Gasification Reactor Burner Vortex Slag Formation
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Solution Overview
Problem
Gasification reactors with low-ash feeds face challenges in forming an insulating slag layer, leading to reduced operational lifespan and efficiency, especially when refractory brickwork is required, which is prone to damage from high temperatures.
Innovation Solution
The design features burners that create a spirally formed gas flow within the combustion chamber, forcing slag to the wall and allowing for the formation of an insulating slag layer without refractory brickwork, even with low-ash feeds, thereby extending the reactor's operational period and increasing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If refractory brickwork is used to line the combustion chamber wall, then the chamber can withstand high temperatures, but the operational lifespan is reduced due to damage and dissolution from temporarily high gas temperatures
Solution Approach 1:
The patent replaces expensive, temperature-resistant refractory brickwork with a more economical alternative: a protective slag layer that forms on the inner wall surface. This slag layer acts as a sacrificial protective barrier that can be replenished or reformed during operation, eliminating the need for costly refractory materials while extending operational lifespan between maintenance cycles.
2Productivity
If a low-ash feed is used for gasification, then feed quality and efficiency are improved, but an insulating slag layer cannot form on the combustion chamber wall
Solution Approach 1:
The patent introduces an intermediary mechanism to enable slag layer formation from low-ash feeds. By injecting process water or steam at specific locations (such as through water injection nozzles or steam generators positioned near the burners), the system creates localized conditions that promote slag formation on the wall surface, even when the feed itself has low ash content. This intermediary water/steam injection acts as a catalyst for slag layer formation.
Solution Approach 2:
The patent changes the chemical and physical parameters of the system by injecting water or steam into the combustion zone. This injection modifies the local temperature, pressure, and chemical composition, enabling slag formation from low-ash feeds. The water/steam injection alters the feed composition in-situ, transforming it into a condition suitable for slag layer formation while maintaining the benefits of low-ash feed gasification.
3Device complexity
If the combustion chamber wall is directly exposed to high temperatures without insulation, then structural simplicity is maintained, but heat loss increases and operational efficiency decreases
Solution Approach 1:
The patent implements a self-service thermal insulation system where the combustion chamber wall generates its own protective insulating layer. The slag layer forms automatically on the inner wall surface through the interaction of feed ash, injected water/steam, and combustion conditions. This self-forming slag layer provides thermal insulation without requiring external refractory materials or complex insulation structures, maintaining structural simplicity while reducing heat loss.
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 enables efficient and prolonged operation on low-ash feeds by forming a protective slag layer, avoiding the need for refractory brickwork and enhancing reactor capacity compared to prior art.
Implementation Method 1
directing the burners through the wall of the combustion chamber a spirally formed gas flow results in the combustion chamber which forces the slag to the wall
Implementation Method 2
a protective layer of slag will form on the wall of the combustion chamber when an ash-containing feed is used as feed for the gasification reactor. The caked layer of slag will be responsible for the thermal insulation between the combustion chamber and the tubes
Data Source
Figure 1
Figure 1a
Figure 2
AI summary
Gasification reactor vessel (1), comprising a combustion chamber (6) in the upper half of the vessel, provided with a product gas outlet (7) at the bottom end of the combustion chamber (6), a burner (2) positioned such that, in use, it fires into the combustion chamber (6), said burner (2) provided with at least supply conduits for an oxidiser gas and a carbonaceous feed, wherein between the wall (8) of the combustion chamber (6) and the wall of vessel (1) an annular space (9) is provided, and wherein the wall (8) of the combustion chamber (6) comprises an arrangement of interconnected tubes (vertical arranged or helical coiled), and wherein two burner (2) openings are present in the wall of the combustion chamber, which burner openings are located at the same horizontal level and are positioned diametrical relative to each other and wherein in the burner opening a burner (2) is present.