Gasifier Cooling Wall Burner Opening Design
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Solution Overview
Problem
Conventional gasifier walls with complex curved cooling tube configurations require high processing accuracy, leading to increased man-hours and complexity in structure and heat transfer efficiency, particularly in forming openings for burners exposed to high temperature gases.
Innovation Solution
A cooling wall design featuring straight and curved portions of cooling tubes, where the curved portions are arranged to form a cylindrical shape around the opening, reducing the need for complex curved shapes and allowing for easier installation and reduced heat transfer constraints, with a refractory material-filled seal box to prevent gas leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wall tubes are curved outwardly to form a substantially truncated cone shape around the burner opening, then the gap between the burner and wall tubes is reduced and tightness is improved, but the structure becomes complex and requires high processing accuracy
Solution Approach 1:
The wall tube is divided into multiple segments: a straight section, a first curved section forming a cylindrical shape, and a second curved section forming a truncated cone shape. This segmentation allows each section to serve a specific function while simplifying the overall manufacturing process compared to a single complex curve.
Solution Approach 2:
The first curved section is formed in advance to create a cylindrical shape that provides preliminary support and positioning for the burner. This preliminary action ensures proper alignment and reduces the complexity of final assembly, as the burner is already positioned correctly by the pre-formed cylindrical section.
2Reliability
If wall tubes are curved outwardly to form a substantially truncated cone shape, then the gap between burner and wall tubes is reduced, but processing accuracy requirements increase and man-hours increase
Solution Approach 1:
The curvature is divided into two distinct sections: a first curved section with a cylindrical shape and a second curved section with a truncated cone shape. Each section has standardized curvature radii and angles that can be manufactured with conventional precision, avoiding the need for high-precision single-step complex curving.
Solution Approach 2:
The use of standardized cylindrical and truncated conical curvatures with defined radii (R1, R2) and angles (θ1, θ2) allows for repeatable manufacturing processes. These geometric forms are easier to produce with standard tube bending equipment compared to arbitrary complex curves, thereby reducing processing accuracy requirements.
3Ease of operation
If complex curved wall tube configurations are used to form openings, then burner positioning is improved, but heat transfer efficiency decreases due to increased surface area exposed to high temperature gases
Solution Approach 1:
The wall tube configuration is segmented into functional zones: the straight section maintains optimal heat transfer characteristics, the first curved section provides burner positioning support, and the second curved section creates the opening. This segmentation allows the heat transfer-critical straight section to remain as long as possible while still achieving proper burner positioning.
Solution Approach 2:
Different sections of the wall tube are given different geometric properties suited to their local function: the straight section optimizes heat transfer, the first curved section provides structural support for positioning, and the second curved section creates the necessary opening. This local optimization balances heat transfer efficiency with ease of burner installation.
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
This design simplifies the structure of the opening, reduces the portion exposed to high temperature gases, and decreases heat transfer loss, while maintaining the integrity of the gasifier wall and preventing gas leakage, thus improving manufacturing efficiency and reducing operational costs.
Implementation Method 1
a gasifier wall is structured in a wall-like shape with a plurality of cooling tubes (wall tubes) in which a cooling medium such as water flows through
Implementation Method 2
effective heat transfer into the wall tubes of the gasifier wall
Implementation Method 3
a refractory material is filled in the seal box
Data Source
AI summary
A cooling wall includes: a wall surface defined by arrangement of central axes of a plurality of cooling tubes; and an opening formed in a part of the wall surface in which a burner is installable, each of the plurality of cooling tubes forming the opening has a straight portion and a curved portion, the plurality of cooling tubes include a first cooling tube whose first virtual axis extending in an axial direction of the straight portion overlaps the opening, and a second cooling tube whose second virtual axis extending in an axial direction of the straight portion is located outside an outer circumference of the opening in a radial direction, the curved portion of the first cooling tube is arranged so as to form a curve along the outer circumference surface of the opening and on a surface along the wall surface.