Porous Roller Solids Deaeration for Coal Gasification
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Solution Overview
Problem
Current dry coal gasification systems face inefficiencies due to shear failure zones and flow stagnation issues when conveying fine particulate materials, particularly pulverized coal, which leads to mechanical inefficiencies and high operational costs.
Innovation Solution
A solids supply system comprising a deaeration zone with porous roller or belt assemblies that compact particulate materials before entering a pump zone, allowing effective conveyance through the development of stress-transmitting bridges, thereby eliminating shear failure and flow stagnation zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fine particulate materials are conveyed through pumping systems, then material transport is achieved, but shear failure zones and flow stagnation occur leading to mechanical inefficiency
Solution Approach 1:
The system performs preliminary deaeration and compaction of fine particulate materials before they enter the pumping zone. The deaeration zone removes air pockets and the compaction zone densifies the material, creating optimal conditions for efficient pumping and preventing shear failure zones and flow stagnation during transport
Solution Approach 2:
The system changes physical parameters of the particulate material through controlled deaeration and compaction processes. By adjusting density, air content, and particle arrangement before pumping, the material becomes suitable for efficient transport without mechanical losses
2Reliability
If external force is applied to compress powdery material, then deaeration is achieved, but material overly consolidates and clogs the inlet or transport channel
Solution Approach 1:
The system divides the deaeration and compaction process into separate sequential zones: first the deaeration zone removes air pockets gently, then the compaction zone applies controlled density adjustment. This segmentation prevents over-consolidation and clogging by avoiding excessive force in a single step
Solution Approach 2:
The deaeration zone performs preliminary air removal before the compaction zone applies density adjustment. This preliminary action prevents air pockets from causing uneven consolidation and clogging during subsequent compaction and pumping operations
3Use of energy by moving object
If cycling lock hopper is used to pump dry coal to high pressure, then thermal cold gas efficiency is improved, but mechanical efficiency remains low due to high pressure tanks, valves, and gas compressors
Solution Approach 1:
The system extracts and removes air pockets from the particulate material through the deaeration zone before pumping. By eliminating air pockets that would otherwise require high-pressure containment and complex valve systems, the system achieves high pressure transport with simpler equipment
Solution Approach 2:
The system replaces complex mechanical high-pressure systems (tanks, valves, compressors) with a streamlined approach using pre-deaerated and compacted material flow. The controlled deaeration and compaction enable efficient high-pressure pumping without traditional high-pressure equipment
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 system achieves mechanical efficiency of up to 80% and can pump pulverized dry coal to pressures over 1200 psi, significantly reducing operational costs and enhancing the reliability of dry coal gasification processes.
Implementation Method 1
a roller system comprising a plurality of porous roller assemblies, or a belt system comprising a plurality of porous belt assemblies, operable to deaerate and convey the solids
Implementation Method 2
The deaeration zone includes a roller system containing a plurality of porous roller assemblies, or a belt system containing a plurality of porous belt assemblies
Data Source
AI summary
A solids supply systems having a solids deaeration zone and a solids pump zone, and to methods for supplying the solids e.g., pulverized dry coal, to an application, e.g., gasification process. The solids deaeration zone includes a roller system containing a plurality of porous roller assemblies, or a belt system containing a plurality of porous belt assemblies. The solids deaeration zone is operable to deaerate and convey the solids to the solids pump zone. In the solids deaeration zone, the solids become sufficiently compacted prior to and upon entry into the solids pump zone to be effectively conveyed through the solids pump zone.