Hydrothermal Carbonization Reactor Pressure Loss Reduction
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Solution Overview
Problem
Existing hydrothermal carbonization processes for pasty products and sewage treatment plant sludge face challenges such as high thermal requirements, size limitations of reactors, and issues with heat exchange coefficients and scaling, particularly for solid products with high dryness.
Innovation Solution
The process optimizes hydrothermal carbonization by preheating the product using a thermal fluid heated externally, injecting an acid solution to create a liquid ring and reduce pressure losses and scaling, and using an unmixed, wall-heated, baffled reactor to achieve efficient carbonization while minimizing equipment size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If indirect heating by circulating thermal fluid in a jacket surrounding the reactor is used, then the reactor can be heated without direct steam injection, but the size of the reactor is limited because heat transfer only takes place on the wall of the reactor and the internal volume must be heated
Solution Approach 1:
A thermal fluid circulates in a closed loop system consisting of a reactor jacket, a heat exchanger, and a pump. The thermal fluid acts as an intermediary to transfer heat from the carbonized product back to the product to be treated, enabling indirect heating without direct steam injection and avoiding vapor pressure issues while heating the internal volume efficiently
Solution Approach 2:
Heat from the hot carbonized product leaving the reactor is recovered through a heat exchanger to preheat the thermal fluid, which then circulates to heat the cold product to be treated. This recovers waste heat that would otherwise be lost, reducing overall thermal requirements and enabling larger reactor volumes
2Loss of energy
If preheating of the product to be treated is provided by the product leaving the reactor using an oil loop, then heat recovery is achieved, but the preheating is partial and limited to a temperature significantly lower than the reactor temperature to avoid scaling
Solution Approach 1:
A thermal fluid circulates in a closed loop system consisting of a reactor jacket, a heat exchanger, and a pump. The thermal fluid acts as an intermediary to transfer heat from the carbonized product back to the product to be treated, enabling indirect heating without direct steam injection and avoiding vapor pressure issues while heating the internal volume efficiently
Solution Approach 2:
The system operates with the thermal fluid circulating at controlled temperatures through the reactor jacket, allowing the product to be heated to the full carbonization temperature T0 without the scaling limitations of direct steam injection. The thermal fluid temperature and flow rate are optimized to achieve complete heating while preventing scale deposition
3Object-affected harmful factors
If the product to be treated is preheated to a lower temperature to avoid scaling, then scaling is reduced, but the heating time to reach carbonization temperature increases and the reactor dimensions must be relatively large
Solution Approach 1:
A thermal fluid circulates in a closed loop system consisting of a reactor jacket, a heat exchanger, and a pump. The thermal fluid acts as an intermediary to transfer heat from the carbonized product back to the product to be treated, enabling indirect heating without direct steam injection and avoiding vapor pressure issues while heating the internal volume efficiently
Solution Approach 2:
The system operates with the thermal fluid circulating at controlled temperatures through the reactor jacket, allowing the product to be heated to the full carbonization temperature T0 without the scaling limitations of direct steam injection. The thermal fluid temperature and flow rate are optimized to achieve complete heating while preventing scale deposition
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 approach reduces thermal requirements, allows for the construction of larger unmixed reactors, and effectively controls heat exchange and scaling issues, enabling efficient carbonization and dehydration of pasty products and sludge.
Implementation Method 1
preheating in an exchanger, by a thermal fluid which circulates in a closed loop, and which receives heat from the products leaving the reactor
Implementation Method 2
at least in one place in the tube, to create a liquid ring against the inner wall of the tube
Implementation Method 3
heated to carbonization temperature T0, generally between 140°C and 280°C
Implementation Method 4
hydrothermal carbonization is a process which, by increasing the temperature and pressure of an organic compound in the liquid phase, aims to induce chemical reactions
Data Source
Figure 1~3
AI summary
A method and corresponding facility for the hydrothermal carbonisation of pasty products or waste, or sewage treatment plant sludge, in a pressurised reactor (3) heated to carbonisation temperature T0, generally between 140 °C and 280 °C. According to the method, before being inserted into the reactor, the products to be treated undergo the following steps: pressurisation, preheating in an exchanger (2), by a thermal fluid that flows in a closed loop, and that receives heat from the products coming out of the reactor; the thermal fluid is heated in the loop by an external heat source (12), downstream from the exchange with the products coming out of the reactor, and upstream from the preheating of the products entering the reactor, and the temperature of the product to be treated, preheated by the thermal fluid, when it enters the reactor (3), is between the carbonisation temperature T0 and T0 - 100°C. Moreover, the product to be treated flows in at least one tube (1b), including in the preheating exchanger (2), until it enters the reactor (3), and in at least one location of the tube (1b), liquid is injected (20) to create a liquid ring (A) against the inner wall of the tube (1b), and reduce the pressure drops.