Plug-Resistant Nozzle for Fluidized Particulate Flow
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Solution Overview
Problem
Conventional nozzles in gasification processes are prone to particulate buildup, which can lead to interruptions and require time-consuming rodding or drilling for clearance, as they are not effective in resisting significant nozzle blockages due to their design extending through pressure shells and refractory layers.
Innovation Solution
The design of plug-resistant nozzles with a gas entry segment, a gas exit segment oriented at an angle of 70° to 110°, and an access segment aligned with the gas exit segment, which reduces the likelihood of particulate accumulation and allows for easier ejection of blockages by fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional nozzles extend through the pressure shell and refractory layer to fluidize particulates, then the nozzle can effectively introduce fluid into the fluid/particulate mixture, but the nozzle becomes prone to significant particulate buildup and blockage
Solution Approach 1:
The nozzle is divided into multiple segments (first segment, second segment, third segment) with different orientations. The first segment extends through the pressure shell at an angle, the second segment extends through the refractory layer substantially parallel to the first segment, and the third segment is coaxial with the second segment. This segmentation allows each portion to optimize for its specific function while reducing overall particulate accumulation.
Solution Approach 2:
The nozzle employs asymmetric orientation angles between segments rather than symmetric alignment. The first segment is oriented at a specific angle relative to the second segment, and the third segment is oriented at a different angle relative to the second segment. This asymmetric configuration disrupts particulate flow patterns and reduces buildup on nozzle surfaces.
2Length of moving object
If conventional nozzles are made long enough to extend through the pressure shell and refractory layer, then the nozzle can reach the fluid/particulate mixture, but the particulate blockage becomes too great to blow out
Solution Approach 1:
The long nozzle is segmented into three distinct portions with different orientations and functions. This segmentation creates multiple ejection paths and reduces the effective length of any single narrow passage, allowing fluid pressure to more effectively blow out particulate blockages compared to a single long continuous nozzle.
Solution Approach 2:
The nozzle transitions from a single linear path to a multi-dimensional segmented structure with different orientation angles. The third segment is oriented at an angle different from the second segment, creating a three-dimensional flow path that facilitates particulate ejection by changing the direction of fluid flow and reducing direct axial pressure buildup.
3Reliability
If the nozzle segments are oriented at specific angles (70°-110°), then the nozzle resists particulate buildup, but the nozzle design becomes more complex
Solution Approach 1:
The complex angled orientation is achieved by dividing the nozzle into three manageable segments rather than attempting to create a single complex bent nozzle. Each segment can be manufactured separately with standard angles and then assembled, reducing manufacturing complexity while achieving the desired anti-buildup orientation.
Solution Approach 2:
The asymmetric angle configuration (70°-110° between segments) is implemented through modular segmented construction rather than monolithic fabrication. This allows standard machining processes to create each segment at the required angles, and assembly techniques to join them, thereby managing manufacturing complexity while maintaining the asymmetric geometry needed for particulate resistance.
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 configuration effectively resists particulate buildup and allows for efficient ejection of blockages without the need for extensive rodding or drilling, maintaining process continuity and reducing downtime.
Implementation Method 1
introduce a fluid, e.g., a gas, into the fluid/particulate mixture to fluidize the particulates so that they will continue to flow through the fluid conveying structure
Implementation Method 2
a gas exit segment coupled to the gas entry segment, wherein a longitudinal axis of the gas exit segment is oriented at an angle of between about 70° and about 110° with respect to a longitudinal axis of the gas entry segment
Data Source
AI summary
Apparatus, systems, and methods for fluidizing particulates in a fluid/particulate mixture. A nozzle can include a gas entry segment, a gas exit segment, and an access segment. The gas exit segment can be coupled to the gas entry segment, and a longitudinal axis of the gas exit segment can be oriented at an angle of between about 70° and about 110° with respect to a longitudinal axis of the gas entry segment. The access segment can be coupled to the gas entry segment and the gas exit segment, and a longitudinal axis of the access segment can be substantially aligned with the longitudinal axis of the gas exit segment.