Multi-Injector Gasifier Design for IGCC Flow Mixing

Solution Overview

Problem

Conventional gasifiers in integrated gasification combined cycle (IGCC) power plants face issues with poor mixing, residence time, and uniformity of flow, leading to suboptimal performance and coal handling capacity.

Innovation Solution

A multi-injector gasifier design with uniquely oriented injectors configured to inject fuel, oxygen, or their combination into the gasification chamber, enhancing mixing and residence time through crosswise and opposing flows, thereby improving turbulence and carbon conversion efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional gasifier design is used, then device complexity is low, but mixing quality and flow uniformity are poor

Engineering Contradiction:

Improvedevice complexityVSAvoidmixing quality

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The gasifier employs multiple injectors (first injector in top wall, second injector in side wall) instead of a single injector, dividing the fuel injection function into separate components. This segmentation allows each injector to be positioned and oriented independently to achieve better flow distribution and mixing quality throughout the gasification chamber.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The injectors are positioned at different locations (top wall and side wall) and oriented at different angles relative to the outlet axis. The first injector has its injection axis non-perpendicular to the outlet axis, creating localized flow patterns that improve overall mixing. Each injector provides tailored flow characteristics to its specific region of the chamber.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If conventional gasifier design is used, then device complexity is low, but residence time is insufficient

Engineering Contradiction:

Improvedevice complexityVSAvoidresidence time

Core Design Contradiction:

Ease of manufactureVSDuration of action of moving object

Solution Approach 1:

The injector orientation creates dynamic flow patterns with crosswise and opposing flows that enhance turbulence within the gasification chamber. The first injector's non-perpendicular orientation relative to the outlet axis generates complex flow trajectories, increasing the time required for gas to traverse the chamber and improving residence time for gasification reactions.

Inventive Principle:

Principle #15Dynamics

3Productivity

If multi-injector design is implemented, then carbon conversion efficiency is improved, but device complexity increases

Engineering Contradiction:

Improvecarbon conversion efficiencyVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The gasifier employs multiple injectors (first injector in top wall, second injector in side wall) instead of a single injector, dividing the fuel injection function into separate components. This segmentation allows each injector to be positioned and oriented independently to achieve better flow distribution and mixing quality throughout the gasification chamber.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The injectors are positioned at different locations (top wall and side wall) and oriented at different angles relative to the outlet axis. The first injector has its injection axis non-perpendicular to the outlet axis, creating localized flow patterns that improve overall mixing. Each injector provides tailored flow characteristics to its specific region of the chamber.

Inventive Principle:

Principle #35Parameter changes

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-injector design increases carbon conversion efficiency and coal handling capacity, achieving better performance by optimizing mixing and residence time within the gasification chamber.

Implementation Method 1

the first and second injectors are configured to inject fuel, oxygen, or a combination thereof, into the chamber

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 2

enhancing mixing and residence time through crosswise and opposing flows, thereby improving turbulence

Methodology Applied

Scientific EffectTurbulence: Turbulence

Implementation Method 3

IGCC technology may convert the hydrocarbon feedstock into a gas mixture of carbon monoxide (CO) and hydrogen (H2), i.e., syngas, by reaction with steam in a gasifier

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS8696774B2Gasification system and method using fuel injectors

Publication Date: 2014.04.15 AIR PROD & CHEM INC

AI summary

A system is provided that comprises a gasifier with an enclosure disposed about a chamber, wherein the enclosure comprises a top wall, a bottom wall, and a side wall between the top and bottom walls. The gasifier also comprises an outlet disposed in the bottom wall, a first injector disposed in the top wall, and a second injector disposed in the side wall, wherein the first and second injectors are configured to inject fuel, oxygen, or a combination thereof, into the chamber.