Multi-Burner Gasification Reactor Refractory Life
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current gasification reactors face issues such as low carbon conversion, inefficient syngas production, and short refractory lining life due to improper burner settings and flow distributions, leading to suboptimal performance in processing hydrocarbon materials.
Innovation Solution
A multi-burner gasification reactor design with paired burners set at 180 degrees and a refractory lining system that includes brick-supporters and a scrubbing chamber to enhance mixing, diffusion, and residence time distribution, along with a syngas and slag outlet for efficient ash handling, ensuring high carbon conversion and extended refractory lining life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single central burner is used for gasification, then the reactor structure is simple, but the residence time distribution is wide (0.01s to 32s) resulting in low carbon conversion (94-95%)
Solution Approach 1:
The single central burner is segmented into multiple burners arranged in specific patterns (e.g., four burners at the corners of a square). This segmentation creates multiple jet streams that interact to form a more uniform flow field, narrowing the residence time distribution and improving carbon conversion to above 96%.
Solution Approach 2:
The burner arrangement transitions from a single-point (0D) or linear (1D) configuration to a two-dimensional planar arrangement (e.g., square pattern). This dimensional change creates a more distributed flow field that improves residence time uniformity and carbon conversion efficiency.
2Device complexity
If the gasification burner is set at the center line of the top of the reactor, then the structure is simple, but the residence time distribution is wide ranging from 0.01s to 32s
Solution Approach 1:
The single central burner position is segmented into multiple burner positions arranged in a pattern (e.g., four burners at corners of a square). This segmentation creates multiple flow paths that converge, narrowing the residence time distribution and ensuring more uniform material processing.
Solution Approach 2:
The burner configuration moves from a single-point location to a two-dimensional arrangement. This spatial redistribution of burners creates a more uniform velocity field and narrows the residence time distribution, reducing the time loss from 32s to a more concentrated range.
3Productivity
If multiple burners are used to increase carbon conversion, then the carbon conversion improves, but the burner setting becomes very complex including startup burner, gasification burner, etc.
Solution Approach 1:
The complex multi-burner system is segmented into functionally identical or similar burners arranged in a symmetric pattern. This segmentation allows all burners to operate under the same control parameters, simplifying the overall burner setting and control strategy while maintaining high carbon conversion.
Solution Approach 2:
Each burner in the array is designed with identical or locally optimized characteristics suited to its position. This local quality approach allows uniform operation across all burners, avoiding the need for complex differential control settings while achieving high carbon conversion through the collective effect of multiple burners.
4Volume of stationary object
If the syngas outlet is small, then the reactor structure is compact, but the refractory bricks near syngas and slag outlet have short life (2000-3000 hours)
Solution Approach 1:
The syngas outlet configuration is expanded from a single-point opening to a two-dimensional enlarged outlet area. This dimensional expansion distributes the high-velocity syngas and molten slag flow over a larger area, reducing localized thermal and mechanical stress on refractory bricks and extending their service life beyond 3000 hours.
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 multi-burner reactor achieves high carbon conversion rates (up to 99%) and effective gas content, with a longer refractory lining life and reduced specific energy consumption, making it suitable for large-scale industrial applications.
Implementation Method 1
the controlled processes are diffusion and mixing which should be reinforced
Implementation Method 2
the controlled processes are diffusion and mixing which should be reinforced
Implementation Method 3
the upward velocity of the impinging-flow is decreased, which can ensure the life of the refractory bricks
Implementation Method 4
Gasification processes take place in the following manner: Slurry or pulverized hydrocarbon materials are injected into the gasification reactor
Implementation Method 5
main chemical reactions among hydrocarbon material, oxygen and steam are listed as follows: C+O2═CO2
Implementation Method 6
To overcome the effect of thermal expansion of the refractory bricks on burner displacement, brick-supporters should be provided
Data Source
AI summary
Disclosed is a multi-burner gasification reactor for gasification of slurry or pulverized hydrocarbon feed materials and industry applications thereof. Burners are disposed on the periphery or top of a gasification reactor vessel, wherein the side burners are at a small downward angle relative to the horizontal plane, which can prolong the life of refractory bricks. The operating pressure of the gasification reactor is 0.1˜12 MPa, and the operating temperature thereof is 1350° C.˜1700° C. The gasification reactor is applicable to a hot-wall lining as well as a cold-wall lining. The notable advantages of the gasification reactor are carbon conversion is high and can reach 99%, and the effective gas content is high; specific coal consumption and specific oxygen consumption are low; and it is applicable to a large coal gasification plant that processes above 3000 tons of coal per day.