EP4396497B1 - System zur selbsttragenden verbrennung von eisenpartikeln und verfahren dafür - Google Patents

System zur selbsttragenden verbrennung von eisenpartikeln und verfahren dafür

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Publication number
EP4396497B1
EP4396497B1 EP22862465.6A EP22862465A EP4396497B1 EP 4396497 B1 EP4396497 B1 EP 4396497B1 EP 22862465 A EP22862465 A EP 22862465A EP 4396497 B1 EP4396497 B1 EP 4396497B1
Authority
EP
European Patent Office
Prior art keywords
air flow
tube
iron
iron particles
combustion
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP22862465.6A
Other languages
English (en)
French (fr)
Other versions
EP4396497A1 (de
EP4396497C0 (de
EP4396497A4 (de
Inventor
Jeffrey Myles BERGTHORSON
Samson BOWEN-BRONET
Martin ARALOV
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Royal Institution for the Advancement of Learning
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Royal Institution for the Advancement of Learning
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Publication of EP4396497A1 publication Critical patent/EP4396497A1/de
Publication of EP4396497A4 publication Critical patent/EP4396497A4/de
Application granted granted Critical
Publication of EP4396497C0 publication Critical patent/EP4396497C0/de
Publication of EP4396497B1 publication Critical patent/EP4396497B1/de
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
    • F23C1/00—Combustion apparatus specially adapted for combustion of two or more kinds of fuel simultaneously or alternately, at least one kind of fuel being either a fluid fuel or a solid fuel suspended in a carrier gas or air
    • F23C1/12—Combustion apparatus specially adapted for combustion of two or more kinds of fuel simultaneously or alternately, at least one kind of fuel being either a fluid fuel or a solid fuel suspended in a carrier gas or air gaseous and pulverulent fuel
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G OR C10K; LIQUIFIED PETROLEUM GAS; USE OF ADDITIVES TO FUELS OR FIRES; FIRE-LIGHTERS
    • C10L5/00—Solid fuels
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
    • F23C7/00—Combustion apparatus characterised by arrangements for air supply
    • F23C7/002—Combustion apparatus characterised by arrangements for air supply the air being submitted to a rotary or spinning motion
    • F23C7/004—Combustion apparatus characterised by arrangements for air supply the air being submitted to a rotary or spinning motion using vanes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
    • F23C9/00—Combustion apparatus characterised by arrangements for returning combustion products or flue gases to the combustion chamber
    • F23C9/006—Combustion apparatus characterised by arrangements for returning combustion products or flue gases to the combustion chamber the recirculation taking place in the combustion chamber
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23D—BURNERS
    • F23D1/00—Burners for combustion of pulverulent fuel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23D—BURNERS
    • F23D17/00—Burners for combustion simultaneously or alternately of gaseous or liquid or pulverulent fuel
    • F23D17/005—Burners for combustion simultaneously or alternately of gaseous or liquid or pulverulent fuel gaseous or pulverulent fuel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J15/00—Arrangements of devices for treating smoke or fumes
    • F23J15/02—Arrangements of devices for treating smoke or fumes of purifiers, e.g. for removing noxious material
    • F23J15/022—Arrangements of devices for treating smoke or fumes of purifiers, e.g. for removing noxious material for removing solid particulate material from the gasflow
    • F23J15/025—Arrangements of devices for treating smoke or fumes of purifiers, e.g. for removing noxious material for removing solid particulate material from the gasflow using filters
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J15/00—Arrangements of devices for treating smoke or fumes
    • F23J15/02—Arrangements of devices for treating smoke or fumes of purifiers, e.g. for removing noxious material
    • F23J15/022—Arrangements of devices for treating smoke or fumes of purifiers, e.g. for removing noxious material for removing solid particulate material from the gasflow
    • F23J15/027—Arrangements of devices for treating smoke or fumes of purifiers, e.g. for removing noxious material for removing solid particulate material from the gasflow using cyclone separators
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G OR C10K; LIQUIFIED PETROLEUM GAS; USE OF ADDITIVES TO FUELS OR FIRES; FIRE-LIGHTERS
    • C10L2200/00—Components of fuel compositions
    • C10L2200/02—Inorganic or organic compounds containing atoms other than C, H or O, e.g. organic compounds containing heteroatoms or metal organic complexes
    • C10L2200/0204—Metals or alloys
    • C10L2200/024—Group VIII metals: Fe, Co, Ni, Ru, Rh, Pd, Os, Ir, Pt
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G OR C10K; LIQUIFIED PETROLEUM GAS; USE OF ADDITIVES TO FUELS OR FIRES; FIRE-LIGHTERS
    • C10L2250/00—Structural features of fuel components or fuel compositions, either in solid, liquid or gaseous state
    • C10L2250/06—Particle, bubble or droplet size
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23B—METHODS OR APPARATUS FOR COMBUSTION USING ONLY SOLID FUEL
    • F23B2900/00—Special features of, or arrangements for combustion apparatus using solid fuels; Combustion processes therefor
    • F23B2900/00003—Combustion devices specially adapted for burning metal fuels, e.g. Al or Mg
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
    • F23C2700/00—Special arrangements for combustion apparatus using fluent fuel
    • F23C2700/06—Combustion apparatus using pulverized fuel
    • F23C2700/063—Arrangements for igniting, flame-guiding, air supply in
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23D—BURNERS
    • F23D2204/00—Burners adapted for simultaneous or alternative combustion having more than one fuel supply
    • F23D2204/20—Burners adapted for simultaneous or alternative combustion having more than one fuel supply gaseous and pulverulent fuel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23J—REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J2217/00—Intercepting solids
    • F23J2217/40—Intercepting solids by cyclones

Definitions

  • This disclosure generally relates to the field of metal fuel combustion, more specifically to a system and method for producing a self-sustained turbulent iron flame with iron particles.
