Gasifier Slag Discharge System with Continuous Circulation Bypass
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Solution Overview
Problem
The existing slag discharge systems in gasifiers require intermittent operation of the circulation pump, leading to slag accumulation and blockages, and increased temperatures due to stagnation of slag water, which affects the efficiency and reliability of the discharge process.
Innovation Solution
A slag discharge system with a slag separation device, circulation pump, lock hopper, slag water reflux line, and optional bypass and stirring mechanisms that allow continuous operation of the pump, preventing blockages and maintaining slag water cooling by parallel operation of the slag discharge and reflux lines, and providing temporary storage and microfiltration to manage slag accumulation and concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the circulation pump is operated intermittently to discharge slag from the lock hopper, then the slag can be discharged from the lock hopper, but the circulation pump cannot operate continuously causing slag accumulation and blockage in the slag discharge line
Solution Approach 1:
The system divides the water flow path into two separate lines: a slag discharge line for transporting slag and a bypass line for continuous water circulation. This segmentation allows the circulation pump to operate continuously through the bypass line while slag is discharged through the discharge line, preventing both blockage and maintaining productivity.
Solution Approach 2:
The bypass line acts as an intermediary pathway that allows water to circulate continuously through the cooler and back to the slag hopper without passing through the lock hopper. This intermediary path enables continuous pump operation while slag discharge occurs separately through the main discharge line.
2Productivity
If the water flow is stopped during slag discharge from the lock hopper, then the slag can be discharged, but the slag water temperature increases due to lack of cooling
Solution Approach 1:
The water circulation system is segmented into two paths: the slag discharge line which stops during slag discharge, and the bypass line which continues to circulate water through the cooler. This segmentation allows slag discharge operations while maintaining continuous cooling through the bypass path, preventing temperature increase.
Solution Approach 2:
The bypass line is pre-configured to provide continuous cooling circulation independent of the slag discharge operation. This preliminary action ensures that cooling is already in place before slag discharge begins, preventing temperature increase during the discharge process.
3Length of stationary object
If the lock hopper is disposed on a lower portion of the gasifier to enable gravity-based slag discharge, then the installation position of the gasifier becomes high increasing the overall height, but if the lock hopper is disposed on the side at a lower level, then the overall height is reduced but continuous pump operation is required
Solution Approach 1:
The bypass line serves as an intermediary water flow path that enables continuous pump operation when the lock hopper is positioned at a lower level. This intermediary path compensates for the loss of gravity-based discharge by maintaining continuous circulation, allowing the system to achieve compact height while operating continuously.
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
Enables continuous operation of the circulation pump during slag discharge, prevents blockages, and maintains slag water cooling, ensuring efficient and reliable slag handling without increasing the temperature of the slag water.
Implementation Method 1
a water flow from the slag hopper to the slag separation device is formed in the slag discharge line by a circulation pump
Implementation Method 2
a slag separation device which is connected to a downstream end of the slag discharge line and separates the slag from the mixture of the slag and the slag water
Implementation Method 3
the slag falls into the slag water, is rapidly cooled to be solidified and crushed
Implementation Method 4
it is possible to continuously operate the circulation pump even when the slag of the lock hopper is discharged, preventing the blockage of the intake of the slag discharge line, and preventing an increase of the temperature of the slag water
Data Source
AI summary
This slag discharge system (1) includes: a slag hopper (5) of a coal gasifier (2); a slag discharge line (7) that discharges a mixture of slag and slag water (W); a slag separation device (10) that separates the slag from the mixture of slag and slag water (W); a circulation pump (24) that forms a water flow from the slag hopper (5) to the slag separation device (10) in the slag discharge line (7); a lock hopper (14) that stores slag which has been separated at the slag separation device (10) and discharges the same out of the coal gasifier (2) system; a slag discharge valve (15) that is provided on a lower outlet of the lock hopper (14); and a slag water return flow line (20) for returning the slag water (W) which has been separated at the slag separation device (10) to the slag hopper.