Rapid Cooling of Corrosive High-Temperature Gas With Water Films
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Solution Overview
Problem
Existing methods for cooling high temperature, corrosive gases face issues such as apparatus instability, blockage of heat exchangers, and limited material durability, leading to safety risks and high investment costs.
Innovation Solution
An apparatus comprising cylindrical housings with jackets and inner cylinders, combined with water film and mist generation members, effectively cools high temperature gases by forming stable water films and mists to protect the apparatus from corrosion and blockage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a nickel-based material is used to cool high temperature HCl and Cl2 gas, then the material can withstand high temperature and corrosion, but the material cannot withstand water precipitation and acid-containing liquids severely corrode it
Solution Approach 1:
A water film is introduced as an intermediary layer between the corrosive gas and the nickel-based heat exchanger surface. The water film absorbs the corrosive components (HCl, Cl2) through washout action, preventing direct contact with the metal surface while allowing efficient heat transfer to occur through the thin water layer
Solution Approach 2:
The system creates a composite protective layer consisting of water vapor and liquid water film on the heat exchanger surface. This composite structure provides both thermal insulation and corrosion protection, combining the heat transfer properties of water with the protective washout effect against corrosive gases
2Strength
If a tantalum material is used to cool corrosive gas, then the material can withstand hydrochloric acid solution, but the material cannot be used at temperatures greater than 260°C
Solution Approach 1:
The water film serves as a mediator that allows the system to operate at temperatures above 260°C by absorbing the corrosive components before they reach the tantalum surface. This protects the tantalum material from direct exposure to concentrated HCl while maintaining the cooling function at elevated temperatures
3Productivity
If a shell-and-tube heat exchanger is used to cool high temperature gas, then the gas can be cooled efficiently, but catalyst particles in the reaction gas easily block the heat exchanger
Solution Approach 1:
The water film system extracts and removes catalyst particles from the gas stream through washout action before they can reach and block the heat exchanger tubes. The water film captures the particles in the liquid phase, preventing them from depositing on the heat transfer surfaces while maintaining efficient heat transfer
Solution Approach 2:
The water film acts as an intermediary trapping medium that captures catalyst particles through inertial impaction and diffusion processes. This prevents particle deposition on the heat exchanger while allowing continuous operation, solving the blockage problem without sacrificing cooling efficiency
4Strength
If a quench tower with nozzle is used to form water film for protection, then the tower is protected from high temperature gas, but the water film thickness is affected by gas velocity and dry wall appears locally causing irreversible damages
Solution Approach 1:
The system dynamically adjusts the water film thickness and distribution based on gas flow conditions. By optimizing nozzle positioning, water flow rates, and gas velocity profiles, the water film maintains uniform thickness throughout the quench tower even under varying operational conditions, preventing local dry walls
Solution Approach 2:
The system changes multiple parameters including water flow rate, nozzle angle, gas velocity, and water pressure to optimize water film formation. By coordinating these parameters, a uniform and stable water film is achieved that provides consistent protection against high temperature corrosive gases without local dry-out
5Strength
If heat-resistant mortar lining is used in the quench tower, then the tower can be protected from high temperature, but the mortar cracks seriously under continuous switching between high temperature and low temperature
Solution Approach 1:
The water film serves as a thermal intermediary that provides continuous cooling to the quench tower interior surface. This prevents rapid temperature fluctuations and thermal shock by maintaining a more stable temperature profile, eliminating the cracking problem associated with thermal cycling while preserving thermal protection
Solution Approach 2:
The water film provides continuous cooling action throughout the quench tower, maintaining steady-state temperature conditions. This continuous cooling prevents the thermal shock that causes mortar cracking during temperature switching, while still providing effective thermal protection against high temperature gases
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 solution prevents heat exchanger blockage, extends apparatus lifespan, and ensures safe, reliable operation at elevated temperatures, reducing material limitations and investment costs.
Implementation Method 1
effectively cools high temperature gases by forming stable water films and mists to protect the apparatus from corrosion and blockage
Data Source
AI summary
The apparatus includes one or more cylindrical housings connected to one another, a jacket on an outer side of a housing, an inner cylinder disposed at least in an interior of a first cylindrical housing, a heat insulation gasket, inner members, a corrosive high temperature gas inlet disposed on the heat insulation gasket, a gas and liquid phase outlet disposed at a bottom of the housing or a bottom of a last housing and a coolant inlet and outlet connected to an interior of the jacket. The heat insulation gasket seals the first cylindrical housing and a top of the inner cylinder in the interior of the first cylindrical housing. The inner members are distributed along a wall of the housing, communicate an interior of the jacket with an interior of the housing, and distribute a liquid in the interior of the jacket to the interior of the housing.