Modular Heat Exchanger for Particulate Cooling
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Solution Overview
Problem
Current methods for cooling particulates from a gasification process, such as dropping hot particulates into water or using large fluidized beds, are inefficient and prone to energy consumption and operational disruptions, lacking flexibility and reliability.
Innovation Solution
A heat exchanger system with coils and a support grid within a cylindrical housing, allowing for efficient heat transfer using a coolant, which can be easily expanded or contracted to meet cooling demands and maintain particulate flow without energy-intensive operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a large fluidized bed with cooling coils is used to cool particulates, then cooling capacity is improved, but device complexity and energy consumption increase
Solution Approach 1:
The cooling system is divided into multiple independent vertical heat exchanger units rather than using a single large fluidized bed. Each unit contains coils with cooling channels that can be independently configured and maintained, reducing overall system complexity while providing sufficient cooling capacity through parallel operation.
Solution Approach 2:
The patent replaces the mechanical fluidized bed system with a thermal conduction-based coil system. Instead of relying on mechanical fluidization and large-scale moving parts, the invention uses stationary coils with internal cooling channels that transfer heat from particulates to coolant through thermal conduction, eliminating the need for complex fluidization mechanics.
2Temperature
If a large fluidized bed is used to cool particulates, then cooling capacity is improved, but ease of operation deteriorates due to high energy input requirements
Solution Approach 1:
The patent replaces the energy-intensive mechanical fluidized bed system with a passive thermal conduction system using coils. The coils with internal cooling channels allow heat transfer without requiring high energy input for fluidization, making the system easier to operate with lower energy consumption while maintaining effective cooling capacity.
Solution Approach 2:
The heat exchanger units are designed to operate with coolant flowing through internal channels, utilizing the natural heat transfer from hot particulates to the coolant. The system requires minimal external energy input beyond what is needed to circulate the coolant, allowing the cooling process to occur passively through thermal gradients.
3Temperature
If a large fluidized bed is used to cool particulates, then cooling capacity is improved, but reliability deteriorates as a single point of failure can halt the entire gasification process
Solution Approach 1:
The cooling system is segmented into multiple independent vertical heat exchanger units that can operate in parallel. If one unit malfunctions, the others continue to provide cooling capacity, preventing complete system failure and allowing the gasification process to continue uninterrupted, thus improving overall reliability.
Solution Approach 2:
The modular design allows individual heat exchanger units to be isolated, removed, and replaced without shutting down the entire system. Failed units can be discarded or sent for repair while the remaining units continue operation, enabling quick recovery and maintaining process continuity.
4Temperature
If a large fluidized bed is used to cool particulates, then cooling capacity is improved, but adaptability deteriorates as the system cannot be easily expanded or contracted
Solution Approach 1:
The system is divided into independent modular heat exchanger units that can be easily added or removed based on cooling demands. Each unit functions autonomously, allowing the system capacity to be scaled up or down flexibly without redesigning the entire system, thus providing high adaptability to changing operational requirements.
Solution Approach 2:
The modular configuration enables dynamic adjustment of system capacity. Units can be selectively activated or deactivated based on real-time cooling requirements, allowing the system to adapt flexibly to varying particulate loads and cooling demands without being locked into a fixed configuration.
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 heat exchanger system effectively cools particulates while being adaptable and reducing energy consumption, ensuring continuous gasification process operation by maintaining particulate flow and flexibility in cooling capacity.
Implementation Method 1
one or more coils at least partially disposed within the housing and in fluid communication with the inlet and the outlet, the one or more coils comprising a plurality of tubulars connected by return bends
Data Source
AI summary
Methods, systems, and apparatus for cooling particulates are provided. The apparatus can include one or more coils at least partially disposed within a cylindrical housing. The one or more coils can include a plurality of tubulars connected by return bends disposed at one or more ends thereof. The apparatus can further include a support grid at least partially disposed within the housing and secured to one or more inner surfaces of one or more sidewalls thereof. The support grid can include a plurality of cross members formed of a series of concentric cylinders connected together by a plurality of radially disposed gussets. An outermost concentric cylinder can be disposed proximate the one or more inner surfaces of the one or more sidewalls, and at least one of the one or more coils can be secured to at least one of the cross members, at least one of the gussets, or both. The support grid can also include one or more beams having a first end and a second end fastened to different points on the one or more inner surfaces of the one or more sidewalls. The cross members can be disposed on at least one of the one or more beams.