  • CN111853762 which describes an aluminum flame igniting with methane and a mixture of air and oxygen.
  • '762 describes a burner with a plurality of micro-holes having a diameter of 0.8 mm that stabilize the aluminum flame.
  • '762 reports using a flat flame burner to obtain the stabilized laminar aluminum flame that burns without the continuous addition of methane. Accordingly, although a stabilized flame was obtained without a hydrocarbon feed, the scalability of a flat flame burner is limited.
  • a continuous combustion system for iron particles comprising: a multi-annular combustion tube having an inlet and an outlet, the multi-annular combustion tube defining in cross-section at least three distinct passages from the inlet to the outlet; the multi-annular tube comprising:
  • the system further comprises an air gap that provides a quaternary air flow into the cyclonic inlet is defined between the cyclonic inlet and the reactor outlet.
  • the system further comprises a quaternary flow provided in the combustion reactor by a pressurized air flow through injection ports in the combustion reactor.
  • the multi-annular combustion tube is a triple concentric tube.
  • the system further comprises a filter downstream of the cyclonic separator to capture the oxidized iron particles that escape the cyclonic separator.
  • the system further comprises a magnetic separator downstream of or incorporated in the cyclonic separator.
  • the system further comprises a temperature controlling system coupled to the cyclonic separator.
  • the system further comprises an energy generator.
  • the energy generator is selected from a heat engine, a Stirling engine or a steam engine.
  • the inner annular space further comprises flame arrestor beads.
  • the system further comprises pressure valves in the inner annular space to relieve the pressure in case of pressure build-up.
  • the system further comprises a metal-fuel storage compartment comprising a metal-fuel powder silo and a compressed air system coupled to the metal-fuel powder silo providing the primary air flow with the iron particles suspended.
  • the system further comprises a combustible shut-off valve.
  • the system further comprises an enclosure that reflects radiation, the enclosure housing the combustion reactor.
  • a method of burning iron particles comprising: providing multi-annular flow to a combustion reactor through a divergent nozzle, the multi-annular flow comprising:
  • the method further comprises providing a quaternary air flow upstream of the cyclone to control the temperature and further oxidize the iron particles.
  • the pilot combustible flow is provided for less than 1 minute.
  • the step of recovering the oxidized iron particles includes controlling the temperature of the walls of the cyclone.
  • the iron particles have a size of between 1 and 100 ⁇ m.
  • the oxidized iron particles are at least 60 % by weight magnetite (Fe 3 O 4 ).
  • the oxidized iron particles comprise less than 1 % of particles having a size of less than 8 ⁇ m.
  • a continuous combustion system for iron particles as a fuel that achieves a sustained turbulent iron flame without the addition of a combustible (e.g. a hydrocarbon fuel) other than to ignite the flame.
  • a combustible e.g. a hydrocarbon fuel
  • the combustion of iron similarly to other fuels, will produce heat which can be captured to produce electricity or heated water, or used as is.
  • Iron as a fuel source is advantageous because iron is non-toxic, non-explosive and safe to transport and store.
  • the combustion of iron does not produce any carbon contaminants such as CO and CO 2 in contrast with fossil fuels and coal where the emissions of CO 2 are of great concern for the atmosphere. Accordingly, an essentially carbon free power system that is sustainable is achieved.
  • the gas exhaust of an iron burner can be released into the atmosphere without any significant environmental concerns because the product obtained has a negligible content of iron oxide nanoparticles, CO 2 , and nitrogen oxide (NOx: NO and NO2) species.
  • iron oxide nanoparticles CO 2 , and nitrogen oxide (NOx: NO and NO2) species.
  • NOx nitrogen oxide
  • iron is an abundant element that can advantageously be recycled and reused.
  • the sustainability of the present system and methods is further supported by capturing the oxidized iron particles so that they can be reduced (recycled) back to their original non-oxidized form.
  • a high recovery or capture efficiency of oxidized iron particles of more than 97%, and in some embodiments more than 99% is achieved.
  • the recovery is performed with a cyclone which can eliminate the need for consumables such as filters, wet scrubbers and the like.
  • a continuous cycle of recyclable fuel that does not introduce CO 2 into the atmosphere can be implemented to replace other non-sustainable fuels.
  • iron particles refers to micron size particles of iron, for example an iron powder.
