Refractory Wall Cooling Layer Slag Solidification
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Solution Overview
Problem
Refractory walls in gasification devices are prone to corrosion from molten slag, leading to reduced service life and increased costs due to frequent replacements, which hampers the productivity and efficiency of carbonaceous fuel gasification processes.
Innovation Solution
A refractory wall design comprising a hotface layer, a backing layer, a cooling layer, and a compressible layer with a shield, where the cooling layer cools the hotface layer through the backing layer, causing slag to deposit and solidify, thereby protecting the wall from corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional refractory walls are used in gasification devices, then the device can operate at high temperatures, but the refractory walls are corroded by molten slag leading to short service life
Solution Approach 1:
The refractory wall is divided into multiple functional layers: a hotface layer resistant to slag corrosion, a backing layer for structural support, and a cooling layer with channels for circulating cooling medium. This segmentation allows each layer to perform its specific function optimally, with the hotface layer protecting against corrosion while the cooling layer maintains temperature control
Solution Approach 2:
A slag layer is introduced as an intermediary protective barrier between the molten slag and the refractory wall. This slag layer forms on the hotface surface and acts as a protective coating that prevents direct contact between the corrosive molten slag and the refractory material, thereby extending service life
2Reliability
If refractory walls are periodically replaced due to corrosion, then the device can maintain performance, but productivity is reduced and costs increase
Solution Approach 1:
The multi-layer refractory wall structure with integrated cooling channels enables continuous operation without periodic shutdowns for replacement. The cooling layer continuously removes heat through circulating cooling medium, maintaining the refractory wall integrity indefinitely, thus eliminating downtime and maintaining continuous productivity
3Reliability
If cooling is applied to the refractory wall, then slag deposits and solidifies protecting the wall, but the structure becomes more complex
Solution Approach 1:
The cooling function is merged directly into the refractory wall structure by integrating cooling channels within the backing layer. This combination eliminates the need for separate external cooling systems, as the cooling medium flows through channels built into the wall itself, achieving protection while minimizing additional structural complexity
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 extends the service life and performance of gasification devices by preventing corrosion and allowing for continuous operation, enhancing productivity and reducing maintenance costs.
Implementation Method 1
a cooling layer around the backing layer and configured to cool the hotface layer via the backing layer
Implementation Method 2
cooling the hotface layer via, the backing layer by the cooling layer so that a portion of the slag deposits on at least a part of the hotface layer
Data Source
AI summary
A refractory wall comprises a hotface layer comprising a hotface surface configured to be adjacent to a carbonaceous gasification environment, a backing layer facing the hotface layer, and a cooling layer facing the backing layer and configured to cool the hotface layer via the backing layer. A gasification device and a gasification process are also presented.