Autothermal Reformation Reactor Nozzle Design
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Solution Overview
Problem
The existing methods for producing synthesis gas through autothermal reformation face challenges such as short residence time, high entry momentum of fuel and oxidizing agent, and inefficient mixing, leading to suboptimal conversion and increased reactor size and complexity.
Innovation Solution
The oxidizing agent is introduced separately into the reaction space and converted to synthesis gas in an oxidation zone, while the fuel is introduced at multiple points in a recirculation zone, allowing for increased residence time and optimized supply nozzle design, reducing entry momentum and promoting efficient mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If oxidizing agent and fuel are supplied coaxially and coannularly, then direct reaction occurs, but residence time is short and entry momentum is high
Solution Approach 1:
The supply of oxidizing agent and fuel is segmented into separate nozzles positioned at different locations. The oxidizing agent is supplied centrally while fuel is supplied annularly at a different axial position, creating distinct injection zones that prevent immediate direct reaction and extend residence time.
Solution Approach 2:
The injection strategy transitions from coaxial alignment to spatial separation in both radial and axial dimensions. By positioning fuel nozzles annularly and at a downstream axial location relative to the oxidizing agent nozzle, the system utilizes dimensional separation to reduce entry momentum effects and extend residence time.
2Productivity
If oxidizing agent and fuel are supplied coaxially, then reaction occurs, but mixing is inefficient
Solution Approach 1:
The nozzle system is segmented into multiple independent injection points: a central oxidizing agent nozzle and multiple annularly arranged fuel nozzles. This segmentation allows each nozzle type to be optimized independently while achieving comprehensive mixing through the distributed arrangement.
Solution Approach 2:
Multiple fuel supply nozzles are merged into a symmetric annular arrangement around the central oxidizing agent nozzle. This merging creates a balanced, rotationally symmetric pattern that improves mixing efficiency while maintaining structural simplicity and ease of manufacture.
3Productivity
If high entry momentum is used, then fuel and oxidizing agent are supplied effectively, but conversion is suboptimal
Solution Approach 1:
The fuel is supplied at a location downstream of the oxidizing agent injection point, allowing the oxidizing agent to establish a initial flow pattern first. This preliminary action creates a more favorable flow field that reduces the effective entry momentum of subsequent fuel injection and promotes better mixing and conversion.
Solution Approach 2:
The reaction space itself acts as an intermediary zone between the separately supplied oxidizing agent and fuel. By positioning fuel injection downstream, the system allows the oxidizing agent flow to mediate the mixing process, reducing momentum conflicts and improving conversion efficiency.
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 approach enhances conversion efficiency, reduces by-product formation, and allows for a simpler and more reliable optimization of the reaction process, enabling a more efficient and stable synthesis gas production with improved reactor design.
Implementation Method 1
In an oxidation zone inside the reactor, the oxidizing agent reacts with the gaseous reformate present therein, exothermally
Implementation Method 2
in a reformation zone, in which it is converted into a gas mixture rich in hydrogen by an endothermal reaction
Data Source
Figure 1a~1b
Figure 2
Figure 3a~3b
AI summary
For producing synthesis gas by autothermal reformation of gaseous, liquid and/or solid fuels, the fuel is reacted with an oxidizing agent in a reaction space at a pressure of 10 to 120 bar and a reaction space temperature of 800 to 2,000 °C to obtain synthesis gas, wherein the oxidizing agent is introduced centrally in the upper region of the reaction space and wherein a flame is formed in the reaction space. The oxidizing agent is introduced into the reaction space separate from the fuel.