WO2009035334A1 - Device and method for mixing at least two fluid flows for combustion - Google Patents
Device and method for mixing at least two fluid flows for combustion Download PDFInfo
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- WO2009035334A1 WO2009035334A1 PCT/NO2008/000315 NO2008000315W WO2009035334A1 WO 2009035334 A1 WO2009035334 A1 WO 2009035334A1 NO 2008000315 W NO2008000315 W NO 2008000315W WO 2009035334 A1 WO2009035334 A1 WO 2009035334A1
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
- F23D14/46—Details, e.g. noise reduction means
- F23D14/62—Mixing devices; Mixing tubes
- F23D14/64—Mixing devices; Mixing tubes with injectors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
- B01F25/30—Injector mixers
- B01F25/31—Injector mixers in conduits or tubes through which the main component flows
- B01F25/313—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced in the centre of the conduit
- B01F25/3132—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced in the centre of the conduit by using two or more injector devices
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
- B01F25/30—Injector mixers
- B01F25/31—Injector mixers in conduits or tubes through which the main component flows
- B01F25/313—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced in the centre of the conduit
- B01F25/3132—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced in the centre of the conduit by using two or more injector devices
- B01F25/31322—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced in the centre of the conduit by using two or more injector devices used simultaneously
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
- B01F25/30—Injector mixers
- B01F25/31—Injector mixers in conduits or tubes through which the main component flows
- B01F25/313—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced in the centre of the conduit
- B01F25/3133—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced in the centre of the conduit characterised by the specific design of the injector
- B01F25/31331—Perforated, multi-opening, with a plurality of holes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F33/00—Other mixers; Mixing plants; Combinations of mixers
- B01F33/80—Mixing plants; Combinations of mixers
- B01F33/81—Combinations of similar mixers, e.g. with rotary stirring devices in two or more receptacles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F33/00—Other mixers; Mixing plants; Combinations of mixers
- B01F33/80—Mixing plants; Combinations of mixers
- B01F33/81—Combinations of similar mixers, e.g. with rotary stirring devices in two or more receptacles
- B01F33/811—Combinations of similar mixers, e.g. with rotary stirring devices in two or more receptacles in two or more consecutive, i.e. successive, mixing receptacles or being consecutively arranged
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- 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
- F23C13/00—Apparatus in which combustion takes place in the presence of catalytic material
- F23C13/06—Apparatus in which combustion takes place in the presence of catalytic material in which non-catalytic combustion takes place in addition to catalytic combustion, e.g. downstream of a catalytic element
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- 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
- F23C6/00—Combustion apparatus characterised by the combination of two or more combustion chambers or combustion zones, e.g. for staged combustion
- F23C6/04—Combustion apparatus characterised by the combination of two or more combustion chambers or combustion zones, e.g. for staged combustion in series connection
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
- F23D14/20—Non-premix gas burners, i.e. in which gaseous fuel is mixed with combustion air on arrival at the combustion zone
- F23D14/22—Non-premix gas burners, i.e. in which gaseous fuel is mixed with combustion air on arrival at the combustion zone with separate air and gas feed ducts, e.g. with ducts running parallel or crossing each other
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
- F23D14/46—Details, e.g. noise reduction means
- F23D14/72—Safety devices, e.g. operative in case of failure of gas supply
- F23D14/82—Preventing flashback or blowback
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- 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
- F23C2900/00—Special features of, or arrangements for combustion apparatus using fluid fuels or solid fuels suspended in air; Combustion processes therefor
- F23C2900/13002—Catalytic combustion followed by a homogeneous combustion phase or stabilizing a homogeneous combustion phase
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- 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
- F23C2900/00—Special features of, or arrangements for combustion apparatus using fluid fuels or solid fuels suspended in air; Combustion processes therefor
- F23C2900/99001—Cold flame combustion or flameless oxidation processes
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- 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
- F23C2900/00—Special features of, or arrangements for combustion apparatus using fluid fuels or solid fuels suspended in air; Combustion processes therefor
- F23C2900/9901—Combustion process using hydrogen, hydrogen peroxide water or brown gas as fuel
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E20/00—Combustion technologies with mitigation potential
- Y02E20/34—Indirect CO2mitigation, i.e. by acting on non CO2directly related matters of the process, e.g. pre-heating or heat recovery
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
Abstract
The present invention relates to a device for transforming at least two fluid flows into a number of minor fluid flows and mixing said minor flows. Said device comprises at least two hollow sectional cylinder or cone bodies which lie one on top of each other in a coaxial manner forming at least two annular spaces, a plate (50) covering one end of said bodies perpendicular to the bodies axis having inlets through which said fluidflows (25, 20) are fed to said spaces and a distributor plate (11) located at the opposite end of said bodies and optionally at least one distributor plate located within said bodies. All said distributor plates are perpendicular to the bodies axis, where said distributor plates cover the entire cross-sectional area of said spaces and said distributor plates have a number of channels (45) and holes (40) through which said fluid flows are fed from said spaces to a mixing zone located adjacent to each of said disks. Furthermore, the present invention relates to a method for transforming at least two fluid flows into a number of minor fluid flows and mixing said minor flows. Said method is performed in said device where said fluidflows are fed through said inlets into said spaces towards said distributor plate(s) and further through said holes and channels into said mixing zone where a homogeneous mixing between said minor flows occurs. The present invention also relates to a use of said device and method.
