Membrane Wall Gasifier for Waste Tire Refractory Protection
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Solution Overview
Problem
Current gasification technologies face challenges in extending the lifespan of gasifier refractory materials, leading to high maintenance costs and capital expenditures due to refractory degradation, especially when processing waste tires, which also pose environmental concerns.
Innovation Solution
A process utilizing a membrane wall reactor for the gasification of shredded waste tire material, either alone or co-processed with residual oil, where the tire material is introduced as a free-flowing fluidized feedstock with controlled oxygen, forming a slag layer that protects the reactor and allows for continuous operation, reducing refractory degradation and maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If refractory-lined gasifiers are used for waste tire gasification, then the reactor can withstand high temperatures, but the refractory material degrades rapidly leading to short operational life
Solution Approach 1:
The patent changes the operating parameters by operating at slightly lower temperatures (800-1000°C) compared to conventional gasifiers, and introduces a protective slag layer that fundamentally changes the thermal environment of the refractory material, reducing thermal stress and chemical degradation
Solution Approach 2:
The patent introduces molten slag as an intermediary protective layer between the high-temperature gasification zone and the refractory lining. This slag layer absorbs thermal energy and protects the refractory material from direct exposure to extreme conditions, thereby extending its operational life
2Productivity
If conventional gasification processes are used for waste tires, then syngas can be produced, but high maintenance costs and capital expenditures are incurred due to refractory degradation
Solution Approach 1:
The molten slag layer serves as a protective intermediary that reduces wear and degradation of the refractory lining, thereby extending the time between maintenance interventions and reducing overall maintenance costs while maintaining continuous syngas production
Solution Approach 2:
The patent enables continuous operation by maintaining a stable protective slag layer that prevents refractory degradation, allowing the gasifier to operate for extended periods without shutdown for maintenance, thus ensuring continuous syngas production
3Object-affected harmful factors
If waste tires are processed without proper gasification technology, then environmental pollution occurs, but advanced gasification technologies have high operational costs
Solution Approach 1:
The patent employs a self-sustaining process where the waste tire feedstock provides its own heat through partial oxidation, and the resulting molten slag automatically forms a protective layer on the reactor walls, eliminating the need for external energy input and reducing operational costs while ensuring environmentally sound processing
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 enhances the operational efficiency and longevity of the gasification process, reduces environmental impact by effectively processing waste tires, and produces valuable syngas that can be used as a feedstream in refineries, thereby addressing both economic and environmental issues.
Implementation Method 1
Gasification uses partial oxidation to convert any carbon contained in a feedstock into synthesis gas consisting of carbon monoxide (CO) and hydrogen
Implementation Method 2
convert CO to hydrogen through the water gas shift reaction represented by CO+H2O═CO2+H2
Implementation Method 3
The waste tire particles are preferably introduced in the form of a free-flowing fluidized feedstream into the combustion chamber
Data Source
AI summary
A process for the production of a synthesis gas containing hydrogen and carbon monoxide utilizes shredded waste tires that are substantially free of metal particles as a feedstream, either alone or in combination with a residual oil feedstream, for gasification in the combustion chamber of a tubular wall membrane partial oxidation gasification reactor in the presence of a predetermined amount of oxygen. Optionally, the product synthesis gas is introduced as the feedstream to a water gas shift reactor to enhance the hydrogen content of the final product stream.