  • the iron particles have a diameter of between 1 ⁇ m and 500 ⁇ m, between 1 ⁇ m and 200 ⁇ m, between 1 ⁇ m and 100 ⁇ m, between 10 ⁇ m and 100 ⁇ m, between 20 ⁇ m and 100 ⁇ m, between 10 ⁇ m and 50 ⁇ m or between 20 ⁇ m and 50 ⁇ m.
  • An advantage of the iron particles of the present invention is that they do not need to have a uniform particle distribution.
  • the terms “burn”, “burning”, “burnt” and the like in the context of the combustion of iron particles refer to the oxidation reaction that iron undergoes in a turbulent iron flame.
  • turbulent iron flame refers to a flame sustained by the combustion of iron particles in a turbulent flow profile. The turbulent iron flame therefore does not have a constant shape nor a constant size, in contrast with a laminar flame which is generally characterized by a constant conical shape.
  • the terms “stabilize”, “stabilization”, “sustained”, “self-sustained” and the like in the context of the turbulent iron flame mean that the turbulent iron flame can burn and continue burning by combusting the iron particles without the addition of an external stimuli such a combustible such as a hydrocarbon.
  • the present invention has demonstrated experimentally the heterogeneous combustion of iron with negligible production of nanometric iron oxides.
  • the iron particles start to burn in the solid phase, producing solid iron oxides.
  • the combustion products can contain ferrous oxide (FeO), or wüstite, in a liquid state.
  • FeO ferrous oxide
  • the iron particles burn as liquid droplets.
  • the melting point of iron(III) or hematite and then above 1870 K, the melting point of iron (II, III) oxide, or magnetite, liquid iron droplets are burned to produce liquid iron oxides.
  • the present invention demonstrates efficient combustion of iron particles with a limited production of iron oxide nanoparticles. In some embodiment, the present invention does not produce any iron oxide nanoparticles from the combustion of iron.
  • Figure 1 illustrates a longitudinal cross section of a combustion zone 1 of the continuous combustion system according to the present invention.
  • the multi-annular combustion tube can comprise three or more combustion tubes.
  • the multi-annular combustion tube is composed of a first tube 10, a second tube 20, and a third tube 30.
  • the first tube 10 is innermost and defines a first passage providing a primary air flow 11.
  • the primary air flow 11 has iron particles 12 suspended in air 13.
  • Solid iron particles are dense and rapidly settle in a quiescent environment. In order to keep them in suspension, a minimum level of either laminar or turbulent air/gas flow is required. In addition, the combustion of solid iron particles depends on their size distribution and morphology. The flow rate required to suspend larger iron particles can exceed the laminar burning velocity of the iron flame. Therefore, turbulent flow is essential to stabilizing heavily laden or large particle flows. Generally, turbulent flames are suited for scalability (including large industrial scale) while laminar flames are not. In addition, the turbulence in a turbulent iron flame causes mixing which in turn increases the efficiency of the combustion. This is in contrast with a laminar flow where limited mixing occurs. The use of laminar flames is limited to laboratory or domestic scale.
  • a dispersion of iron particles at an appropriate iron mass flow rate is needed. This can be achieved with a powder dispersion device connected to an iron-fuel storage compartment comprising an iron particle silo and by sizing of the central iron pipe along with an additional air flow provided by a compressed air system that can be adjusted to form the primary air flow 11.
  • the primary air flow 11 helps control the velocity and concentration of the iron-air mixture.
  • the appropriate iron mass flow rate will vary based on the scale of the system. In one embodiment, the appropriate mass flow rate of iron is between 1 g/s to 2 g/s, which yields a thermal power of roughly 10 kW for a final reaction product being magnetite.
  • FIG 2 shows a radial cross section across line A-A the multi-annular tube of Figure 1 .
  • the multi-annular tube 2 is a triple concentric tube that comprises the first tube 10, the second tube 20, and the third tube 30.
  • the pre-combustion section 3 is shown.
  • the multi-annular tube can be supported by a base plate 14.
  • the second tube 20 is optionally supported by a secondary tube holder 25 and can comprise a combustible tube 20a that is optionally supported by a combustible tube holder 26.
  • a second passage is defined in the inner annular space between the first tube 10 and the second tube 20.
  • a secondary air flow 21 is provided in the inner annular space, the secondary air flow 21 comprises a combustible as a fuel and air during ignition and air during combustion.
  • the term "combustible" as used herein refers to a species that can be used to a ignite flame with a spark stimulus.
  • the combustible can be a hydrocarbon fuel, hydrogen or any suitable gas that ignites to obtain a flame, for example methane, ethane, propane or butane.
  • the secondary air flow 21 is a mixture of a combustible flow 21a and an air flow 21b.
  • the second tube 20 has a flame arrestor mechanism 22, for example flame arrestor beads such as ceramic beads that are enclosed in a porous housing 23 (e.g. a mesh).
  • the second tube 20 comprises an ignition point of a spark generator to generate a pilot flame 24.
  • the flame arrestor mechanism 22 avoids flashback. Flashback is the phenomenon where a flame burns too quickly compared to the incoming flow and travels back to the source of the flow which can lead to explosion.
