Steam Generator Cyclone Separator for Particle Removal
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Solution Overview
Problem
Existing steam generators have complex constructions that fail to effectively separate aerosols and fine ash particles from flue gases, leading to caking and glazing issues on pipes, which damages components and requires complex downstream separation methods.
Innovation Solution
Incorporating a cyclone separator between the first and second passes of the steam generator to separate coarse and fine particles, including aerosols, and utilizing a compact tube-fin-tube evaporator design with a recirculation gas line for optimized combustion and heat utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional steam generator construction without integrated particle separation is used, then the construction is simpler, but aerosols and fine ash particles cannot be separated from flue gases, leading to caking and glazing on pipes that damage components
Solution Approach 1:
The patent combines the particle separation function with the existing steam generator structure by integrating a cyclone separator into the flue gas pathway between the first and second passes. This merging approach enables effective aerosol and fine ash particle removal without adding completely separate downstream separation systems, thus improving component protection while controlling construction complexity.
Solution Approach 2:
The cyclone separator is positioned to perform particle separation before the flue gases enter the second pass with heat exchange components. This preliminary action removes harmful particles in advance, preventing caking and glazing on pipes before they occur, thereby protecting components proactively rather than requiring complex remedial systems.
2Reliability
If downstream separators are added to remove fine ash particles, then particle removal effectiveness improves, but the device complexity and cost increase significantly
Solution Approach 1:
Instead of adding separate downstream separation systems, the patent merges the particle separation function into the existing steam generator structure by utilizing the space between the first and second passes for a cyclone separator. This integrated approach achieves effective particle removal while avoiding the complexity and cost of completely separate downstream separation equipment.
Solution Approach 2:
The cyclone separator acts as an intermediary device that handles particle separation within the existing steam generator framework. By positioning it between the first and second passes, it serves as a mediating component that removes particles before they reach vulnerable heat exchange surfaces, eliminating the need for complex downstream separation systems.
3Use of energy by moving object
If a compact tube-fin-tube evaporator design is used, then heat utilization efficiency improves, but the construction becomes more complex
Solution Approach 1:
The patent employs a tube-fin-tube evaporator design that changes the geometric parameters of the heat exchange structure by adding fins to the tubes. This parameter change significantly increases the heat transfer surface area and improves heat utilization efficiency, allowing maximum temperature of flue gases to be used efficiently to convert feed water into steam.
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 results in a simplified, compact, and cost-effective steam generator with almost particle-free flue gases, reducing component damage and enabling efficient heat utilization, with improved combustion efficiency and reduced emissions.
Implementation Method 1
the integration of a cyclone between the first and second pass makes it possible to separate coarse as well as very fine particles or aerosols from the flue gas
Implementation Method 2
a separating device, in particular a cyclone, arranged between the first and the second pass
Implementation Method 3
an evaporator for generating the steam... the evaporator of the first pass of the steam generator comprises a tube-fin-tube design through which water/steam can flow
Implementation Method 4
The flue gases from the grate firing that flow upwards through the evaporator
Implementation Method 5
at least one second pass with at least one superheater... in which the steam is heated to the temperature required for the consumer
Implementation Method 6
at least one second pass with at least one superheater and/or at least one economizer... through which they flow downwards
Implementation Method 7
the outflow area of the second pass is connected to the combustion chamber via a recirculation gas line, so that at least part of the flue gases cooled in the second pass of the steam generator can be returned to the combustion chamber
Data Source
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AI summary
The generator has a combustion chamber (11) and a vaporizer (13) arranged in a traction unit (1). A heat exchanger (15a), a super-heater (21), an air pre-heater and/or an economizer (22) are arranged in another traction unit (2). A stoker-fired furnace (12) is arranged in the combustion chamber. A separation device (3) e.g. cyclone, is arranged between the traction units. The separation device is used for depositing a particulate matter e.g. aerosol, to the traction units. The latter traction unit is connected with the combustion chamber over a recirculation gas line (23). An independent claim is also included for a steam plant comprising a hot gas spacer.