Modular Endogas Generator Tube Bundle Flow Modulation
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Solution Overview
Problem
Existing endogas generators face challenges in modulating flow rates while maintaining optimal composition, especially at reduced rates, due to limitations in catalyst activity and system design, leading to inefficiencies and potential catalyst damage.
Innovation Solution
A modular endogas generator with a tube bundle configuration using noble metal oxide-based catalysts, each catalyst tube being independently supplied and cooled, allowing for adjustable flow rates without compromising composition, and featuring a heating chamber with burners to ensure uniform temperature distribution across the catalyst bed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the flow rate is reduced to modulate production, then productivity is improved (lower production demand), but the gas velocity in the retort decreases causing incomplete contact with catalyst and loss of optimal composition
Solution Approach 1:
The single retort is divided into multiple parallel retorts (first, second, and third retorts). Each retort can be independently supplied with gas mixture through separate control valves, allowing the system to maintain optimal gas velocity in each retort even when overall production demand is reduced by excluding certain retorts from operation.
Solution Approach 2:
The system dynamically adjusts the number of active retorts based on production demand. Control valves independently regulate the gas mixture flow to each retort, enabling the system to maintain optimal operating conditions (gas velocity, composition) in active retorts while modulating total output by activating or deactivating specific retorts.
2Quantity of substance
If a single large diameter retort is used, then catalyst volume is sufficient for nominal production, but the system becomes complex and less modulable when production reduction is needed
Solution Approach 1:
Instead of using a single large diameter retort, the system employs multiple smaller diameter retorts arranged in parallel. This segmentation provides sufficient total catalyst volume while enabling independent control of each retort through separate supply lines and control valves, significantly improving system modulability without increasing overall complexity.
Solution Approach 2:
Each retort is equipped with its own control valve and supply mechanism, allowing local adjustment and independent operation. This local control capability enables flexible modulation of production by activating or deactivating specific retorts based on demand, while each retort maintains optimal local operating conditions.
3Productivity
If excessive reduction in flow rate occurs, then productivity matches low demand, but catalyst is exposed to localised excess temperatures causing early damaging
Solution Approach 1:
The catalyst is distributed across multiple separate retorts rather than concentrated in a single retort. When production demand is reduced, the system excludes specific retorts from operation while maintaining optimal flow rates in active retorts, preventing localised excess temperatures and protecting catalyst durability.
Solution Approach 2:
The system dynamically redistributes the gas mixture flow among available retorts based on operational conditions. By actively controlling the number and configuration of active retorts, the system maintains optimal flow velocity and temperature distribution in active catalyst beds, preventing thermal runaway and catalyst damage even at reduced overall production levels.
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
Enables production of endogas with constant optimal composition at flow rates reduced by up to 90% of the nominal rate, while reducing system complexity and costs, and allowing for efficient maintenance by enabling selective catalyst tube exclusion and replacement.
Implementation Method 1
a heating chamber which supplies heat to a catalytic reactor
Implementation Method 2
supplies heat to a catalytic reactor, placed in its interior
Implementation Method 3
an endothermic reaction of incomplete combustion between air and methane (or another hydrocarbon), performed with a lack of oxygen and in the absence of water/steam, to form reducing substances such as CO
Implementation Method 4
endothermic reaction of incomplete combustion between air and methane
Implementation Method 5
followed by a heat exchanger, generally gas/water, for cooling the reaction products rapidly so as to prevent the reaction from proceeding further
Data Source
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AI summary
A description is given of a generator of endogas (100) which comprises an outer heating chamber (1) for supplying heat to an inner catalytic reactor containing a catalyst based on oxides of noble metals for the partial oxidation of a mixture of air-methane (or another hydrocarbon) and at least one heat exchanger for the rapid cooling of the endogas produced wherein the catalytic reactor inside the heating chamber (1) is constituted by at least three catalyst tubes (4) arranged in the form of a tube bundle, each of which having a diameter equal to or smaller than 80 mm, said catalyst tubes (4) being arranged parallel one to the other in the form of a tube bundle, each catalyst tube (4) being in fluid communication with a respective supply tube (5), outside of said heating chamber (1).