  • the section of the second tube 20 where a combustible and air mix can be equipped with a pressure relief valve 27, which automatically opens if pressure were to build up.
  • the pilot flame 24 that is established is used to ignite the incoming iron particles 12 to produce a turbulent iron flame 51. Once the turbulent iron flame 51 has been ignited and has stabilized, the pilot flame 24 is extinguished. The pilot flame 24 may be extinguished by closing a combustible shut-off valve.
  • the stabilization of the turbulent iron flame 51 is achieved in part thanks to the tertiary air flow 31.
  • the tertiary air flow 31 is provided in an outer annular space defined between the second tube 20 and the third tube 30.
  • the third tube comprises a swirl generator 32 and a lateral air inlet 33.
  • the air flow 31 passes through the swirl generator 32 to become a turbulent swirling flow.
  • the swirl generator 32 comprises a mount 32a, a bottom plate 32b and a top plate 32c.
  • Figure 4A illustrates an exemplary embodiment of a bottom plate 32b
  • Figure 4B illustrates an exemplary embodiment of a top plate 32c.
  • Both the top plate 32b and the bottom plate 32c have an o-ring 34 and prism shaped protrusions 35.
  • the prism shaped protrusions 35 of the bottom plate 32b and the top plate 32c can be arranged to interlock and form radial channels, can be arranged to interlock and form tangential channels, or can be positioned so as the protrusions 35 are not in contact and form a series of both radial and tangential channels.
  • Figures 4C and 4D show an exemplary assembly of the bottom plate 32b and the top plate 32c to form a swirl generator 32. The different configurations possible by moving the plates of the swirl generator 32 relative to each other allow the formation of various optimizable gaseous swirls.
  • this exemplary swirl generator 32 is suitable for optimizing the swirl at a laboratory scale however other swirl generators 32 are contemplated by the present invention for example at industrial scale.
  • the present invention is not limited to the exemplified swirl device of Figures 4A-4D and includes other swirl geometries such as fixed-vane swirlers and variable-vane swirlers.
  • Figure 5 shows a perspective cross section of the combustion zone 5.
  • a divergent nozzle 40 is positioned at the outlet of the multi-annular combustion tube.
  • the divergent nozzle 40 also known as a quarl, has a diverging geometry (for example a diverging diameter) downstream from the outlet of the multi-annular combustion tube.
  • the divergent nozzle 40 is a truncated cone as can be seen in Figure 5 .
  • the divergent nozzle is a frustum of a right circular cone.
  • frustum is to be understood as is known in the art, and can be defined as the basal part of a solid cone or pyramid formed by cutting off the top by a plane parallel to the base or the part of a solid intersected between two substantially parallel planes.
  • the divergent nozzle 40 helps stabilize the flame and direct the flow into the combustion reactor 50.
  • the use of a swirl generator 32 forms a central recirculation zone 53, which creates a reverse flow near the divergent nozzle 40. This helps stabilize the flame, but a jet with too large a velocity can still blow off a flame as the particles have too much inertia to stay in the recirculation zone 53.
  • turbulent burning velocities of iron or any metal
  • the combustion reactor 50 helps to contain, stabilize and guide the turbulent iron flame 51 so that its heat can be captured.
  • the walls 52 of the combustion reactor can be made of fused quartz or other suitable materials.
  • the combustion chamber is in fluid communication and hydraulically connected with the divergent nozzle 40.
  • the combustion chamber has an outlet 54 opposite the inlet.
  • the turbulent iron flame 51 extends throughout the combustion chamber 50 such that the secondary oxidation zone of the turbulent iron flame 51 reaches transiently the outlet 54.
  • a quaternary air flow can be introduced at the secondary oxidation zone 56 through an air gap 55 between the outlet 54 and the cyclonic inlet 61.
  • the quaternary air flow can be provided by a pressurized air flow entering the combustion chamber at various locations.
  • the secondary oxidation zone 56 extends into the cyclonic inlet 61.
  • the cyclonic inlet 61 may be elongated (e.g. linear tube, undulating tube, serpentine tube, etc.) to extend the secondary oxidation zone 56.
  • Figure 6A illustrates the quaternary air flow 57 entering at the air gap 55. Because of the suction at the cyclone 60, the pressure at the cyclonic inlet 61 is smaller than that of the reactor outlet 54.
  • the quaternary air flow 57 entering from the air gap is sucked into the cyclonic inlet 61 and does not substantially disrupt the flow in the reactor 50.
  • the quaternary air flow 57 allows for a temperature control that is critical to minimizing nanoparticle formation and preventing NOx formation.
  • the quaternary air flow 57 is provided by a pressurized air flow entering the combustion chamber 50 at various locations as illustrated in Figure 6B .
  • the air gap can be eliminated or sealed and air injection ports 58 on the combustion chamber 50 can be used instead.
  • Figure 6B shows a combustion chamber made out of several steel sections with optional viewing windows 59a, air injection ports 58 and optional air sampling ports 59b.
