Multi-orifice Burner for Viscous Hydrocarbon Gasification
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Solution Overview
Problem
The gasification of asphalt fractions from tar sands is challenging due to high viscosity and ash content, leading to short burner lifetimes and temperature fluctuations, which result in burner damage and inefficiencies in upgrading processes.
Innovation Solution
A partial oxidation process using a multi-orifice burner with separate passages for hydrocarbon, oxidizer gas, and moderator gas, where the moderator gas has a higher exit velocity than the oxidizer gas, effectively breaking up the hydrocarbon feed and reducing flame instability, thereby extending burner life and improving process efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If high feed temperatures are used to improve the flow ability of viscous hydrocarbon feed, then the feed flowability is improved, but burner tip damage occurs due to temperature fluctuations and short burner lifetime
Solution Approach 1:
The burner is divided into multiple separate passages (hydrocarbon passage, oxidizer passage, moderator passage) that operate independently. This segmentation allows each passage to be optimized for its specific function and protects the burner tip by distributing thermal load across multiple zones rather than concentrating it at a single point.
Solution Approach 2:
A moderator gas passage is introduced as an intermediary between the hydrocarbon feed and the oxidizer. The moderator gas (typically steam or carbon dioxide) stabilizes the combustion process and reduces temperature fluctuations at the burner tip, thereby extending burner lifetime while still allowing high feed temperatures to improve flowability.
2Quantity of substance
If the feed contains ash and solid hydrocarbon agglomerates, then the feed represents a realistic tar sands product, but burner damage occurs and burner lifetime is reduced
Solution Approach 1:
The multi-passager design segments the feed handling function from the combustion function. The hydrocarbon passage can handle ash-containing feeds without directly exposing the burner tip to the full impact of ash and agglomerates, as the combustion occurs in separate zones.
Solution Approach 2:
The moderator gas acts as a cushioning medium that protects the burner tip from direct exposure to ash and solid agglomerates. By introducing this protective gas layer beforehand, the harmful effects of ash accumulation and thermal shock are reduced, extending burner lifetime.
3Device complexity
If a simple burner design is used, then the device complexity is low, but temperature fluctuations cause burner damage and process inefficiency
Solution Approach 1:
The burner is structured with separate passages for hydrocarbon feed, oxidizer, and moderator gas. This segmentation provides inherent stability by isolating the combustion zones and preventing temperature fluctuations from propagating through the entire burner structure, thereby improving operational reliability.
Solution Approach 2:
Each passage in the burner is designed with specific local qualities optimized for its function. The hydrocarbon passage handles viscous feeds, the oxidizer passage controls combustion intensity, and the moderator passage stabilizes temperatures. This localized optimization provides overall system stability without requiring complex external control mechanisms.
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
This approach results in a stable and longer-lasting burner operation, reducing burner damage and temperature fluctuations, and produces a synthesis gas mixture of hydrogen and carbon monoxide that can be used for power generation and hydrogen addition in tar sands upgrading processes, enhancing overall process efficiency and reducing waste.
Implementation Method 1
the exit velocity of the moderator gas is greater than the exit velocity of the oxidizer gas, effectively breaking up the hydrocarbon feed and reducing flame instability
Implementation Method 2
by performing a partial oxidation on said hydrocarbon feed using a multi-orifice burner
Data Source
AI summary
A process to prepare a synthesis gas mixture comprising hydrogen and carbon monoxide from a liquid hydrocarbon feedstock containing between 0.1 and 4 wt % ash comprises performing a partial oxidation on a hydrocarbon feed using a multi-orifice burner provided with an arrangement of separate co-annular passages, wherein the hydrocarbon flows through a passage of the burner, an oxidizer gas flows through a separate passage of the burner and wherein the passage for hydrocarbon feed and the passage for oxidizer gas are separated by a passage through which a moderator gas flows and wherein the exit velocity of the moderator gas is greater than the exit velocity of the oxidizer gas.