Description
DEVICE AND METHOD FOR MIXING AT LEAST TWO FLUID FLOWS FOR COMBUSTION
The present invention relates to a device and a method for transforming at least two fluid flows into a number of minor fluid flows and mixing said minor flows to a homogeneous mixture. Furthermore, the present invention relates to a reactor for performing a chemical reaction between said fluids.
By means of the present invention a fast and an efficient mixing between at least two fluids (fluid 1 , fluid 2, fluid 3 ....) can be performed. Furthermore, dependent upon the chemical composition of the fluids, a chemical reaction can be performed in the mixed flow of said fluids.
A mixing of two fluids in its simplest form can be made by connecting two flow lines (pipes or tubes) together by means of a T-joint. Dependent upon the fluids and the flow characteristics the fluids will have a complete homogeneous mixing a certain distance downstream the T-joint. If the available downstream distance is insufficient for complete mixing, then this can be solved by installing an inline mechanical mixer. Such inline mixers have been known for many years and are available on the market.
Incomplete or inhomogeneous mixing can also be restricted by chemical reactions between components of the fluids. In many situations one would like to premix two fluids to a homogeneous mixture before any reaction takes place. In case of fast chemical reactions this can be difficult to obtain. Such a problem can arise when one or both fluids are at a high temperature level. To overcome such a problem one or both component may have to be cooled.
A known problem is the mixing of an oxidant flow with a flow containing hydrogen. Normally one would prefer to premix the two flows before the combustion takes place. As hydrogen is a very fast reacting component there is a risk that the combustion moves backward from the combustion chamber to the point of mixing (i.e. to the inline mixer). This problem is known as flashback combustion. Potentially this will result in a very high temperature that could melt or damage the inline mixer or other components. To prevent this a fast shut down must be performed.
Another means for mixing one fluid into another is an injector or a nozzle system. Preferably such a mixing system is used for mixing a minor flow into a larger flow. By injecting a low viscosity fluid at high speed through a nozzle this fluid can be spread out and mixed with the main fluid. Normally such an injection nozzle will be placed in the centre of a pipe or tube containing the main fluid. If the injected flow is a fuel with fast reaction components there is a risk of having an inhomogeneous mix when the reaction starts. A result of this is local concentration variations resulting in locally high temperature peaks in the combustion flame. Such local high peak temperatures can result in a high degree of NOx formation. Release of NOx gases to the atmosphere is a major environmental issue and obligations are put on the industry to reduce the emission of NOx (the Gothenburg protocol).
An insufficient or inhomogeneous mixing causes problems with present technology of mixing. More precise this is related to the time to establish a complete homogeneous mix between the fluids to be mixed. A tctlong time lag before a complete homogeneous mixing is established can, especially in case of a combustion, result in formation of unwanted components. A mixing prior to combustion is named premix. Premix is normally safe with slow reaction components, but premix of an oxidant and a fuel containing hydrogen or any other fast reacting component can cause flashback combustion problems. Another problem related to an inhomogeneous mixing before a combustion start is concentration variations that can give locally higher temperatures than the average flame temperature and thus result in a high NOx concentration.
The main objective of the present invention was to arrive at device and a method for mixing at least two fluidflows to a homogeneous mixture before any reaction between any components in said fluids takes place.