  • This combustion chamber can be fitted such that there is no air gap between the entrance of the cyclone ducting and the end of the combustion chamber.
  • the air injected at the quaternary injection ports was up to 1200 cm 3 /s, and the NOx measurements were below 3 ppm for all test conditions.
  • the embodiments of Figure 6A and Figure 6B provide similar flame stability and characteristics as well as NOx performance.
  • a cyclone 60 downstream of the reactor outlet 54 is a cyclone 60 having a cyclonic inlet 61, a gas outlet 62, and a particle outlet 63.
  • the cyclonic inlet 61 is in fluid communication with the combustion reactor 50.
  • the cyclonic inlet 61 and the reactor outlet 54 are physically separated so as to provide an air gap from which an additional air stream (to the burner flow rates) will flow into the cyclonic inlet 61. This has the effect of reducing the temperature of the particles and impeding the creation of nanometrically sized particles.
  • the cyclone receives hot, abrasive, oxidized iron particles.
  • Cyclones are usually designed to collect, dry, cold, larger, non-abrasive particles. In general, the higher the fluid mass flow (and velocity) through a cyclone, the higher its collection efficiency. Thus most prior art cyclones are designed to develop flow rates and velocities as high as possible for a given application. Commercial cyclones use relatively high flow rates, to remove larger waste media and generally have lower efficiency since the captured material is waste and not needed for another purpose. In contrast, the cyclone of the present invention is designed to keep the flow rate at a minimum, so as to not disturb the flame closely upstream of the cyclone and to maintain the exhaust as hot as possible. In some embodiments, the cyclone suction rate is less than 100 CFM, less than 80 CFM or less than 60 CFM, less than 40 CFM, less than 20 CFM or less than 10 CFM.
  • the other reason for the relatively low suction rate of the cyclone is to control the flow of the additional air stream, which is for example cold ambient air, thus controlling the mixture temperature.
  • the cyclone sucks air in from the surrounding, in addition to the burner exhaust, and mixes the two.
  • this significantly reduces, and in some embodiments eliminates, the creation of NOx and nanoparticles in the combustion products, by controlling their temperature (in this case reducing it), at the right moment.
  • the temperature is maintained high enough to promote a high, if not complete, level of oxidation of the fuel, which increases the combustion efficiency of the system, as well as yielding high-quality heat products for better heat extraction.
  • the temperature of the particles in the mixture within the secondary oxidation zone 56 is maintained between about 500 to about 1377°C.
  • the products of the combustion of the present invention comprise at least 60 %, at least 65 %, at least 70 %, or at least 75% by weight of magnetite.
  • the cyclone 60 can collect the hot oxidized iron particles with more than 99% efficiency.
  • a filter is used to achieve such high efficiency.
  • a filter is not required nor is it desired due to its entrapment of the powder and the high temperature of the particles which could damage the filter. Indeed, this would incur additional unnecessary operational costs.
  • a fine particle filter is added to the present system for the purpose of verifying the collection efficiency of the cyclonic separator.
  • the combustion reactor 50 can have walls 52 made of transparent fused quartz coupled with an enclosure that surrounds it and captures all the incident radiation of flame and focuses it towards the heat transfer mechanism.
  • the walls of the enclosure can for example be made of stainless steel that is polished to a mirror finish so that all incoming radiation is reflected and not absorbed.
  • electricity can be generated from the turbulent iron flame by using a heat engine which uses temperature gradients to drive a piston and create electricity, a steam engine coupled to a turbine, or a Stirling engine.
  • the Stirling engine requires a flow of water to cool the working fluid which produces hot water in addition to electricity. Only the coils of the engine are coated such that they absorb the maximum amount of radiation possible. In this manner, only the engine coils will get hot as the flame radiation will not heat reflective/non absorbing surfaces.
  • the coils allow for a heat transfer that is completely separated from the flow of the iron particles, which means that the engine coils will be kept clean. This is a requirement for the operation of the Stirling engine.
  • the flow of burnt particles into the cyclone is advantageously unimpeded despite the heat collection.
  • power can be generated with a steam turbine engine where the iron burner would act as the boiler.
  • heat produced from the turbulent iron flame is captured by a double walled, cast or tube wrapped steel combustion chamber within which water is circulated to absorb heat from the flame, as illustrated in Figure 7 .
  • Water 55a flows through a flow meter 55b and a thermocouple 55c and then into the coils 56. The water 55a will heat up in the coils and become hot water/steam 55d which then passes through a second thermocouple 55e to then power the steam engine.
  • the secondary oxidation zone 56 and the cyclone 60 are designed to maintain the incoming hot gases from the combustion reactor 50 at a desired temperature to promote oxidation, impede nanometric particles and NOx formation, and to improve heat extraction quality.
  • Multi-stage heat extraction can be done for example through a secondary fluid cooling cycle, e.g. a water jacket 64 as illustrated in Figure 8 .
  • the fluid is circulated through a water jacket mated to the cyclone or through copper heat exchangers on the cyclone body 65. Heat present in the exhaust and the particles can be collected and used for further energy generation, auxiliary heat or preheat of the burner system.
