Slag Discharge System with Reverse Flow Backwashing
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Solution Overview
Problem
The existing slag discharge systems in gasifiers face blockages due to high-density slag accumulation, particularly during start-up or temporary shutdown, which can hinder the operation of the gasifier.
Innovation Solution
A slag discharge system with a reverse flow operation mode that uses a circulation pump to create a water stream for slag removal and includes a reverse flow line for backwashing to prevent blockages, along with a selective supply unit to manage water flow and a water supply line for external water use, ensuring continuous operation without external water dependency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the lock hopper is disposed below the gasifier to utilize gravity for slag discharge, then the slag discharge efficiency is improved, but the height from the installation surface to the upper part of the gasifier is increased
Solution Approach 1:
The patent inverts the conventional downward gravity-based discharge by implementing an upward water stream-based discharge. The circulation pump creates an upward water stream in the slag discharge line that carries slag from the slag bath to the lock hopper disposed at the same level or higher, eliminating the need for height differential while maintaining discharge efficiency
Solution Approach 2:
The patent employs hydraulic principles by using a water stream generated by a circulation pump to transport slag. The water stream carries slag particles upward through the slag discharge line to the lock hopper, replacing gravity-based discharge with fluid dynamics-based transport
2Length of stationary object
If the circulation pump is used to create a water stream for slag removal, then the slag can be discharged to the lock hopper at the same level, but the system becomes dependent on external water supply
Solution Approach 1:
The system uses itself to provide the necessary water for slag discharge. The circulation pump draws water from the slag bath itself and creates the water stream needed for slag transport, eliminating the need for external water supply systems while maintaining continuous operation capability
Solution Approach 2:
The slag cooling water in the slag bath serves multiple functions: it cools the slag, provides the fluid medium for slag suspension, and acts as the working fluid for the circulation pump to generate the water stream for slag discharge, eliminating the need for separate water supply systems
3Productivity
If the slag suction port is positioned at the bottom to maximize slag removal, then the slag discharge capability is improved, but the suction port becomes vulnerable to blockage by accumulated slag
Solution Approach 1:
The system performs preliminary action by continuously circulating water through the slag bath before slag accumulation reaches blocking levels. The circulation pump maintains a constant water stream that prevents slag from settling and accumulating around the suction port, proactively preventing blockages rather than reacting to them
Solution Approach 2:
The circulation pump operates continuously to maintain an uninterrupted water stream through the slag discharge line. This continuous flow prevents slag from accumulating and blocking the suction port or discharge line, ensuring uninterrupted slag removal capability while maintaining system reliability
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
The system effectively prevents blockages in the slag suction port and discharge line, ensuring smooth gasifier operation by using reverse flow and external water supply to manage slag accumulation and prevent vacuum formation.
Implementation Method 1
a water stream from the slag bath to the lock hopper is formed in the slag discharge line by a circulation pump
Implementation Method 2
a reverse flow line having one end connected to the slag cooling water feed line, and the other end connected to a downstream side of the circulation pump
Implementation Method 3
a selective supply unit which makes it possible to selectively supply the slag cooling water discharged from the circulation pump to the slag cooling water circulation line and the reverse flow line
Data Source
AI summary
A system is disclosed provided with: a slag bath that retains slag cooling water and receives slag; a slag cooling water feed line and a slag pump outlet via which the slag and the slag cooling water are pumped and fed to a slag separation device; a circulation pump that forms a water flow for pumping out the slag; a slag cooling water circulation line linking from the slag separation device to the slag bath; a reverse flow line that causes the slag cooling water dispensed from the circulation pump to flow in reverse in the slag cooling water feed line; a selective supply unit capable of selectively supplying the slag cooling water dispensed from the circulation pump to the slag cooling water circulation line and the reverse flow line; and a water supply line, one end of which is connected to the slag cooling water feed line.