Ceramic Obstacles for Slag Agglomeration
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Solution Overview
Problem
Gasification systems face challenges in removing ash particles with diameters less than 10 μm, as cyclones are ineffective, and existing candle filters are prone to corrosion, fragile, and costly, requiring additional separation steps and maintenance.
Innovation Solution
A slag agglomerator using ceramic matrix composite obstacles to increase the size of small slag droplets, allowing cyclone separation without the need for candle filters, by actively cooling the obstacles to solidify and bond slag droplets, forming larger particles that can be removed from the gas stream.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cyclone separators are used to remove ash particles, then larger ash particles can be removed, but ash particles with diameters less than 10 μm are not easily removed
Solution Approach 1:
The patent applies preliminary action by using a cooling section to condense fine ash particles into larger droplets before they enter the cyclone separator. The cooling section is positioned upstream of the cyclone, allowing ash particles to be pre-agglomerated into larger structures that can then be effectively removed by the cyclone's vortex separation mechanism.
Solution Approach 2:
The patent changes the physical state and size parameters of ash particles by cooling them from high temperature gas phase to condensed liquid/droplet phase. This parameter change increases particle size and density, making them suitable for cyclone separation while maintaining effective removal of fine particles.
2Productivity
If candle filters are used to remove fine ash particles, then ash removal efficiency improves, but the filters are vulnerable to corrosion and require frequent replacement
Solution Approach 1:
The patent extracts and eliminates the candle filter component from the system by using a cooling section combined with cyclone separation. Instead of relying on fragile candle filters that are prone to corrosion, the system uses a robust cooling and cyclone configuration that achieves the same fine ash removal function without the reliability issues of candle filters.
Solution Approach 2:
The cooling section acts as an intermediary device between the ash-generating process and the cyclone separator. It condenses fine ash particles into larger droplets that can be effectively handled by the cyclone, serving as a mediator that enables ash removal without requiring vulnerable candle filters.
3Productivity
If candle filters are used for ash separation, then ash removal is achieved, but installation and maintenance costs increase
Solution Approach 1:
The patent replaces expensive, maintenance-intensive candle filters with a more economical cooling section and cyclone configuration. The cooling section uses standard cooling elements and the cyclone is a robust, low-maintenance device, collectively providing ash removal at lower installation and maintenance costs compared to candle filter systems.
4Productivity
If high temperatures are used during ash separation, then separation efficiency improves, but ceramic candle filters become fragile and susceptible to cracks
Solution Approach 1:
Instead of using high temperature to maintain ceramic filter integrity, the patent inverts the approach by using a cooling section to reduce the temperature of ash particles before cyclone separation. This temperature reduction prevents thermal stress and cracking in the cyclone structure while maintaining effective separation through the cooled, condensed ash droplets.
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 solution enhances the efficiency and cost-effectiveness of gasification systems by eliminating the need for candle filters, reducing maintenance and installation costs, and enabling sufficient ash removal using cyclones alone, while maintaining system integrity and performance.
Implementation Method 1
a cooling section to cool the syngas stream to a temperature sufficient to condense and solidify the small slag droplets
Implementation Method 2
followed by a cyclone separator to separate the slag particles from the syngas stream
Data Source
AI summary
A slag agglomerator includes an inlet, an outlet and a plurality of obstacles. The inlet receives a flow of gas and slag droplets and the outlet allows the flow of gas and slag droplets to exit the agglomerator. The obstacles are oblique or perpendicular to the flow of gas and slag droplets and have an exterior surface containing a ceramic matrix composite.