Another objective of the present invention was to arrive at a reactor for performing a chemical reaction between said fluids.
In accordance with the present invention, these objectives are accomplished in a device comprising at least two hollow sectional cylinder or cone bodies which lie one on top of each other in a coaxial manner forming at least two annular spaces, a plate 50 covering one end of said bodies perpendicular to the bodies axis having inlets through which said fluidflows 25,20 are fed to said spaces, a distributor plate 11
located at the opposite end of said bodies and optionally at least one distributor plate located within said bodies. All said distributor plates are perpendicular to the bodies' axis, where said distributor plates cover the entire cross-sectional area of said spaces and said distributor plates have a number of channels 45 and holes 40 through which said fluid flows are fed from said spaces to a mixing zone located adjacent to each of said disks.
Said distributor plate has penetrating holes and said channels are internal diametric channels with channel openings in the peripherical surface of said plate and said channel wall has holes leading to said plate surface.
Furthermore, these objectives are accomplished in a method where said method is performed in said device where said fluidflows are fed through said inlets into said spaces towards said distributor plate (s) and further through said holes and channels into said mixing zone where a homogeneous mixing between said minor flows occurs.
Said objectives are also accomplished in a reactor comprising said device, a mixing chamber located adjacent to said device and a reactor chamber located adjacent to said mixing chamber.
At least two main flows (fluid 1 , fluid 2 ... ) are transformed by means of a distributor plate to a large number of (multiple) smaller flows of fluid 1 , fluid 2 etc. to perform an efficient mixing. These smaller flows of fluid are directed or oriented out from small holes in said distributor plate and efficiently mixed at a short distance from the plate. The efficiency of the mixing will depend upon the flow velocity and the numbers, shape, angle and dimension of the holes.
Furthermore, by means of the present invention the holes can be distributed over the surface area of the distributor plate analogous to a chessboard pattern where for instance the holes for fluid 1 are placed in the "white" squares and the holes for fluid 2 are placed in the "black" squares.
The position of the inlets of the distributor plate will depend on the entering position of the flows (fluid 1 and fluid 2). For instance, when one of the flows (fluid 1) is fed through an inner annulus of a pipe, tube or chamber and directed to the inlet surface
(i.e. the surface directly opposite to the outlet surface) of the distributor plate and fed in to holes or channels in the plate. Preferably fluid 1 will flow directed straight through the distributor plate to the outlet holes. If suitable (to improve mixing efficiency) the channels can have an angle or orientation directing the outlet flow in a direction deviating from 90° to the surface plane. The other main flow will preferably enter the distributor plate from an outer annulus or chamber surrounding the inner volume of the entering flow. From this outer annulus fluid 2 is directed through small channel openings in the sidewall of the distributor plate. These openings are directing the fluid 2 flow in to channels in the distributor plate. From these distributing channels fluid 2 are directed through holes or minor channels leading to the outlet surface of the distributor plate. Preferably, but not necessary, these minor channels of fluid 2 will be directed in a flow direction parallel with the fluid 1 channels and at an angle or orientation of 90° to the surface plane of the distributor plate. The number and distances between the fluid 1 and fluid 2 holes or channels can have a great variation, but normally a large number of holes and a short distance between fluid 1 and fluid 2 holes are desired for efficient mixing. How close and in what number will depend upon the tolerances of the tools making the channels or holes, as well as the material and the area/diameter of the distributor plate. It is important to have a safe margin to prevent unwanted leakage between fluid 1 and fluid 2 in the distributor plate.
The present invention also gives the possibility to mix a third flow or a fluid 3 with fluid 1. Such a premix between fluid 1 and fluid 3 can be done to perform a chemical reaction that make new components that further can be mixed with fluid 2 by means of the present invention. Fluid 3 will preferably, but not necessary, have a minor mass flow compared to fluid 1. Fluid 3 can be mixed in to fluid 1 by means of an injector, dye, and nozzle or by means of the present invention. The fluid resulting from the mixing, and preferably a reaction between fluid 1 and fluid 3, is directed to the inlet surface of the distributor plate and directed through the holes or channels of the distributor plate to the outlet where it is mixed with fluid 2.
