Slag Bath Valve Gas Bubble Control for Flow and Vapor Management
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Solution Overview
Problem
The existing methods for removing slag in synthesis gas production face challenges such as slag getting stuck in constrictions and the release of environmentally harmful vapors, with current solutions like pumping low-solids water or using vacuum gas bubbles not fully addressing these issues effectively.
Innovation Solution
A method involving a short, intensive counterflow of gas or water through the sluice valve to loosen compressed slag, along with cooled water injection to generate a countercurrent and swirl in the slag collection tank, and a system design that includes a narrowed flow channel and external cooling to manage temperature and improve slag flow, while also capturing vapors for environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pumping low-solids water from downstream container to upstream container is used to improve flow, then flow through constrictions is improved, but device complexity and energy consumption increase
Solution Approach 1:
The patent uses a vacuum gas bubble in the head area of the downstream container to create a suction effect that pulls the water/slag stream through the valve areas, eliminating the need for mechanical pumping systems while achieving improved flow rates
Solution Approach 2:
The system uses the vacuum effect generated by the gas bubble itself to drive the flow, where the vacuum suction automatically pulls the slurry through the constrictions without requiring external pumping equipment, making the system self-regulating
2Productivity
If vacuum gas bubble is used to increase flow rate, then flow through valve areas is improved, but control precision and system stability deteriorate
Solution Approach 1:
The system dynamically adjusts the vacuum level by controlling the gas bubble volume in the head area, allowing the flow rate to be regulated through pressure differential changes rather than mechanical valve control, improving both flow rate and control precision
3Productivity
If high temperature operation is maintained in slag formation process, then productivity is improved, but harmful vapor emission increases
Solution Approach 1:
The patent introduces a cooling section with water injection as an intermediary between the high-temperature slag formation zone and the discharge point, where the water cools the slag and condenses harmful vapors before release, allowing high-temperature operation to continue while preventing vapor emission
Solution Approach 2:
The system converts the harmful hot vapors into beneficial cooled slag by injecting water in the cooling section, where the water absorbs heat and condenses vapors, transforming the harmful thermal energy into a cooling mechanism that prevents environmental harm
4Temperature
If slag is quenched and cooled in water reservoir, then temperature control is improved, but slag flowability and discharge efficiency deteriorate
Solution Approach 1:
The cooling process is segmented into multiple zones: initial quenching in the water reservoir, followed by a cooling section with controlled water injection, and finally a discharge zone, allowing temperature control in early stages while maintaining flowability in later stages
Solution Approach 2:
The cooling intensity is varied locally through the cooling section, where water is injected only in specific areas to create localized cooling zones that condense vapors without excessively cooling the bulk slag, maintaining its flowability for efficient discharge
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 ensures optimal slag flow, prevents environmental harm by capturing vapors, and effectively manages high temperatures in the slag formation process, enhancing overall efficiency and safety in slag removal.
Implementation Method 1
a short, e.g. lasting a few seconds, intensive counterflow of gas or water through the upper sluice valve can loosen any bridges of compressed, wedged slag or large particles in order to ensure an optimal flow
Implementation Method 2
a countercurrent against the slag flow is generated in the slag collection/lock container by feeding in colder water
Implementation Method 3
the slag/water flow is cooled
Implementation Method 4
A tangential or secantial feed of the water is advantageous in order to generate swirl and improve cooling
Implementation Method 5
following the constriction a narrowed flow channel is provided, in which the slag/water flow is cooled
Implementation Method 6
a system design that includes a narrowed flow channel and external cooling to manage temperature
Data Source
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AI summary
A method for removing slag accumulating in particular during synthesis gas recovery from slag present in a pressurized container bath in a collecting tank for the slag, in the direction of gravity under the slag bath, wherein optionally a mechanism for breaking the slag is provided under the slag bath and a sluice valve is provided between the containers, is to clearly improve the corresponding processes and plants of the relevant kinds by improving withdrawal of slag and by preventing environmentally harmful exhaust vapors or waste gases. This is achieved in that a space that is in contact with the liquid in the containers and is filled with a gas bubble is provided, in particular an annular space or a separate container, in which the pressure of the gas bubble is controlled by gas supply such that at least part of the water present in the slag sluice/collection space flows through the slag bath valve against the direction of gravity in the direction of the slag bath when the slag bath valve is opened.