Integrated Boiler and Gas Cleaning Unit
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Solution Overview
Problem
Existing boiler and gas cleaning systems are inefficient and lack a compact design, with separate components for combustion, gasification, pyrolysis, and cleaning, which hinders the effective extraction and reuse of heat energy and complicates installation and maintenance.
Innovation Solution
An integrated unit combining a boiler and gas cleaning apparatus, featuring a radiant zone connected to a convection zone with an annular heat exchange chamber and bag filters, where sorbents are injected to react with pollutants, and a moving floor for particulate removal, allowing for efficient heat extraction and compact installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate components are used for combustion, gasification, and cleaning, then each component can be optimized independently, but the system footprint increases and heat energy extraction efficiency decreases
Solution Approach 1:
The patent combines the combustion chamber, gasification chamber, and cleaning apparatus into a single integrated unit. The combustion chamber and gasification chamber are positioned vertically adjacent to each other, with the cleaning apparatus integrated around the heat exchange means that serves both chambers. This merging eliminates the need for separate standalone components while maintaining the ability to optimize each functional zone independently through vertical stacking and modular design.
Solution Approach 2:
The cleaning apparatus is nested around the heat exchange means, which itself surrounds the combustion and gasification chambers. The bag filters are arranged in an annular configuration around the central combustion/gasification axis, creating a nested structure where the cleaning function is concentric with the heat extraction function. This nesting allows multiple functions to occupy the same spatial envelope, reducing overall footprint.
2Ease of manufacture
If separate components are used for combustion, gasification, and cleaning, then each component can be optimized independently, but heat energy extraction and reuse efficiency decreases
Solution Approach 1:
The heat exchange means is positioned to extract heat from both the combustion chamber and gasification chamber simultaneously. The annular heat exchange chamber surrounds both combustion zones, allowing thermal energy to be captured from multiple sources within the integrated unit. This combined heat extraction approach maximizes energy recovery efficiency by utilizing the thermal output of both combustion and gasification processes without requiring separate heat exchangers for each component.
3Adaptability or versatility
If separate components are used for combustion, gasification, and cleaning, then system design flexibility is maintained, but installation and maintenance complexity increases
Solution Approach 1:
By integrating the combustion chamber, gasification chamber, and cleaning apparatus into a single unit with a unified shell and common support structure, the patent reduces the number of separate installations required. The integrated design allows for standardized mounting and connection points, simplifying installation procedures. Maintenance access points are strategically positioned on the external shell, allowing service personnel to access internal components without disassembling multiple separate units.
Solution Approach 2:
The heat exchange means serves multiple functions simultaneously: it extracts heat from both combustion and gasification chambers, supports the structural integrity of the integrated unit, and provides a mounting surface for the cleaning apparatus. The annular heat exchange chamber acts as both a thermal extraction device and a structural framework for the entire system, reducing the need for additional support structures and simplifying the overall design.
4Area of stationary object
If integrated unit is used for combustion and cleaning, then footprint is reduced and heat energy reuse is enhanced, but device complexity increases
Solution Approach 1:
The cleaning apparatus with bag filters is nested around the heat exchange means in an annular arrangement. This nested configuration allows the cleaning function to occupy the same radial space as the heat extraction function, eliminating the need for additional lateral expansion. The vertical stacking of combustion chamber, gasification chamber, and cleaning apparatus creates a compact cylindrical footprint while maintaining all necessary functional zones within a single integrated envelope.
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 integrated unit enhances heat energy reuse, reduces the footprint of the system, and ensures complete combustion of pollutants like hydrocarbons and furans, meeting legal standards, while allowing for efficient operation and maintenance.
Implementation Method 1
a heat exchange means 14 arranged around said radiant zone 10 and convection zone 12
Implementation Method 2
Gases exiting the chamber are typically transferred to a separate cleaner unit... hot smoke and gases passes upwards inside the innermost pack heating it by radiant heat
Implementation Method 3
sorbents are injected to react with pollutants
Implementation Method 4
a moving floor for particulate removal
Implementation Method 5
The cleaner unit typically comprises a bag filter and a baffle system arranged to direct flow of the waste gases into the bag filters
Implementation Method 6
a solid fuel fired boiler unit including gasifiers and pyrolisers... combustion, gasification or pyrolysis occurs
Implementation Method 7
pyrolisers... pyrolysis occurs
Data Source
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AI summary
The invention is concerned with an integrated unit comprising a unitary boiler and gas cleaning apparatus. Preferably the integrated unit comprises a boiler unit, and gas cleaning apparatus, the integrated unit has a reaction unit (4) and further comprises a radiant zone (10) connected to the reaction unit, the radiant zone being connected to a convection zone (12). The integrated unit further comprises a heat exchange means (14) encircling at least one of the radiant zone and the convection zone, and gas cleaning means (16) is preferably provided around at least a part of the heat exchange means. The reaction unit may comprise a fluid bed boiler, gasifier or pyrolytic chamber and wherein fuel is burned completely; burned under pyrolytic conditions; or is gasified. The heat exchange means may comprise an annular heat exchange chamber and the gas cleaning means may be provided in an annular gas cleaning chamber encircling the heat exchange chamber.