Stirling Engine Residual Gas Recovery with Diffusion Chamber
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Solution Overview
Problem
Current systems for converting energy from residual gases in industrial processes, such as those from smelting plants, face inefficiencies due to poor mixing and asymmetric flame propagation at atmospheric pressures, leading to wasted energy and increased CO2 emissions.
Innovation Solution
A system comprising a combustion chamber with a fuel inlet nozzle for dispersing residual gas and an air inlet, combined with a Stirling engine and a gas diffusion chamber that ensures a symmetric velocity profile for the residual gas flow, optimizing mixing and flame propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If residual gas is combusted in an internal flare unit with a Stirling engine, then energy is converted to electricity, but mixing of fuel and air and flame propagation are deteriorated due to atmospheric pressure
Solution Approach 1:
The patent changes the pressure parameter from atmospheric to superatmospheric (above 1 atm) to improve flame propagation and mixing characteristics. This parameter change enables the combustion process to operate more efficiently while maintaining the energy conversion function of the Stirling engine system.
Solution Approach 2:
The system dynamically adjusts operating parameters including pressure, temperature, and flow rates to optimize both energy conversion efficiency and flame propagation. The dynamic operation allows the system to adapt to varying residual gas compositions and maintain optimal performance.
2Productivity
If high pressure injectors are used to optimize flame propagation, then mixing and combustion are improved, but energy efficiency deteriorates due to pressurizing energy consumption
Solution Approach 1:
The system uses the residual gas itself to provide the pressurization needed for optimal combustion. The combustion process and heat release naturally drive the pressurization and flow dynamics, eliminating the need for external energy-consuming compressors or pumps.
Solution Approach 2:
The patent introduces an intermediary mechanism (such as a diffuser or flow conditioning element) that transforms the combustion process into a source of pressure generation, which then feeds back to improve mixing and flame propagation without requiring external energy input.
3Productivity
If residual gas flow has asymmetric velocity profile, then poor mixing occurs, but uniform flame propagation cannot be achieved
Solution Approach 1:
The patent intentionally introduces asymmetric flow conditioning elements or geometric features in the combustion chamber that convert the asymmetric velocity profile into a more uniform flow pattern. These asymmetric features create flow redistribution that promotes even mixing and uniform flame propagation across the combustion zone.
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 achieves efficient energy conversion by ensuring uniform flame propagation and heat distribution across the heat exchanger, maximizing energy conversion efficiency and reducing CO2 emissions.
Implementation Method 1
a nozzle for dispersing the residual gas and facilitating mixing of the residual gas and air
Implementation Method 2
an external flare stack uses pressurized steam in order to create turbulence around the flare tip such that proper mixing of air and residual gas is obtained
Implementation Method 3
The gas diffusion chamber comprises a residual gas inlet through which the residual gas enters the gas diffusion chamber from the residual gas duct, and a residual gas outlet being in fluid communication with the fuel inlet of the combustion chamber. The residual gas is transported in a diffusion direction from the residual gas inlet to the residual gas outlet through the gas diffusion chamber.
Implementation Method 4
a combustion chamber (2) having a fuel inlet (3) configured to receive a flow of residual gas for combustion in the combustion chamber (2)
Implementation Method 5
a Stirling engine (5) having a heat exchanger (6) having a cross-section. A portion of the heat exchanger (6) extends into the combustion chamber (2)
Implementation Method 6
the energy that may be present in the residual gas is transferred into a heat exchanger which drives a heat engine to produce electricity
Data Source
AI summary
A system for conversion of energy in a residual gas generated in an industrial process. The system includes a combustion chamber having a fuel inlet configured to receive a flow of residual gas for combustion in the combustion chamber. The combustion chamber further includes an air inlet. The system also includes a Stirling engine configured to convert heat from the combustion chamber into mechanical energy, the Stirling engine having a heat exchanger, wherein at least a portion of the heat exchanger extends into the combustion chamber. The system further includes a residual gas duct arranged for transporting the residual gas at atmospheric or near atmospheric pressure and an air duct arranged for transporting air at atmospheric or near atmospheric pressure. The system further includes a gas diffusion chamber including a residual gas inlet through which the residual gas enters the gas diffusion chamber from the residual gas duct, and a residual gas outlet in fluid communication with the fuel inlet of the combustion chamber, wherein the residual gas is transported in a diffusion direction from the residual gas inlet to the residual gas outlet. The gas diffusion chamber has such a shape that the flow of residual gas at the fuel inlet is substantially laminar and has a symmetric velocity profile.