By utilizing the device according to the present invention two major separated flows of fluid 1 and fluid 2 can be transformed to a large number of minor flows of fluid 1 and fluid 2. These minor flows of fluid 1 and fluid 2 can further be distributed over a large surface area. The effect of having many small volume flows of two fluids compared to two large volume flows is that the distance from the centre (the bulk) of fluid 1 to the
centre (the bulk) of fluid 2 is dramatically reduced. The result of this reduced distance is that the time before a complete mix can be achieved is reduced.
By means of the present invention the problem of flashback combustion, related to premix of fast reacting components can be eliminated. Normally a static mechanical mixer is used to premix, and an oxidant and a fuel or the fuel is injected by means of an injector into the oxidant. The resulting mixture of oxidant and fuel is then fed to a downstream volume or chamber where combustion takes place. In case of a fast reacting component with a high flame speed a risk occurs that the flame or combustion reaction climbs counter current (backwards) in the fuel-oxidant feed line. The result will be that the flame or combustion zone will move backward to the mixing point of fuel and oxidant or place of premix. This could be as prior mentioned a mechanical inline mixer. Combustion is not allowed to burn outside the combustion chamber and such a situation cause a sudden shut down. By introducing the present invention the need of a traditionally mechanic inline mixer is eliminated. The oxidant and the fuel will be mixed directly at high speed and very efficient directly in front of the combustion zone, ensuring that a complete mix is established before ignition takes place. Thus we have a very fast and efficient premix directly in front of the combustion zone. The efficiency and mixing speed is due to converting the two large or major flows to be mixed into a multiple set of minor flows that are distributed even over the vertical area of the combustion chamber. If for some reason and irregular situation arises that causes reduction of the flow velocity of the injected oxidant and/or fuel, then no combustion is possible to establish outside the combustion chamber and thus the problem of flashback related to inline mixers are eliminated. Thus the present invention can also works as a flame arrestor or flame extinguisher in case of flashback problems.
By the present invention a compact, economic and efficient device for dividing at least two main fluids into a multiple set of smaller flows of the same fluids is obtained. Furthermore, these smaller flows of fluid can be mixed faster and more efficient than with a traditional mixing of said main flows. Another feature of the present invention is the flexibility towards operating with different fluid systems. To obtain a distributed and uniform mix of a gas in to a liquid can be very important with respect to mass transfer from the gas phase to the liquid phase. By the present invention it is possible to make a fast complete mix of low viscosity fluids as well as a uniform distribution of droplets or gas bubbles of one fluid into another fluid.
The present invention will now be further described by way of examples and with reference to the accompanying drawings in which:
Figure 1 shows the device according to the present invention.
Figure 2 shows a reactor according to the present invention.
Figure 3 shows the fluid streams through the distributor plate according to the present invention.
Figure 4 shows detail features of the distributor plate.
Figure 5a shows a two-stage combustion reactor according to the present invention.
Figure 5b shows another combustion reactor according to the present invention.
Figure 6 illustrates a gas power plant where a reactor according to the present invention is utilized.
Figure 7 illustrates a combustion configuration.
Figure 8 shows a process flow diagram for a gas power plant utilizing a reactor according to the present invention.
Figure 9 shows a process flow diagram for a CO2 absorber plant.
Figure 1 shows an embodiment of a device according to the present invention. Fluid 1 (20) enters towards a distributor plate 11 ,12 in an inner annular space centrally in a tube 30 (or a sectional cylinder or a cone body). Fluid 1 is by means of the distributor plate divided into a large number of minor flows of fluid 1 (21) through small holes, channels or narrow passages 40. Preferably these minor flows of fluid 1 are evenly distributed over the inner and outer surface area of the distributor plate 11 ,12. Dependent on the backpressure and the flow area of the channels or holes 40 a large increase in flow velocity can be achieved compared to the main fluid 1 flow (20).
Typically the flow velocity will be in the range of 25 - 100 m/s for low viscosity fluids (i.e. gases).
The other main flow, fluid 2 (25), which is to be mixed with fluid 1 , is entering another annulus 50 of said tube 30. Fluid 2 is fed towards the outer radial edge 15 of the distributor plate and directed in to channels 45 which preferably are oriented 90 degrees angle compared to channels or holes 40. Said channels 45 are preferably open straight through the distributor plate, as shown in Figures 3 and 4. Figures 3 and 4 show detail drawings of the distributor plate. Furthermore, Figures 3 and 4 show in more detail the channels or hole in the distributor plate. From the channels 45 there are holes or channels 46 leading out to the outlet surface of the distributor plate 12. These channels 46 are preferably oriented parallel to the channels 40 and are distributed evenly over the surface area of the distributor plate. Preferably the outlet holes of fluid 1 (21) and fluid 2 (26) are distributed accordingly to a chess pattern for a most efficient mixing.
