Phosphorus Coal Gasification Reactor for Yellow Phosphorus and Syngas
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Solution Overview
Problem
The existing methods for producing yellow phosphorus are energy-intensive and generate excessive heat, requiring significant electrical energy for heating and resulting in high CO2 emissions, while the coal gasification process produces limited CO, which is difficult to utilize on a large scale.
Innovation Solution
A phosphorus coal gasification reaction device that integrates coal gasification and phosphate rock reduction, using a reactor with distinct zones and burners to achieve combined production of yellow phosphorus and syngas, where heat from coal gasification is utilized for phosphate rock reduction, reducing the need for electrical energy and CO2 emissions by leveraging silicon and aluminum elements from coal ash.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the electric furnace method is used to produce yellow phosphorus, then the phosphorus production is achieved, but the power consumption is extremely high (13,800 to 14,500 kWh per ton)
Solution Approach 1:
The patent combines the phosphate rock reduction process with the coal gasification process into a single integrated system. The coal gasification reactor simultaneously performs coal conversion and provides the high-temperature environment needed for phosphate rock reduction, eliminating the need for separate electric furnaces and significantly reducing power consumption.
Solution Approach 2:
The patent converts the harmful high-temperature heat that needs to be discharged in traditional coal gasification into a useful resource by utilizing it for phosphate rock reduction. The combustion zone temperature of 1,800-2,000°C that would otherwise require cooling is now harnessed to drive the endothermic reduction reactions, turning a waste heat problem into a productive thermal resource.
2Quantity of substance
If coal gasification is used to produce syngas, then syngas is generated, but the temperature is too high (1,800 to 2,000° C.) and requires large amounts of cooling medium
Solution Approach 1:
The patent transforms the excessive heat that must be discharged in conventional coal gasification into a beneficial thermal resource for phosphate rock reduction. The high-temperature zone (1,800-2,000°C) is utilized to drive the endothermic reduction reactions, converting what was previously a waste heat disposal problem into a productive thermal input for phosphorus production.
Solution Approach 2:
The coal gasification reactor is designed to perform multiple functions simultaneously: coal gasification to produce syngas, phosphate rock reduction to produce phosphorus vapor, and heat generation for driving these reactions. This multi-functional design eliminates the need for separate heating systems and cooling infrastructure.
3Productivity
If traditional methods are used, then yellow phosphorus production is achieved, but CO2 emissions are excessive
Solution Approach 1:
The patent merges phosphate rock reduction with coal gasification in a single integrated reactor system. This combination allows the coal to serve dual purposes as both the reducing agent for phosphate rock and the fuel source for heat generation, thereby reducing the need for additional fossil fuel combustion and associated CO2 emissions.
Solution Approach 2:
The patent converts the CO2 that would otherwise be emitted from separate phosphorus production and coal gasification processes into a useful component of the syngas product. By integrating the processes, the carbon from coal becomes part of the valuable syngas mixture rather than being discharged as waste CO2, improving carbon utilization efficiency.
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 increases the yield of yellow phosphorus, reduces CO2 emissions, and efficiently utilizes thermal energy, achieving a more sustainable and energy-efficient production process.
Implementation Method 1
a combustion zone, a phosphate rock reduction zone, and a slag bath zone from top to bottom. Two to eight combustion burners are symmetrically arranged on the combustion zone; the combustion temperature of pure oxygen and pulverized coal in the combustion zone is up to 1800 to 2000° C.
Implementation Method 2
fuel gas is introduced, by the auxiliary burner, into the reduction area and the slag bath zone for stamping and liquid sealing
Implementation Method 3
liquid-state molten slags enter the slag quench chamber for water quenching to form glass having crystallites of about 1 mm
Data Source
AI summary
Disclosed is a phosphorus coal gasification reaction device for combined production of yellow phosphorus and syngas, including a stock bin, a mineral aggregate lock hopper, a phosphorous coal gasification reactor, a slag quench chamber and a slag lock hopper. In the phosphorous coal gasification reactor, a drying zone, a dry distillation zone, a combustion zone, a phosphate rock reduction zone, and a slag bath zone are formed from top to bottom. A gas product outlet communicating with the phosphorous coal gasification reactor is installed at a top of the phosphorous coal gasification reactor, two to eight fuel burners are symmetrically arranged on the combustion zone, and an auxiliary burner communicating with the slag bath zone is arranged at the bottom of the slag bath zone. The reactor device can improve the production capacity of the yellow phosphorus, and reduce the emission of CO2.