  • heat extraction at the cyclone impedes the creation of NOx from the burning iron particles. More precisely, the temperature control throughout the whole system keeps the iron particles in a burning mode that inhibits the creation of NOx and nanometric iron oxides. Some heat is extracted from the hot flow, but it remains hot enough to promote complete particle combustion while being cold enough to impede NOx formation.
  • the present system advantageously avoids the sintering of particles throughout the system. Heat extraction at the cyclone is further believed to prevent the sintering of particles and therefore improve the efficiency of collection. Sintering can also lead to an increased size of the iron oxide products compared to the initial iron particles, which would lead to additional steps in recycling the iron oxide to iron fuel such as crushing and separating.
  • the temperature control throughout the system impedes the formation of iron oxide nanoparticles while promoting a high level of iron particle combustion. It has previously been shown that metal particle combustion forms nanoparticles. This is can be due to spontaneous explosions, the combustion regime that the particle is in, and other combinations of parameters.
  • the iron particles initially burn at temperatures higher than the iron and iron-oxide melting temperatures. By controlling the temperature of the mixture, the particles keep their newly formed spherical shape following the melting, but are cooled below the melting point rather quickly. The temperature is controlled by the means of heat extraction and the quaternary air stream (a relatively cold air flow).
  • the addition of a temperature regulation section i.e. the air gap 55 downstream of the combustion reactor 50 but before the inlet to the cyclone 60, can help control which iron oxides are formed.
  • the iron oxide particles may even gain in size (compared to pre-burnt iron particles) due to their oxidation. Accordingly, the oxidized iron particles generally have a size similar to the iron particles pre-burned state (e.g. 10 to 500 ⁇ m). In some embodiments, the oxidized iron particles comprise less than 3%, less than 2%, or less than 1% by weight of particles having a diameter smaller than 8 ⁇ m.
  • the method comprises providing the multi-annular flow in the multi-annular tube to the divergent nozzle and then to the combustion reactor.
  • the multi-annular flow comprises the primary air flow, the secondary air flow and the tertiary air flow.
  • the primary air flow comprises suspended iron particles.
  • the secondary air flow is physically separated from the primary air flow and envelops the primary air flow as described above.
  • the tertiary air flow is also physically separated from the secondary air flow and envelops the secondary air flow.
  • the tertiary air flow is a turbulent swirling flow generated by the swirl generator.
  • a pilot combustible flow is provided in the secondary air flow along with a spark to generate a pilot flame.
  • the pilot flame ignites the turbulent iron flame that oxidizes the iron particles.
  • the combustion reactor has a recirculation zone generated and sustained by the tertiary air flow.
  • the pilot combustible flow is then stopped.
  • the pilot flame e.g. methane flame
  • the oxidized iron particles are recovered with the cyclone.
  • the additional air stream is provided to the cyclone from the air gap between the reactor outlet and the cyclonic inlet. The additional air stream controls the temperature of the oxidized iron particles, preventing nanoparticle formation and reducing NOx formation.
  • the step of recovering the oxidized iron particles includes controlling the temperature of the walls of the cyclone.
  • at least a portion of the iron particles provided in the primary air flow are recycled oxidized iron particles produced by the present method. Since the majority of the oxidized iron products are magnetite which is magnetic, in some embodiments, a magnetic separation with a magnetic separator can be performed to further improve the collection efficiency of the present methods.
  • the method advantageously uses atmospheric air (i.e. about 21 vol. % oxygen) and does not require the addition of oxygen to the air stream. Eliminating the need to add oxygen to the air reduces the steps, complexity, and costs of the operation. In fact, it is an advantage of the present method to achieve an oxygen starved combustion in order to mitigate the formation of nitric oxide species and promote heterogeneous combustion of iron.
  • the oxygen starved combustion can be achieved by optimizing the iron particles flow rate in the primary air flow and/or by optimizing the flow of air in one or more of the primary air flow, the secondary air flow and the tertiary air flow.
  • the powder feeder purchased from Powder & Surface Gmbh was used to create the primary air flow.
  • the iron particles were obtained from Tata Steel Ltd and TLStechnik Spezialpulver Gmbh TM .
  • the primary air flow was characterized by 1.33 g/s of iron with 415 cc/s of air, yielding a central equivalence ratio of roughly 4.
  • the tertiary air flow rate was 2460 cc/s, yielding an overall equivalence ratio of 0.6.
  • the theoretical thermal power of the produced flame was 8.9 kW.
  • the methane ignition flame had a secondary air flow of 370 cc/s with an equivalence ratio of 1, meaning 35 cc/s methane and 335 cc/s air with a thermal power of 1.15 kW.
  • the chosen type of swirl device and the geometry of it were designed for the purpose of stabilizing an iron flame ( Figures 4C and 4D ).
  • the combustion chamber was also designed for this purpose and sized for a 10 kW iron flame. With the design according to the present invention, it was possible to create a stable flame without other heat or fuel sources (such as methane) that remained self-sustained for over 20 minutes.
  • the system included a stratified burner, which had an iron particle rich primary air flow, and leaner outer flows (secondary air flow and tertiary air flow).
