Modular Heating Module for Pyrohydrolysis Reactor Maintenance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pyrohydrolysis reactors for acid regeneration, particularly those using fluidized bed technology, are inconvenient for maintenance due to their non-modular design, leading to high maintenance costs and long shutdown times as many components are difficult to access and require significant disassembly and reassembly.
Innovation Solution
A modular heating module for pyrohydrolysis reactors featuring a fuel distribution system, carrier element with built-in coupling units, and individually removable burner units, allowing for separate supply and replacement of burner and oxidant elements without detaching the fuel distribution system, thus simplifying maintenance and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a non-modular reactor design is used, then the heating elements can be integrated into the reactor structure, but maintenance requires long shutdown times and huge technological efforts for disassembling and reassembling
Solution Approach 1:
The heating module is divided into separate, interchangeable components including burner units, carrier elements, and distribution systems. This segmentation allows individual components to be maintained or replaced without disassembling the entire reactor, resolving the contradiction between structural integration and ease of repair.
Solution Approach 2:
The heating module is designed with dynamic, reversible connections that allow it to be easily assembled and disassembled. The carrier element can be detached from the reactor and burner units can be individually replaced, providing the flexibility needed for quick maintenance while maintaining structural integrity during operation.
2Device complexity
If heating elements are integrated into the reactor base plate, then the reactor structure is simplified, but maintenance of heating elements requires detaching the entire base plate
Solution Approach 1:
The heating module is segmented into a carrier element and multiple burner units that can be independently accessed and replaced. This allows maintenance of individual burner units without detaching the entire carrier element or base plate, reducing shutdown time while maintaining structural simplicity.
Solution Approach 2:
The carrier element is pre-assembled with all burner units and connection elements in a modular configuration. This preliminary modular assembly allows the heating module to be quickly installed as a complete unit and enables rapid replacement of individual components during maintenance without complex disassembly procedures.
3Ease of operation
If a complex network of ducts and pipes is used for fuel distribution, then each burner unit can be individually supplied with fuel, but the construction becomes complex and maintenance difficult
Solution Approach 1:
The fuel distribution system is merged with the carrier element to form an integrated modular unit. The distribution channels are built into the carrier element itself rather than being separate external ducts, simplifying the overall construction while maintaining the ability to individually supply each burner unit through the modular design.
Solution Approach 2:
The carrier element serves multiple functions: it acts as the structural support for the burner units, contains the fuel distribution channels, and provides the connection interface with the reactor. This multi-functionality reduces the need for separate complex ductwork while enabling individual burner supply through its integrated design.
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 modular design reduces maintenance efforts and costs, enhances operator convenience, and improves site safety by allowing for on-site or off-site assembly and maintenance, reducing leakage risks and enabling faster replacement of defective components.
Implementation Method 1
a fuel distribution system being in fluid communication with a fuel source
Implementation Method 2
the connector element is in fluid communication with the coupling element of said coupling unit and wherein the connector element is in fluid communication with the burner element
Implementation Method 3
The heating elements typically consist of a set of Fuel-Nozzles and Mixing Nozzles
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to a heating module for use in a pyrohydrolysis reactor, the heating module comprising: -- a fuel distribution system being in fluid communication with a fuel source, -- a carrier element having a plurality of built-in coupling units, wherein a coupling unit of the plurality of coupling units comprises a coupling element, wherein the coupling element of said coupling unit is in fluid communication with the fuel distribution system, -- a plurality of burner units arranged on the carrier element, wherein a burner unit of the plurality of burner units comprises a connector element and a burner element, wherein the connector element is in fluid communication with the burner element, wherein the connector element is reversibly connected to the coupling element of said coupling unit and wherein the connector element is in fluid communication with the coupling element of said coupling unit.