Figure 2 shows tube (or tip) 30 placed inside a larger pipe, tube, sectional cylinder or cone body 60. By such a design tube 30 can be used as a burner tip. In such a case the two fluids 1 and 2 is an oxidant and a fuel. Shortly after the outlet surface 12 of the distributor plate a mixing between the minor flows of fluid 1 and fluid 2 (21 and 26) will be achieved. A mixing zone 70 with a homogeneous or near homogeneous mix is established. Downstream said mixing zone is a combustion or reaction zone 80. By proper design all the minor flows of fluid 1 and fluid 2 is fast and efficiently mixed to a homogeneous composition before entering to a combustion zone, a chemical reaction zone or any other zone where a fast and efficient homogeneous mix of two fluids are important.
The present invention can also be used for higher viscous fluids (liquids) to make droplets of one or both of the fluids 1 and 2. If one of the fluids is a liquid and the other fluid is a gas, then the present invention can be used to make and distribute gas bubbles of fluid 1 in to fluid 2 or vice versa.
Figure 5a shows a two-stage combustion system utilizing the present invention. In the inner annulus 20 a third flow, fluid 3, is injected and distributed and mixed with fluid 1 by means of a nozzle 90. Preferably fluid 3 is a slow reacting fuel (i.e. natural gas) and
fluid 1 is an oxygen-containing component. By balancing an amount of fuel and oxygen according to stoichiometry (ca. 0.5 mole O2 per mole natural gas (methane)) and feed this flow, fluid 4, to a catalytic section a partial oxidation can be performed. By the partial oxidation a new fluid 5 that contains CO and hydrogen (i.e. synthesis gas) is made. Fluid 5 with the fast reacting component hydrogen can further by means of the present invention be mixed with another oxygen containing fluid 2 and thereafter, with proper stoichiometric balancing, perform a complete oxidation to an exhaust flow, fluid 6. As temperature is increased by the POx stage and hydrogen is a fast reacting component such and arrangement have the potential to perform a nearly complete stoichiometric flameless oxidation (combustion). By nearly complete stoichiometric oxidation an exhaust gas maximized in CO2 concentration and minimized in O2 concentration can be produced. Such a combustor has the potential to be used by a gas turbine system or gas power plant that includes CO2 capture as described in the example below.
Figure 5b shows the same system as in Figure 5a but here fluid 3 is mixed with fluid 1 by the present invention instead of using an injector nozzle. The advantage of this is to reduce the length of mixing and make a shorter burner.
Example
Mixing of two or more components is part of most chemical production processes, and it is well known that the mixing method can have a great influence on the efficiency of a process as well as the product quality. The present invention is suitable for mixing gas and liquid as well as mixing of gas and liquid and vice versa. The present invention can be used for the following applications:
• Injection and mixing of gas bubbles in to a liquid
• Injection and mixing of liquid droplets in to a liquid • Injection and mixing of liquid droplets in to a gas (for example a drying process)
• mixing of fluids with different components prior to a chemical reaction
• mixing of an oxidant and a fuel
In the following is given an example of utilization of the present invention in a gas power plant with CO2 capture. By use of the present invention CO2 capture can be made more efficient and NOx formation can be reduced. A high combustion temperature is necessary for high efficiency of a gas power plant. If a gas combustion flame has peak temperatures above 155O0C this will significantly increase the NOx formation even though the average flame temperature is much lower. By use of the present invention the peak temperatures in a flame can be reduced and thus significantly reduce the NOx formations in a combustion process.
Furthermore, the present invention has great potential for a more efficient combustion process by taking advantage over its ability to combust a hydrogen rich fuel.
Recirculation of a part of the exhaust gas is a method for increasing the CO2 concentration of the off gas (exhaust) to the absorber of a CO2 capture plant. By utilizing the present invention nearly all available oxygen could be consumed to obtain a maximum CO2 concentration. This is not possible with a conventional natural gas burner. A flame will be unstable and extinguish when oxygen concentration is lower than 1-2%. By reforming the natural gas to synthesis gas (H2 + CO), and use this as fuel, a much lower oxygen concentration can be achieved due to the improved combustion efficiency of hydrogen.
