Metal Alloy Reactor Liner with Coolant Passages
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Solution Overview
Problem
Reactor vessel liners, such as those used in carbonaceous fuel gasifiers, face issues with durability and thermal stress due to thermal expansion mismatches between ceramic and metal components, leading to high operating expenses and potential thermal shock damage.
Innovation Solution
A reactor vessel liner system with a metal alloy liner that includes coolant passages and a secure attachment mechanism to manage thermal stresses, featuring a flange attachment and non-slag coating to reduce thermal expansion mismatches and enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If refractory tiles are used to insulate the reactor vessel, then the vessel is protected from high temperatures, but the tiles become damaged quickly and require frequent replacement
Solution Approach 1:
The patent changes the material parameter from ceramic refractory tiles to metal alloy liner, fundamentally altering the thermal and mechanical properties. The metal alloy provides both thermal protection and significantly extended service life by eliminating the brittleness and thermal shock susceptibility of ceramic tiles while maintaining high-temperature resistance.
Solution Approach 2:
The patent employs a composite structure consisting of a metal alloy liner with embedded coolant channels. This composite design combines the high-temperature resistance of metal alloys with the cooling capability of circulating coolant, creating a system that withstands thermal environments while extending component lifespan through active temperature management.
2Temperature
If refractory tiles are used for insulation, then thermal protection is provided, but long warm-up and cool-down periods are required to avoid thermal shock
Solution Approach 1:
The patent incorporates hydraulic cooling by circulating coolant through channels embedded in the metal alloy liner. This active cooling system rapidly removes heat from the liner, enabling quick cool-down periods and reducing warm-up times by preventing thermal shock accumulation, thereby eliminating the lengthy time requirements associated with refractory tile systems.
Solution Approach 2:
The metal alloy material fundamentally changes the thermal response characteristics compared to refractory tiles. The superior thermal conductivity and lower heat capacity of the metal alloy enable faster thermal transients, reducing both warm-up and cool-down times while maintaining thermal protection through the active cooling system.
3Duration of action of stationary object
If ceramic panels with coolant channels are used, then cooling effectiveness and durability are improved, but thermal expansion mismatch between ceramic and metal components causes problems
Solution Approach 1:
The patent achieves material homogeneity by constructing the entire liner from a single metal alloy material that forms both the structural wall and the coolant channels. This eliminates the ceramic-metal interface and the associated thermal expansion mismatch, preventing stress concentration and deformation at material boundaries while maintaining durability through uniform thermal response throughout the liner structure.
Solution Approach 2:
The patent creates a homogeneous composite where the metal alloy itself forms the coolant channel structure through embedded channels, rather than joining dissimilar materials. This single-material composite approach provides durability through consistent thermal expansion characteristics throughout the entire liner, eliminating the stress problems that arise from bonding ceramic panels to metal vessels.
4Duration of action of stationary object
If a metal alloy liner with coolant passages is used, then thermal stress is reduced and durability is extended, but the device complexity increases
Solution Approach 1:
The patent merges the structural liner function and the cooling function into a single integrated component. The metal alloy liner incorporates coolant channels directly within its structure, combining what would traditionally be separate elements (liner and cooling system) into one unified part, thereby reducing overall system complexity while extending lifespan through effective thermal management.
Solution Approach 2:
The metal alloy liner performs multiple functions simultaneously: it provides structural containment, thermal protection, and active cooling through embedded channels. This multi-functional design eliminates the need for separate ceramic insulation layers and external cooling systems, reducing device complexity while achieving enhanced durability through integrated thermal management.
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 system provides a long-lasting, cost-effective solution that reduces thermal stresses and maintains efficient heat absorption, extending the liner's life and reducing operational costs by using a metal alloy liner with controlled coolant circulation and secure attachment.
Implementation Method 1
circulates a coolant through the plurality of passages to thereby cool the reactor vessel
Implementation Method 2
The liner includes a plurality of passages for conveying a coolant... to control the temperature
Implementation Method 3
a thermal expansion mismatch between the ceramic panels and the metal of the attached reactor vessel or component may be undesired
Data Source
Figure 1~3
Figure 4
AI summary
A reactor vessel liner system includes a liner having an inner wall, an outer wall, and a plurality of passages extending between the inner wall and the outer wall. An attachment member extends outwards from the outer wall for securing the liner.