Oxidation Reactor Inlet Geometry for Refractory Stress Reduction
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Solution Overview
Problem
Existing oxidation reactors for partial oxidation of hydrocarbonaceous feed streams face challenges such as mechanical stress on refractory protective layers, limited reactor diameter, and reduced flexibility in construction, which affect their integrity and efficiency.
Innovation Solution
The oxidation reactor is designed with a combination of a dome-shaped first section and a frustoconical second section, merging into a cylindrical third section, all with refractory protective layers. This configuration allows for improved mixing of product gases, increased reactor volume, and reduced mechanical stress on the refractory lining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a dome-shaped inlet region is used, then the transition from small to large diameter is achieved over a shorter length, but the mechanical stresses from thermal expansion become more complex and the refractory protective layer integrity is compromised
Solution Approach 1:
The inlet region is divided into two separate sections: a dome-shaped first section for achieving diameter transition, and a frustoconical second section for stress distribution. This segmentation allows each section to perform its specific function optimally without compromising the other.
Solution Approach 2:
Different geometric configurations are applied to different sections of the inlet region. The dome-shaped first section provides compact diameter transition, while the frustoconical second section with its gradual slope provides mechanical stress relief, creating local optimization of properties.
2Volume of stationary object
If the reactor diameter is increased, then the reactor volume is increased, but the mechanical stresses on the refractory protective layer increase and affect integrity
Solution Approach 1:
The dome-shaped first section uses a curved spherical geometry to achieve the diameter transition, which distributes thermal expansion stresses more evenly compared to sharp angular transitions, reducing stress concentration points.
Solution Approach 2:
By separating the diameter transition function (dome section) from the stress distribution function (frustoconical section), the design allows the reactor to achieve large volume while the frustoconical section specifically addresses stress management.
3Length of stationary object
If a frustoconical inlet region with large angle is used, then the diameter transition is achieved, but the flame geometry is impaired due to recirculation zones and turbulence
Solution Approach 1:
The dome-shaped first section provides a smooth curved transition that avoids sharp angles, reducing turbulence and recirculation zones while achieving the necessary diameter change, thereby preserving flame geometry.
Solution Approach 2:
The frustoconical second section uses a gentle slope specifically optimized to balance diameter transition with minimal disturbance to the flame, creating local conditions that protect flame geometry while achieving the overall diameter change.
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 innovative reactor design enhances the mechanical stability and thermal control of the oxidation process, increasing the reactor's volume while minimizing forces and stresses on the refractory protective layer, thus improving the overall efficiency and longevity of the reactor.
Implementation Method 1
lined on its inside with one or more layers of refractory material, for example refractory bricks, which thus form protective layers against the heat released in the reactor interior
Implementation Method 2
The partial oxidation of hydrocarbonaceous feed material for production of synthesis gas is typically performed at high reactor temperatures in the range from 1000° C. to 1500° C.
Implementation Method 3
The hydrocarbonaceous feed material and the oxidant are generally mixed in a reactor in close proximity to the injection nozzles
Data Source
AI summary
The invention relates to an oxidation reactor for partial oxidation of a feed stream with an oxygen-containing oxidant stream to give a hydrogen-containing product stream. This partial oxidation may be conducted as a noncatalytic partial oxidation (POX) or as an autothermal reforming (ATR). Useful feed streams here include hydrocarbonaceous streams, but also ammonia-containing streams. According to the invention, the inlet region of the oxidation reactor is configured as a combination of a dome-shaped region with a (frusto) conical region, where the (frusto) conical inlet region merges into the cylindrical section of the oxidation reactor.