POx Reactor Startup Using a Single Burner and Hot Oxygen
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Solution Overview
Problem
Conventional methods for starting up partial oxidation (POx) reactors involve slow heating to avoid damaging refractory linings, leading to disruptive gas flow disruptions and soot production, and require additional equipment or burner swapping, which is inefficient and disruptive to the process.
Innovation Solution
A method involving controlled increases in mass flow rates of primary fuel, oxygen, and auxiliary fuel, combined with pressure and temperature adjustments, using a single burner to gradually raise the reactor temperature and pressure to the operating conditions, without the need for additional equipment or burner swapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional slow heating method is used to avoid damaging refractory linings, then refractory lining protection is improved, but startup time is increased and process continuity is disrupted
Solution Approach 1:
The patent introduces a preliminary hot oxygen generation step before main reactor startup. A separate hot oxygen reactor pre-heats oxygen to high temperature (above 1000°F), which is then introduced into the main POx reactor to rapidly raise the reactor temperature to operating conditions without directly heating the refractory lining, thus protecting it while enabling faster startup
Solution Approach 2:
Hot oxygen serves as an intermediary heating medium between the external heat source and the reactor interior. Instead of directly heating the reactor vessel and refractory lining, the patent uses pre-heated oxygen as a carrier to transfer thermal energy rapidly into the reactor, achieving fast temperature rise while avoiding thermal shock to the refractory lining
2Power
If secondary warmup burner is added to heat vessel interior, then heating capability is improved, but device complexity increases
Solution Approach 1:
The patent makes the primary POx burner multi-functional by enabling it to operate in two modes: (1) generating hot oxygen for the oxidation process, and (2) serving as the heating source during startup. This eliminates the need for a separate secondary warmup burner, maintaining high heating capability while reducing equipment complexity
Solution Approach 2:
The patent merges the functions of the primary burner (oxidation fuel source) and secondary warmup burner (heating source) into a single burner system. The primary burner is configured to first generate hot oxygen, then use that hot oxygen and its combustion products to heat the reactor during startup, combining what would traditionally be separate equipment into one integrated system
3Power
If primary POx burner is replaced with warmup burner, then heating capability is improved, but process continuity is disrupted
Solution Approach 1:
The patent performs preliminary heating of the reactor using hot oxygen generated by the primary burner before switching to normal POx operation. This preliminary action allows the reactor to reach operating temperature without replacing the burner, maintaining continuous operation of the primary burner system and avoiding process disruption
Solution Approach 2:
The patent maintains continuous operation of the primary burner throughout the startup process. Instead of replacing the burner, the system uses the primary burner to generate hot oxygen that continuously heats the reactor during startup, then transitions to normal POx operation without interrupting the burner's useful action, ensuring process continuity
4Power
If hot oxygen is generated by separate reactor, then heating capability is improved, but device complexity increases
Solution Approach 1:
The patent segments the hot oxygen generation function from the main POx reactor by using a separate hot oxygen reactor. This separate reactor is dedicated to generating hot oxygen through combustion of fuel with oxygen, which is then transferred to the main reactor. This segmentation allows the main reactor to focus on POx operation while the separate unit handles heating, improving heating capability with acceptable complexity
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
Enables efficient and continuous startup of POx reactors, minimizing soot production and maintaining process continuity by gradually increasing temperature and pressure, thus avoiding equipment disruptions and optimizing operational efficiency.
Implementation Method 1
combustion of the primary fuel and the oxygen in the burner, and combustion of the product stream and the auxiliary fuel
Implementation Method 2
The combustion generates a product stream that emerges from the burner. The products of combustion of the product stream and the auxiliary fuel are passed into the interior of the reactor to continue to increase the operating temperature of the reactor
Implementation Method 3
Partial oxidation (POx) reactors typically operate at temperatures of 1316°C (2400F) or above. To start up operation of a POx reactor... the conventional methodology for starting up operation of the POx reactor involves heating the vessel interior
Data Source
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AI summary
In a reactor for partial oxidation of feedstock employing a hot oxygen stream that is generated by a suitable burner, the same burner that generates and provides the hot oxygen stream in full-scale partial oxidation operation can be employed in the starting-up of the partial oxidation reactor by suitable control of the characteristics of the feed to the burner, or of the pressures.