rate of refractory material degradation, extending its lifespan and reducing the need for frequent replacements by limiting slag penetration and maintaining operational continuity.

Implementation Method 1

reacts with the refractory material to form protective spinel layers

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Implementation Method 2

operating the gasifier at a temperature higher than the melting temperature of the slag such that the feed material forms the liquid slag

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS8333813B2Gasifier additives for improved refractory life

Publication Date: 2012.12.18 AIR PROD & CHEM INC

AI summary

Embodiments disclosed herein provide hydrocarbon additives and methods of making and using the same. The additives are suitable for use in conjunction with gasifiers, furnaces, or other high-temperature vessels. The additives may be part of an input stream to a reaction vessel of a hydrocarbon gasifier. The additives may include materials that at least partially reduce the infiltration of slag into the refractory material.