Regenerator Deposit Removal via Reducing Gas
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Solution Overview
Problem
Heat recovery regenerators in furnaces, such as those used in glass melting, face issues with plugging due to the formation of alkali and sulfate deposits, which reduces heat transfer efficiency and requires frequent and disruptive cleaning, leading to production losses and increased energy consumption.
Innovation Solution
A method involving the use of a gaseous reducing stream, comprising components like carbon monoxide and hydrogen, is passed through the regenerator in the opposite direction to the flue gas flow to react with and remove deposits, preventing plugging and maintaining heat recovery efficiency without interrupting furnace operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If heat recovery regenerators are used to recover heat from high temperature exhaust streams, then fuel consumption is reduced, but deposits form in the regenerator causing plugging and requiring frequent cleaning
Solution Approach 1:
The patent applies the 'Blessing in disguise' principle by converting the harmful deposits into beneficial gaseous products. The reducing gas stream reacts with the alkali and sulfate deposits to form gaseous products that can be combusted, thus transforming the plugging problem into a useful fuel source while maintaining heat recovery efficiency
Solution Approach 2:
The patent applies 'Parameter changes' by altering the chemical environment within the regenerator. By introducing a reducing gas stream with specific composition (hydrogen, carbon monoxide, hydrocarbons) and controlling its flow rate and temperature, the patent changes the chemical reactions occurring in the regenerator to prevent deposit accumulation and enable continuous operation
2Loss of energy
If regenerator cleaning is performed to remove deposits, then heat transfer efficiency is restored, but production is interrupted causing economic losses
Solution Approach 1:
The patent applies 'Continuity of useful action' by enabling continuous regenerator operation without shutdowns. The reducing gas stream is introduced during normal operation to continuously prevent deposit buildup, eliminating the need for periodic cleaning shutdowns and maintaining both heat transfer efficiency and production rate simultaneously
Solution Approach 2:
The patent applies 'Self-service' by enabling the regenerator to clean itself through chemical reactions. The reducing gas stream reacts with deposits in-situ, and the resulting gaseous products are combusted in the furnace, allowing the system to maintain its own performance without external intervention or shutdowns
3Quantity of substance
If regenerator passages are narrowed by deposits, then air flow capacity is reduced, but this forces fuel reduction and lowers glass pull rate
Solution Approach 1:
The patent converts the harmful deposit accumulation into a beneficial process where deposits are chemically transformed into gaseous products. This prevents passage narrowing and maintains air flow capacity, allowing the system to operate at full production rate without forced reductions
4Reliability
If thermal cleaning is performed by increasing regenerator temperature to melt deposits, then deposits are removed, but the operation is slow and interrupts normal furnace operation
Solution Approach 1:
The patent applies 'Parameter changes' by fundamentally changing the cleaning mechanism from thermal melting to chemical reaction. Instead of increasing temperature to melt deposits over several days, the reducing gas stream enables rapid chemical conversion of deposits at normal operating temperatures, reducing cleaning time from days to hours
Solution Approach 2:
The patent replaces the mechanical/thermal cleaning system with a chemical reaction system. Rather than using high temperature to melt and physically remove deposits, the system uses reducing gases to chemically convert deposits into removable gaseous products, enabling faster and less disruptive cleaning
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 effectively prevents deposit buildup, maintains heat recovery efficiency, and allows for smaller regenerator designs with equal performance, reducing capital costs and energy consumption while avoiding production losses during cleaning.
Implementation Method 1
passing a gaseous reducing stream through the first passageway in the direction opposite to the flow direction of the flue gas stream in contact with said deposits to react the gaseous reducing stream with the deposits and thereby causing removal of deposits from the surfaces
Implementation Method 2
passing a gaseous flue gas stream comprising gaseous combustion products from the furnace through a first passageway in a heat recovery device wherein the first passageway has surfaces exposed to the flue gas stream, to heat the surfaces and cool the flue gas stream
Implementation Method 3
combusting fuel and gaseous oxidant in a furnace to generate heat of combustion which heats a charge in the furnace and generate gaseous combustion products
Data Source
AI summary
A thermochemical regenerator system is operated without encountering accumulation of unwanted solids on the interior surfaces of the passages through which flue gas passes.