Segmented Gas Guide Tube for Synthesis Gas Cooling
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Solution Overview
Problem
Existing methods for cooling synthesis gas in reactors face challenges such as pressure fluctuations, inadequate cooling leading to hot gas streams, and inefficient coolant penetration at high pressures, particularly during transient operating states.
Innovation Solution
A reactor design featuring a double-walled gas guide tube with an annular gap for coolant flow, a baffle to form a coolant film on the inner tube, and an orifice to create a coolant spray, ensuring thorough mixing and effective cooling of synthesis gas across a wide operating range without the need for high-pressure coolant injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a simple gas guide tube with water injection is used, then the risk of hot gas stream formation is reduced, but at higher operating pressures the high density and viscosity of synthesis gas requires the cooling medium to have high momentum to penetrate into the core of the gas flow, which requires high differential pressure and large coolant jet diameter, going against the requirement for small coolant droplets for quick and effective cooling
Solution Approach 1:
The gas guide tube is divided into an inner tube and an outer tube, creating an annular gap between them. This segmentation allows coolant to be introduced at the top and flow downward through the annular gap, enabling effective cooling without requiring high differential pressure or large jet diameters.
Solution Approach 2:
The cooling approach transitions from axial injection (into the core of the gas flow) to radial cooling (through the annular gap between inner and outer tubes). This dimensional change allows coolant to effectively cool the synthesis gas without requiring high momentum, as the coolant flows in a different spatial dimension relative to the gas flow direction.
2Temperature
If immersion quench is used, then direct cooling of synthesis gas is achieved, but the filling level of quench water must be controlled within a narrow range to avoid pressure fluctuations or uncooled synthesis gas breakthrough
Solution Approach 1:
The design extracts the filling level control requirement by eliminating the need for a water reservoir with a free surface. Instead, coolant is introduced through a controlled feed at the top of the gas guide tube, flowing downward through the annular gap without requiring narrow filling level control to prevent pressure fluctuations or uncooled gas breakthrough.
3Temperature
If free quench arrangement is used, then cooling is achieved through direct contact with coolant, but partial regions of the gas flow may not be adequately cooled if nozzles are blocked, leading to hot gas streams that can overheat and damage components
Solution Approach 1:
The gas guide tube is segmented into inner and outer tubes with an annular gap, creating a distributed cooling path. This segmentation ensures that coolant flows continuously through the entire circumference of the gas flow, preventing localized blockages from causing inadequate cooling in specific regions, thus maintaining uniform cooling and preventing hot gas stream formation.
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 design ensures reliable and safe cooling of synthesis gas, preventing overheating and damage to components, while maintaining effective cooling even at high pressures and during reactor startup, with reduced risk of coolant blockages and hot gas formation.
Implementation Method 1
the gas guide tube has an inner tube and an outer tube, as a result of which an annular gap is formed between the inner tube and the outer tube, wherein the annular gap is connected fluidically to the coolant feed, thus enabling coolant to flow through the said gap
Implementation Method 2
the inner tube has an opening to the annular gap in the gas inlet region of the gas guide tube, and a baffle is arranged in the region of this opening, thus enabling a liquid film of coolant to be produced on the inner side of the inner tube
Implementation Method 3
an orifice is arranged in the gas outlet region of the gas guide tube, thus enabling a spray of coolant to be produced within the cooling space
Data Source
AI summary
A reactor for producing synthesis gas by partial oxidation of a carbon-containing fuel, having a reaction space and a cooling space, wherein a cooled gas guide tube connects the reaction space and the cooling space to one another. The gas guide tube has a gas inlet region, which adjoins the reaction space, and a gas outlet region, which adjoins the cooling space. The gas guide tube has an inner tube and an outer tube, as a result of which an annular gap is formed, wherein the annular gap is connected fluidically to a coolant feed, and the inner tube has an opening to the annular gap in the gas inlet region of the gas guide tube, and a baffle is arranged in the region of this opening, and an orifice is arranged in the gas outlet region of the gas guide tube.