Partial Oxidation Reactor Inlet Design for Synthesis Gas Yield
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Solution Overview
Problem
Partial oxidation reactors face challenges with high reactor temperatures, recirculation zones leading to short reaction times and material attrition, and increased costs due to the need for cooling to prevent corrosion, which are exacerbated by higher throughput requirements.
Innovation Solution
A partial oxidation reactor design featuring a cylindrical or frustoconical inlet region with a smaller diameter than the main reactor portion, reducing the recirculation zone and increasing residence time, along with a burner configuration that minimizes thermal stress and eliminates the need for coolant passage, thereby enhancing synthesis gas production and extending equipment life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the reactor operates at high throughput, then productivity increases, but material attrition and corrosion increase due to larger recirculation zones
Solution Approach 1:
The reactor is segmented into two distinct geometric zones: a first region with a smaller cross-sectional area and a second region with a larger cross-sectional area. This segmentation allows the recirculation zone to be confined to the first region, preventing it from affecting the entire reactor volume and reducing material attrition while maintaining high throughput capability.
Solution Approach 2:
Different regions of the reactor are given different geometric properties - the first region has a smaller cross-sectional area designed to contain recirculation, while the second region has a larger cross-sectional area optimized for product withdrawal. This local differentiation allows each zone to perform its specific function optimally without compromising the other.
2Reliability
If coolant passages are added to prevent corrosion, then reliability improves, but device complexity and cost increase
Solution Approach 1:
The harmful recirculation zone is extracted and confined to a specific first region of the reactor rather than being distributed throughout the entire reactor volume. By removing the recirculation effect from the majority of the reactor space, the need for additional cooling systems is reduced, simplifying the overall device structure.
Solution Approach 2:
The recirculation zone, which normally causes harmful material attrition, is converted into a beneficial concentrated region where it can be contained and managed. By directing recirculation into a dedicated first region, the harmful effects are localized and minimized, eliminating the need for extensive cooling infrastructure.
3Manufacturing precision
If the reactor volume is increased to maintain residence time, then conversion rate is maintained, but productivity per unit volume decreases
Solution Approach 1:
The reactor design transitions from a uniform cross-sectional geometry to a variable cross-sectional geometry along the axial direction. By changing the cross-sectional area between the first and second regions, the reactor optimizes both residence time in the reaction zone and overall throughput capacity, achieving high conversion rates without sacrificing volumetric productivity.
Solution Approach 2:
The geometric parameters of the reactor are changed along its length - specifically, the cross-sectional area varies between the first and second regions. This parameter change allows the reactor to maintain appropriate residence times for high conversion while increasing the overall throughput capacity, thereby improving synthesis gas yield per unit volume.
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 design increases synthesis gas yield per reactor volume, reduces material attrition, and eliminates the need for coolant passage, leading to improved reactor efficiency and extended service life while maintaining high conversion rates.
Implementation Method 1
partial oxidation of a carbon-containing input stream in gaseous form, in liquid form or in solid, particulate form dispersed in a carrier liquid or a carrier gas in the presence of an oxygen-containing oxidant stream
Implementation Method 2
In a recirculation zone the materials present in the flame flow back in the upward direction
Implementation Method 3
passes into a quench space into which water is injected for cooling of raw gas and slag
Implementation Method 4
The quenched raw gas is withdrawn from the quench space in a steam-saturated state
Data Source
AI summary
The invention relates to a partial oxidation reactor (POX reactor) for producing a raw synthesis gas stream by partial oxidation of a carbon-containing input stream in gaseous form, in liquid form or in solid, particulate form dispersed in a carrier liquid or a carrier gas in the presence of an oxygen-containing oxidant stream and optionally a moderator stream containing steam and/or carbon dioxide. The invention further relates to a process for producing a raw synthesis gas stream. The partial oxidation reactor according to the invention provides for introducing a cylindrical or frustoconical inlet region having a constant diameter or a diameter that is smaller on the entrance side. The inlet region is arranged upstream of a cylindrical main reactor portion and represents a bottleneck-like section since the largest diameter of the inlet region is smaller than the diameter of the cylindrical main reactor portion.