Steam Injector Mixing Helical Projections for Feedstock Viscosity
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Solution Overview
Problem
Gasification systems face inefficiencies due to high viscosity of feedstocks, which increases energy consumption and wear on equipment, and reduces throughput, as they enter the gasifier.
Innovation Solution
A steam injector is used to mix steam with the feedstock, increasing its temperature and decreasing viscosity, facilitated by a mixing feature that induces rotation, such as helical projections, to uniformly distribute steam and heat the feedstock before it enters the gasifier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional heat exchangers are used to heat feedstock, then feedstock temperature increases and viscosity decreases, but equipment complexity and maintenance costs increase
Solution Approach 1:
The steam injector combines the heating function and mixing function into a single device. Steam is injected directly into the feedstock stream and mixed through turbulent mixing and rotation, eliminating the need for separate heat exchanger equipment while achieving the same temperature increase and viscosity reduction.
Solution Approach 2:
The invention uses steam (a gas) injected under pressure to heat and mix with the liquid feedstock. The high-velocity steam jet creates turbulent mixing and induces rotation in the feedstock, using pneumatic energy to achieve both heating and mixing functions simultaneously.
2Stability of the object's composition
If steam is injected without rotation induction, then mixing occurs, but mixing uniformity and heating efficiency are insufficient
Solution Approach 1:
The steam injector incorporates a rotation induction element with curved or helical geometry that induces swirling motion in the feedstock stream. This rotational flow pattern enhances mixing uniformity by creating radial and axial velocity components, ensuring thorough distribution of steam throughout the feedstock while maintaining high heating efficiency.
3Productivity
If feedstock viscosity is high, then equipment wear increases and energy consumption increases, but throughput must be maintained
Solution Approach 1:
The steam injector performs preliminary heating of the feedstock before it enters the gasifier. By increasing the feedstock temperature and reducing its viscosity in advance, the system reduces energy consumption and equipment wear during subsequent processing operations, while maintaining required throughput levels.
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 reduces the viscosity of the feedstock, enhancing throughput and efficiency by pre-heating it before gasification, while minimizing equipment wear and maintenance costs compared to traditional heat exchangers.
Implementation Method 1
a mixing feature configured to induce rotation of the feedstock to facilitate mixing the steam flow with the feedstock
Implementation Method 2
mix the steam and the feedstock to form the heated feedstock
Data Source
AI summary
A system includes a first steam injector configured to mix a steam and a feedstock to form a heated feedstock. Additionally, first viscosity of the feedstock is greater than a second viscosity of the heated feedstock. The system also includes a feed system positioned upstream of the first steam injector and configured to supply the feedstock to the first steam injector. In addition, the system includes a steam system configured to supply the steam to the first steam injector. Furthermore, the system includes a gasifier coupled to the first steam injector and configured to receive the heated feedstock.