Partial Oxidation Reactor Warm-Up Burner for Startup Heating

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The startup of partial oxidation reactors is time-consuming and poses safety hazards due to the need to detach and reattach the POX burner, requiring personnel to handle high temperatures and ensuring the reactor vessel is at the correct autoignition temperature without leaks.

Innovation Solution

A warm-up burner is introduced through existing media channels of the POX burner, allowing safe and efficient preheating of the reactor vessel without detaching the main flange, using a smaller secondary flange for connection and an electrical ignition system for reliable ignition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the POX burner is detached and reattached during startup to introduce a warm-up burner, then the reactor vessel can be preheated to autoignition temperature, but the startup process becomes time-consuming and exposes personnel to safety hazards from high temperatures and potential leaks

Engineering Contradiction:

Improvereactor vessel temperatureVSAvoidstartup time

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

The warm-up burner is introduced through the media channels of the POX burner before the main startup process begins. This preliminary action allows the reactor vessel to be preheated to the necessary autoignition temperature while the POX burner remains attached, avoiding the time-consuming detachment and reattachment process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The warm-up burner is nested within the media channels of the existing POX burner structure. This allows the warm-up burner to be positioned inside the reactor system without requiring removal of the POX burner, enabling simultaneous heating and maintaining system integrity.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Ease of operation

If the POX burner is detached during startup, then the warm-up burner can be introduced, but personnel must handle high temperatures and ensure no leaks occur during reattachment

Engineering Contradiction:

Improveburner substitution easeVSAvoidthermal radiation exposure

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The warm-up burner is introduced and positioned through the media channels before any detachment occurs. This preliminary positioning allows the heating process to begin while the POX burner remains securely attached, eliminating personnel exposure to thermal radiation during the substitution process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The media channels serve as an intermediary pathway for introducing the warm-up burner. This intermediary route allows the warm-up burner to be installed without direct handling of hot components, as the channels provide a protected path through the existing burner structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If a warm-up burner is introduced through existing media channels, then burner substitution time is reduced and safety is improved, but the POX burner structure must accommodate additional installation pathways

Engineering Contradiction:

Improvestartup speedVSAvoidPOX burner structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The media channels of the POX burner serve dual functions: their original purpose for fuel and oxidant delivery, and as installation pathways for the warm-up burner. This multi-functionality allows the warm-up burner to be introduced without adding external access points or modifying the overall POX burner structure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The warm-up burner is nested within the existing media channel structure of the POX burner. This nesting approach utilizes the existing geometric space and pathways, avoiding the need for additional external openings or structural modifications to the POX burner housing.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 method reduces the time and risk associated with burner substitution, ensuring safe and efficient startup by achieving autoignition temperatures without exposing personnel to high thermal radiation and minimizing temperature drops.

Implementation Method 1

using a smaller secondary flange for connection and an electrical ignition system for reliable ignition

Methodology Applied

Scientific EffectElectrical ignition: Electric Spark

Implementation Method 2

achieving autoignition temperatures without exposing personnel to high thermal radiation

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 3

allowing safe and efficient preheating of the reactor vessel without detaching the main flange

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 4

preheating of the reactor vessel

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS12459812B2Partial oxidation reactor with warm-up burner for production of synthesis gas

Publication Date: 2025.11.04 LAIR LIQUIDE SA POUR LETUDE & LEXPLOITATION DES PROCEDES GEORGES CLAUDE

AI summary

The invention relates to a partial oxidation reactor (POX reactor) having a warm-up burner for producing synthesis gas by partial oxidation of fluid carbon-containing fuels in the presence of an oxygen-containing oxidant and to a process for startup of the partial oxidation reactor According to the invention the preheating of the partial oxidation reactor is carried out via a dedicated warm-up burner which is introduced via one of the media channels of the POX burner without any need to deinstall the entire POX burner.