Fixed-bed Pyro-gasification Reactor Tar Cracking
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Solution Overview
Problem
Existing fixed-bed pyro-gasification reactors produce high levels of tars in syngas, which require additional thermal or catalytic cracking devices, and have limited yield efficiency.
Innovation Solution
A pyro-gasification reactor design where part of the syngas is used to create a high-temperature zone within the reactor, utilizing a centrally located rotating shaft with arms to distribute heat and crack tars, thereby reducing tar content and enhancing yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a thermal or catalytic tar cracking device is installed outside the reactor, then tar content in syngas is reduced, but device complexity increases and independent equipment is required
Solution Approach 1:
The patent merges the tar cracking function with the reactor structure by installing a cracking device inside the reactor chamber. The cracking device is integrated with the reactor's existing structure, combining two functions (gasification and tar cracking) into a single unit, thereby reducing the need for independent external equipment and simplifying the overall system configuration
Solution Approach 2:
The reactor chamber serves multiple functions: it acts as both the gasification reactor and the tar cracking chamber. The cracking device within the reactor utilizes the high-temperature environment already present in the reactor to perform tar cracking, making the reactor a multi-functional unit that handles both primary gasification and secondary tar removal processes
2Temperature
If more carbonaceous material is consumed for heating, then reactor temperature increases improving gasification efficiency, but yield efficiency decreases
Solution Approach 1:
The patent converts the harmful effect of tar production into a beneficial process by utilizing the high-temperature zone already present in the reactor to crack tars. The tar cracking process is performed using the heat generated by the gasification process itself, turning what would be a waste product (tar) into useful syngas components without requiring additional external energy input
Solution Approach 2:
The reactor system performs self-heating and self-cracking by utilizing its own generated heat. The high-temperature zone created during gasification automatically serves to crack the tars formed in the process, eliminating the need for separate external heating or cracking equipment and maintaining energy efficiency within the system
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 reactor achieves significant tar cracking and increased yield, with less than 30% of carbonaceous material consumed for heating, resulting in cleaner syngas suitable for direct use in engines and turbines.
Implementation Method 1
the combustion of these gases creates a hot zone which is traversed by the other part of the synthesis gases
Implementation Method 2
the other part of the synthesis gases, which are then heated to a high temperature causing the cracking of a large part of the tars produced
Implementation Method 3
the conduit forms a rotating shaft equipped with arms or blades and also ensures mixing of the material and homogeneous distribution of gases and heat within it
Data Source
Figure 1
Figure 2
AI summary
A fixed-bed pyro-gasification reactor comprising a vessel (2), means (4) for supplying the vessel with carbonaceous material to form a bed within the vessel (2), located in an upper portion of the vessel (2), a conduit (10) extending vertically within the vessel (2) so as to be surrounded by the carbonaceous material, the conduit (10) comprising an end (10.1) for collecting syngas, a secondary air supply (12) for injecting it into the conduit, through another end (10.2) of the conduit (10), means (11) for injecting methane into the conduit (10) through the other end (10.2) of the conduit (10), a primary air supply (14) for injecting it into the vessel (2) in a combustion zone of the vessel, and an ignition system (13) at the other end (10.2) of the conduit (10) to cause the combustion of the mixture of air and gas, such as methane or pyrolysis gas.