Regenerative Reactor Mixer Controls Combustion
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Solution Overview
Problem
Conventional regenerative reactors reduce efficiency by bypassing reactants around the regenerative flow path, preventing preheating and thus reducing overall system efficiency due to direct introduction of fuel and oxidant via nozzles or burners in the middle of the reactor, which bypasses the regenerative system's heat recuperation capability.
Innovation Solution
A method and apparatus for controlling combustion in reverse flow regenerative reactors using a gas mixer and flow distribution system that keeps fuel and oxidant substantially separated within regenerative beds, allowing for controlled heat release and efficient mixing and distribution, ensuring that the heat release occurs after the reactants have passed through the recuperator zone, thereby maximizing heat transfer and system efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If reactants are introduced directly via nozzles or burners in the middle of the reactor, then the combustion reaction can proceed, but the reactants bypass the regenerative flow path and cannot be preheated, reducing system efficiency
Solution Approach 1:
The reactor is divided into distinct zones: a first regenerative bed, a second regenerative bed, and an intermediate zone between them. Reactants are introduced sequentially into different zones rather than all at once in the middle, allowing each zone to perform its specific function (preheating, combustion, heat recovery) while maintaining overall system efficiency.
Solution Approach 2:
Reactants are preheated by passing them through the regenerative beds before combustion occurs. The regenerative beds store heat from previous cycles and use it to preheat incoming reactants, so that when combustion occurs in the intermediate zone, the reactants are already at elevated temperature, maximizing heat recuperation efficiency.
2Ease of manufacture
If nozzles or burners are used to introduce reactants perpendicular to flow direction through the side wall, then reactant introduction is simple, but the regenerative system's heat recuperation capability is bypassed
Solution Approach 1:
Instead of introducing reactants through the side wall (radial direction), the system introduces reactants axially through the regenerative beds. This dimensional change allows reactants to flow through the heat-storing medium in the same direction as the main regenerative flow, enabling effective heat transfer while maintaining manufacturing simplicity.
3Adaptability or versatility
If conventional symmetric cycles are used for mild exothermic chemistry, then the reactor can handle simple reactions, but the system cannot execute endothermic chemistry requiring high temperatures
Solution Approach 1:
The reactor operates in periodic cycles, alternating between an exothermic phase (where fuel combustion generates heat) and an endothermic phase (where the stored heat drives endothermic reactions). This periodic operation allows the same reactor to handle both mild exothermic chemistry and high-temperature endothermic chemistry by switching roles of different zones between cycles.
Solution Approach 2:
The system changes operational parameters between cycles: during the exothermic phase, combustion raises temperatures to very high levels for heat storage; during the endothermic phase, the stored heat is released to maintain high temperatures required for endothermic reactions. This parameter switching enables versatility across different reaction types.
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 the overall efficiency of the regenerative reactor system by ensuring that the heat from combustion is effectively utilized for thermal regeneration, maintaining high temperatures and optimizing the temperature gradients across the reactor zones, thereby improving the reactor's thermal efficiency and reaction performance.
Implementation Method 1
the heat from combustion is effectively utilized for thermal regeneration, maintaining high temperatures and optimizing the temperature gradients across the reactor zones
Implementation Method 2
controlling combustion for thermal regeneration of reverse flow regenerative reactors
Implementation Method 3
The mixer/flow distribution apparatus is configured for bidirectional operation, particularly advantageous for reverse flow reactors
Data Source
Figure 1(a)~1(b)
Figure 2~2a
Figure 3a~3
AI summary
The overall efficiency of a regenerative bed reverse flow reactor system is increased where the location of the exothermic reaction used for regeneration is suitably controlled. The present invention provides a method and apparatus for controlling the combustion to improve the thermal efficiency of bed regeneration in a cyclic reaction/regeneration processes. The process for thermal regeneration of a regenerative reactor bed entails (a) supplying the first reactant through a first channel means in a first regenerative bed and supplying at least a second reactant through a second channel means in the first regenerative bed, (b) combining said first and second reactants by a gas mixing means situated at an exit of the first regenerative bed and reacting the combined gas to produce a heated reaction product, (c) passing the heated reaction product through a second regenerative bed thereby transferring heat from the reaction product to the second regenerative bed.