Reactor Intermediate Floor Cooling via Shaped Body
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In existing reactors for hydrocarbon gasification, the intermediate floor separating the reaction and cooling spaces is inadequately cooled due to uneven gas flow, leading to temperature variations and increased material requirements for thermal resistance, resulting in higher costs and complexity.
Innovation Solution
A reactor design featuring a shaped body in the cooling space that partially obstructs the cross-sectional area, deflecting the cooled product gas to flow more evenly over the intermediate floor, enhancing heat transfer and reducing temperature peaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the cooled gas is extracted laterally from the cooling chamber, then the gas extraction is simplified, but the intermediate floor is inadequately cooled and experiences uneven temperature distribution
Solution Approach 1:
The invention introduces a vertical dimension to the gas flow path by extending the cold gas outlet through the intermediate floor into the cooling chamber. This allows cooled gas to rise vertically from below the intermediate floor, creating upward flow that enhances cooling of the intermediate floor's lower surface, complementing the existing lateral extraction at the top.
Solution Approach 2:
The cold gas outlet is segmented into multiple sections: an upper section for lateral gas extraction and a lower section extending through the intermediate floor for vertical gas introduction. This segmentation allows the system to simultaneously achieve simplified lateral extraction and improved intermediate floor cooling through vertical flow.
2Reliability
If the intermediate floor is designed to withstand high temperatures, then safety margin is improved, but material costs and component thickness increase
Solution Approach 1:
The invention enables the intermediate floor to cool itself by allowing cooled gas to flow vertically through the floor structure. The lower section of the cold gas outlet introduces cooled gas directly into the cooling chamber below the intermediate floor, creating natural convection that draws heat away from the intermediate floor, reducing its operating temperature and allowing for thinner, less complex designs.
Solution Approach 2:
Cooled gas acts as an intermediary cooling medium that transfers heat from the intermediate floor to the cooling chamber. By introducing cooled gas vertically through the intermediate floor, heat is conducted from the intermediate floor into the cooled gas, which then carries it away, effectively using the gas as a heat transfer intermediary.
3Object-affected harmful factors
If refractory lining thickness is increased, then heat transfer protection is improved, but construction costs increase
Solution Approach 1:
The cooling system uses the process gas itself to cool the intermediate floor and refractory lining. By extending the cold gas outlet through the intermediate floor, cooled gas flows vertically upward, creating continuous convection that actively removes heat from the refractory lining and intermediate floor, reducing the need for excessive lining thickness.
Solution Approach 2:
The invention changes the thermal parameters of the intermediate floor by introducing active cooling through the vertical gas flow. This reduces the steady-state temperature of the intermediate floor and refractory lining, allowing for optimized (thinner) lining designs that are more cost-effective while maintaining adequate heat transfer protection.
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 design achieves more uniform cooling of the intermediate floor, reduces thermal stresses, allows for lower material temperature and thinner components, and decreases construction costs by enabling the use of more cost-effective materials.
Implementation Method 1
the cooled product gas, after passing through the gas passage located in the intermediate floor of the reactor, flows around the shaped element... leading to improved cooling and a more uniform temperature profile across the surface of the intermediate floor... The arranged shaped element ensures that the cooled product gas flows more evenly over the reactor's intermediate floor before exiting the cooling chamber
Implementation Method 2
cooling chamber for cooling the hot product gas by direct heat exchange with a cooling medium... the hot product gas is cooled by the intensive contact of the hot gas with the cooling medium in the gas passage and/or in the cooling chamber
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3(a)~3(c)
AI summary
The present invention relates to a reactor and a process for producing a product gas, in particular a synthesis gas, by gasifying a hydrocarbon-containing fuel. The reactor has a reaction chamber and a cooling chamber, and an intermediate floor which spatially separates the reaction chamber from the cooling chamber. A gas passage extends through the intermediate floor for conveying the product gas to be cooled from the reaction chamber into the cooling chamber. According to the invention, a shaped element is arranged in the cooling chamber of the reactor, which extends at least partially over a free cross-sectional area of the cooling chamber and partially obstructs the cross-sectional area of the cooling chamber, wherein the shaped element is arranged such that at least a portion of the product gas cooled in the cooling chamber, after flowing around the shaped element, subsequently exits the reactor via the cold gas outlet of the cooling chamber.The arrangement of the molded body results in improved and more uniform cooling of the intermediate floor.