Y-Type Entrained Flow Bed Gasification for Cement Clinker Co-Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The coal chemical industry faces challenges with high water and energy consumption in entrained flow gasification, leading to excessive wastewater generation and inefficient resource utilization, particularly due to the difficulty in controlling ash composition and residence time during the gasification process, which hampers the production of high-quality cement clinker.
Innovation Solution
A Y-type entrained flow bed gasification co-generation process is introduced, where coal is mixed with lime powder and water to create a slurry, then sprayed into a gasification furnace with a top nozzle and side nozzles to form a rotational strike and high temperature reaction zone, extending the residence time of residual ash and allowing for solidification on the furnace wall, followed by chilling and dry method slagging to produce cement clinker and recover thermal energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wet method slag discharge is used in existing entrained flow gasification, then slag can be discharged from the gasification furnace, but it causes excessive water consumption, generates hazardous wastewater and crystallization waste salts, and leads to agglomeration and blockage
Solution Approach 1:
The patent changes the temperature parameter of slag discharge from wet method (high temperature) to dry method (low temperature below 80°C). This parameter change eliminates the need for water in slag discharge, thereby reducing water consumption and avoiding the generation of hazardous wastewater and crystallization waste salts while preventing agglomeration and blockage
Solution Approach 2:
The patent extracts and removes the water-related steps from the slag discharge process. By implementing dry method slag discharge, the harmful effects of water consumption, wastewater generation, and salt crystallization are eliminated, while still achieving effective slag removal from the gasification furnace
2Productivity
If high temperature residual heat is not effectively utilized in existing gasification processes, then the gasification reaction can proceed, but energy consumption is high and resource utilization is inefficient
Solution Approach 1:
The patent converts the harmful high temperature residual heat into a beneficial resource by implementing heat recovery systems. The hot syngas and slag are used to generate steam and electricity, transforming waste heat into useful energy that reduces overall energy consumption and improves resource utilization efficiency
Solution Approach 2:
The patent recovers and reuses high temperature residual heat from both syngas and slag. The hot syngas is cooled to generate steam, and the hot slag is cooled to generate electricity, thereby recovering valuable thermal energy that would otherwise be wasted and reducing the overall energy consumption of the gasification process
3Productivity
If residence time of solid materials is short in gasification furnace, then gasification reaction is efficient, but ash and slag are in blended status making it difficult to control ash composition and produce high-quality cement clinker
Solution Approach 1:
The patent segments the gasification process into two distinct stages: a rapid gasification stage with short residence time for efficient carbon conversion, and a cooling/solidification stage with extended residence time for ash composition control and cement clinker formation. This segmentation allows each stage to optimize its specific function without compromising the other
4Adaptability or versatility
If coal gasification produces cement clinker, then resource utilization is enhanced, but the reducing atmosphere of gasification furnace and oxidizing atmosphere of combustion furnace create different conditions that increase difficulty in co-production
Solution Approach 1:
The patent creates a multi-functional gasification system that simultaneously performs carbon gasification, cement clinker production, and heat generation. By using a single gasification furnace with optimized conditions (temperature 1300-2000°C, extended residence time), the system eliminates the need for separate combustion furnaces and achieves co-production of syngas and cement clinker under unified atmospheric conditions
Data Source
AI summary
A gasification co-generation process of coal powder in a Y-type entrained flow bed, comprising: spraying coal water slurry or coal powder, gasification agent and water vapor into a gasification furnace through a top nozzle and a plurality of side nozzles for performing combustion and gasification with a residence time of 10 s or more; chilling the resulting slag with water, and subjecting the chilled slag to a dry method slagging to obtain gasification slag used as cement clinker; discharging the produced crude syngas carrying fine ash from the Y-type entrained flow bed to perform ash-slag separation.