  • the point of that design was to minimize NO x formation by starving the core of oxygen, while still achieving high combustion efficiency by having the rest of the iron particles burn lean at lower temperatures in the surrounding flow.
  • NO x measurements were taken using a sampling probe at various locations in the burner and cyclone ducting (the burner of Figure 6B was used). Little to no NO x was observed (Table 1).
  • the NOx measurements below 4 ppm demonstrated the ultra-low NOx capabilities of the burner.
  • the oxygen concentration indicated how depleted the air flow is of oxygen, i.e. the oxygen has been used in the combustion of the iron particles.
  • a conventional high efficiency particulate air (HEPA) filter was placed downstream of the cyclone to capture any oxidized iron particles that do not get separated by the cyclone.
  • the filter allowed to quantify the amount of oxidized iron particles that would escape the cyclone by weighing the filter initially when "empty” and then after running the cyclone. After separating more than 10kg of oxidized iron particles, the filter gained less than 10 grams of mass, meaning the cyclone retained more than 99% of the oxidized iron particles dispersed in the system.
  • the X-ray diffraction shown in Table 4 gives information about the specific elements/phases in a sample.
  • Four different powders were tested with XRD analysis: unburnt pure iron, pure iron that had undergone slow oxidation in a thermogravimetric analyzer (TGA), oxidized iron particles from the combustion in the turbulent burner and lastly oxidized iron particles from the combustion in the turbulent burner that have subsequently undergone slow oxidation in the TGA.
  • TGA thermogravimetric analyzer

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Claims (15)

  1. Kontinuierliches Verbrennungssystem für Eisenpartikel (12), umfassend
    ein mehrfach ringförmiges Brennrohr, das einen Einlass und einen Auslass (54) aufweist, wobei das mehrfach ringförmige Brennrohr im Querschnitt mindestens drei getrennte Durchgänge vom Einlass bis zum Auslass (54) definiert; wobei das mehrfach ringförmige Rohr umfasst:
    ein erstes Rohr (10), das ganz innen liegt, wobei das erste Rohr (10) einen ersten Durchgang definiert, der einen primären Luftstrom (11) bereitstellt, wobei die Eisenpartikel (12) in dem primären Luftstrom (11) schweben;
    ein zweites Rohr (20), außerhalb des ersten Rohrs (10), das einen zweiten Durchgang definiert, der ein innerer ringförmiger Raum ist, der zwischen dem ersten Rohr (10) und dem zweiten Rohr (20) definiert ist, wobei der innere ringförmige Raum einen sekundären Luftstrom (21) und einen Pilotbrennstoffstrom bereitstellt, wobei der innere ringförmige Raum ferner einen Zündpunkt eines Funkengebers aufweist, und
    ein drittes Rohr (30), wobei das dritte Rohr (30) außerhalb des zweiten Rohrs (20) positioniert ist, das einen dritten Durchgang definiert, der ein äußerer ringförmiger Raum ist, der zwischen dem zweiten Rohr (20) und dem dritten Rohr (30) definiert ist, wobei der äußere ringförmige Raum einen Wirbelerzeuger (32) umfasst und einen tertiären Luftstrom (31) bereitstellt;
    wobei das erste Rohr (10), das zweite Rohr (20) und das dritte Rohr (30) im Innern des mehrfach ringförmigen Brennrohrs in Stellung verschachtelt sind;
    eine divergierende Düse (40) am Auslass (54) des mehrfach ringförmigen Brennrohrs;
    einen Verbrennungsreaktor (50), der einen Reaktorauslass gegenüber einem Reaktoreinlass umfasst, der mit der divergierenden Düse (40) am Reaktoreinlass in Fluidkommunikation steht und damit hydraulisch verbunden ist, zum Generieren und Stabilisieren einer turbulenten Eisenflamme (51), welche die Eisenpartikel (12) verbrennt und oxidierte Eisenpartikel erzeugt; und
    einen Zyklonbrenner (60), der einen zyklonischen Einlass (61), einen Gasauslass (62) und einen Partikelauslass (63) aufweist, wobei der zyklonische Einlass (61) in Fluidkommunikation mit dem Reaktorauslass (54) steht.
  2. System nach Anspruch 1, wobei ein Luftspalt (55), der einen quartären Luftstrom (57) in den zyklonischen Einlass (61) bereitstellt, zwischen dem zyklonischen Einlass (61) und dem Reaktorauslass (54) definiert ist.
  3. System nach Anspruch 1, ferner umfassend einen quartären Strom, der in dem Verbrennungsreaktor (50) durch einen Druckluftstrom durch Injektionsöffnungen in dem Verbrennungsreaktor (50) hindurch bereitgestellt wird.
  4. System nach einem der Ansprüche 1 bis 3, wobei das mehrfach ringförmige Brennrohr ein dreifach konzentrisches Rohr ist.
  5. System nach einem der Ansprüche 1 bis 4, ferner umfassend ein Filter stromabwärts von dem Zyklonabscheider, um die oxidierten Eisenpartikel einzufangen, die aus dem Zyklonabscheider entweichen.