Figure 6 shows such a combustion system utilized in a gas power plant where air is replaced by an oxygen lean oxidant. Such an oxidant can be made by exhaust recirculation.
To convert the methane rich natural gas to a hydrogen rich synthesis gas, a part of the oxidant is mixed with the natural gas and partially oxidised (POx) in a catalytic process before it is mixed with the rest of the oxidant to an almost complete oxidation (COx). The mixing of the synthesis gas from the POx stage and the oxygen lean oxidant is preferably done by means of the present invention. The feasibility of this combustion process with respect to mass and energy balances is calculated by means of a process simulation; see Figures 7, 8 and 9 and Tables 1 , 2 and 3 and the belonging description.
Figure 7 shows the combustion configuration.
Figure 8 shows a power plant with flue gas recycle. The combustion process is based on the principle of the present invention. The combination of a new burner (i.e. the reactor according to the present invention) and a flue gas recycle makes it possible to achieve stoichiometric combustion. This gives a higher CO2 content and a lower O2 content in the flue gas. This is an advantage for the CO2 removal plant as shown in Figure 9.
In the following the design data and the result of the process simulation is presented.
Atmospheric conditions: Ambient temperature: 150C
Ambient pressure: 1.013 bar
Relative humidity: 60 %
Natural gas feed:
Table 1 : Natural gas composition
Pressure: 30 bar
Temperature: 300C
LHV: 45453.6 kJ/kg
Cooling water: Fresh cooling water Supply temperature: 150C Return temperature: 25°C Sea cooling water:
Supply temperature: 7°C
Return temperature: 17°C Steam system: High pressure steam: Pressure: 129.34 bar
Temperature 5610C Medium pressure steam:
Pressure: 30.96 bar
Temperature 5450C Low pressure steam:
LP steam is extracted from the MP steam turbine. No LP steam is produced.
Pressure: 7.0 bar
Temperature: 3440C
Gas turbine:
The gas turbine is V94.3A from Siemens.
Compressor air inlet flow rate: 273.9 kg/s
Compressor flue gas inlet flow rate: 361.5 kg/s
Compressor inlet pressure: 1.013 bar
Compressor inlet temperature: 2O0C
Compressor outlet pressure: 17.14 bar
Compressor outlet temperature: 4110C
Compressor polytropic efficiency: 0.9119
Expander inlet pressure: 16.46 bar
Expander inlet temperature: 1245 0C
Expander outlet pressure: 1.043 bar
Expander outlet temperature: 6050C
Expander isentropic efficiency: 0.897
Steam turbines:
High pressure:
Inlet pressure: 124.0 bar
Outlet pressure: 32.4 bar
Isentropic efficiency: 0.86
Medium pressure:
Inlet pressure: 30.0 bar
Outlet pressure: 7.03 bar lsentropic efficiency: 0.88 Low pressure:
Inlet pressure: 7.0 bar
Outlet pressure: 0.0413 bar lsentropic efficiency: 0.88
Power plant:
The power plant is basically the power plant V94.3A from Siemens with some modifications.
58% of the flue gas from the HRSG unit is recycled to the air compressor. The gas from the recycle flue gas blower is cooled to 25°C, and condensed water is separated from the gas. The gas is mixed with air at the compressor suction. The air/flue gas mixture temperature is increased by 5°C, giving a 2.5% reduction in total mass flow through the compressor.
The air/flue gas mixture is compressed to 17.14 bar. About 35% of the compressed air is fed to the POx burner where the fuel is partially oxidized at 85O0C. The rest of the air is mixed with the exit gas from POx in the second burner where the fuel is completely oxidized, giving a temperature of 14500C.
About 22% of the total air flow is used for turbine cooling. The mixed turbine inlet temperature (TIT) is 1245°C. The hot gas is expanded to 1.043 bar in the gas turbine.
The exhaust gas enters the HRSG unit at 6050C. The HRSG unit is modified to include a CO2-stripper reboiler coil, which supply 75% of the reboiler heat. The HP and MP steam levels are kept unchanged, but the steam generation loads are adjusted to accommodate the reboiler. No LP steam is generated.
The HRSG unit has 13 coils and the gas exits the unit at 95°C.
LP steam for the CO2-stripper reboiler is extracted from the steam turbine at the medium pressure steam turbine outlet at 7 bar, 3440C and desuperheated to 2000C with water.