  6. System nach einem der Ansprüche 1 bis 5, ferner umfassend einen Magnetabscheider stromabwärts von dem Zyklonabscheider oder darin integriert.
  7. System nach einem der Ansprüche 1 bis 6, ferner umfassend ein Temperaturregelsystem, das mit dem Zyklonabscheider gekoppelt ist.
  8. System nach einem der Ansprüche 1 bis 7, ferner umfassend einen Energieerzeuger,
    wobei der Energieerzeuger wahlweise aus einer Wärmekraftmaschine, einer Stirling-Maschine und einer Dampfmaschine ausgewählt wird.
  9. System nach einem der Ansprüche 1 bis 8, wobei der innere ringförmige Raum ferner Flammenschutzperlen (22) umfasst.
  10. System nach einem der Ansprüche 1 bis 9, ferner umfassend:
    Druckventile in dem inneren ringförmigen Raum, um bei Druckaufbau den Druck abzulassen; und/oder
    einen Stauraum für metallischen Treibstoff, der ein Silo für metallischen Treibstoff und ein Luftdrucksystem, das mit dem Silo für metallischen Treibstoff gekoppelt ist, das dem primären Luftstrom (11) die schwebenden Eisenpartikel (12) bereitstellt, umfasst; und/oder
    ein Brennstoffabsperrventil; und/oder
    eine Einhausung, die eine Strahlung reflektiert, wobei die Einhausung den Verbrennungsreaktor (50) aufnimmt.
  11. Verfahren zur Verbrennung von Eisenpartikeln (12), wobei das Verfahren umfasst:
    Bereitstellen eines mehrfach ringförmigen Stroms für einen Verbrennungsreaktor (50) durch eine divergierende Düse (40) hindurch, wobei der mehrfach ringförmige Strom umfasst:
    einen primären Luftstrom (11), wobei die Eisenpartikel (12) in dem primären Luftstrom (11) schweben,
    einen sekundären Luftstrom (21), der von dem primären Luftstrom (11) physikalisch getrennt ist, wobei der primäre Luftstrom (11) von dem sekundären Luftstrom (21) umhüllt ist, und
    einen tertiären Luftstrom (31), der von der sekundären Luft physikalisch getrennt ist, wobei der sekundäre Luftstrom (21) von dem tertiären Luftstrom (31) umhüllt ist; und wobei der tertiäre Luftstrom (31) ein turbulenter Wirbelstrom ist;
    Bereitstellen des sekundären Luftstroms (21) und eines Funkens, der eine Pilotflamme entzündet (24), für einen Pilotbrennstoffstrom;
    Anzünden einer turbulenten Eisenflamme (51) mit der Pilotflamme (24);
    Zulassen, dass sich die turbulente Eisenflamme (51) stabilisiert und die Eisenpartikel (12) in einer Reaktionszone des Verbrennungsreaktors (50) verbrennen, wobei ein Luftstrom erzeugt wird, der oxidierte Eisenpartikel umfasst, wobei der Verbrennungsreaktor (50) eine Umlaufzone (53) umfasst, welche die Reaktionszone umgibt, die von dem tertiären Luftstrom (31) erzeugt und unterstützt wird;
    Anhalten des Pilotbrennstoffstroms;
    Stabilisieren der turbulenten Eisenflamme (51); und
    Wiedergewinnen der oxidierten Eisenpartikel aus dem Luftstrom mit einem Zyklonbrenner (60).
  12. Verfahren nach Anspruch 11, ferner umfassend das Bereitstellen eines quartären Luftstroms (57) stromaufwärts von dem Zyklonbrenner (60), um die Temperatur zu regeln und die Eisenpartikel weiter zu oxidieren.
  13. Verfahren nach Anspruch 11 oder 12, wobei der Pilotbrennstoffstrom weniger als eine Minute lang bereitgestellt wird.
  14. Verfahren nach einem der Ansprüche 11 bis 13, wobei der Schritt des Wiedergewinnens der oxidierten Eisenpartikel die Regelung der Temperatur der Wände des Zyklonbrenners (60) umfasst.
  15. Verfahren nach einem der Ansprüche 11 bis 14, wobei
    die Eisenpartikel (12) eine Größe zwischen 1 und 100 µm aufweisen; und/oder
    die oxidierten Eisenpartikel mindestens 60 Gewichtsprozent Magnetit (Fe3O4) sind; und/oder
    die oxidierten Eisenpartikel weniger als 1 % Partikel, die eine Größe von weniger als 8 µm aufweisen, umfassen.
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WO2023194903A1 (en) * 2022-04-07 2023-10-12 Technische Universiteit Eindhoven Iron powder as recyclable fuel, and associated systems and methods
FR3145968A1 (fr) 2023-02-20 2024-08-23 Driss LARAQUI ENSEMBLE DE CHAUFFAGE DOMESTIQUE OU RESIDENTIEL (CHAUFFERIE) UTILISANT COMME COMBUSTIBLE DE LA POUDRE METALLIQUE (Fer et/ou Aluminium et/ou Magnesium)
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