The flue gas is cooled to 8O0C in the flue gas cooler before entering the CO2 recovery plant.
CO2 recovery plant:
The flue gas is compressed to 1.068 bar in the flue gas blower before entering the absorber where 85% of the CO2 is absorbed in an amine solution. The rich solution is pumped to the stripper via the lean/rich exchanger. 75% of the stripper reboiler duty is supplied by hot flue gas and 25% is supplied by LP steam. The lean solution is flashed and the gas is fed to the stripper through a steam ejector. The lean solution is cooled in the lean/rich exchanger and the lean solution cooler before entering the absorber. The CO2 from the stripper at 1.47 bar is compressed to 150 bar.
Results:
Table 2 gives the energy figures to the gas power process based on a new burner concept utilizing the present invention.
Table 2: Energy efficiency
The power plant with the new burner concept achieves about 51% energy efficiency and the net power production 351.7 MW. The corresponding power plant without CO2 capture has net power production of 392 MW with energy efficiency 56.6%.
The combination of the new burner and flue gas recycle makes it possible to achieve stoichiometric combustion. This gives a higher CO2 content and a lower O2 content in the flue gas. The total flue gas flow to the CO2 recovery plant is reduced. This gives a reduction in the absorber size. This is an advantage for the CO2 removal plant.
The gas turbine is air cooled. This means that the O2 content is increased and the CO2 content is reduced in the flue gas compared to the burner outlet.
Stream data for the burner system's inlet and outlet streams are given in Table 3.
Table 3 Stream data for the burner system
Claims
1. A device for transforming at least two fluid flows into a number of minor fluid flows and mixing said minor flows, characterised in that said device comprises:
- at least two hollow sectional cylinder or cone bodies which lie one on top of each other in a coaxial manner forming at least two annular spaces,
- a plate (50) covering one end of said bodies perpendicular to the bodies axis having inlets through which said fluidflows (25,20) are fed to said spaces,
- a distributor plate (11) located at the opposite end of said bodies and optionally at least one distributor plate located within said bodies, all said distributor plates are perpendicular to the bodies axis, where said distributor plates cover the entire cross-sectional area of said spaces and said distributor plates have a number of channels (45) and holes (40) through which said fluid flows are fed from said spaces to a mixing zone located adjacent to each of said disks.
2. A device according to claim 1, characterised in that said distributor plate has penetrating holes and said channels are internal diametric channels with channel openings in the peripherical surface of said plate and said channel wall has holes leading to said plate surface.
3. A device according to claims 1 and 2, characterised in that said device comprises
- two hollow sectional cylinder or cone bodies which lie one on top of the other in a coaxial manner forming two annular spaces,
- a plate covering one end of said bodies perpendicular to the bodies axis having inlets through which said fluid flows are fed to said spaces,
- a distributor plate located at the opposite end of said bodies perpendicular to the bodies axis where said distributor plate covers the entire cross-sectional area of said spaces and said distributor plate has a number of channels and holes through which said fluid flows are fed from said spaces to a mixing zone located adjacent to said distributor plate.
4. A device according to claims 1 and 2, characterised in that said device comprises
- three hollow sectional cylinder or cone bodies which lie one on top of each other in a coaxial manner forming three annular spaces,
- a plate covering one end of said bodies perpendicular to the bodies axis having a number of inlets through which said fluid flows are fed to said spaces,
- a distributor plate located at the opposite end of said bodies and a distributor plate located within said bodies, all distributor plates perpendicular to the bodies axis, where said distributor plates cover the entire cross-sectional area of said spaces and said distributor plates have a number of channels and holes through which said fluid flows are fed to a mixing zone located adjacent to each of said distributor plates.
5. A method for transforming at least two fluid flows into a number of minor fluid flows and mixing said minor flows, characterised in that said method is performed in a device according to claims 1-4 where said fluidflows are fed through said inlets into said spaces towards said distributor plate(s) and further through said holes and channels into said mixing zone where a homogeneous mixing between said minor flows occurs.
6. A reactor for performing a chemical reaction between at least two fluids, characterised in that said reactor comprises a device according to claims 1-4, a mixing chamber located adjacent to said device and a reactor chamber located adjacent to said mixing chamber.
7. A method for performing a chemical reaction between at least two fluid flows, characterised in that said fluid flows are transformed into a number of minor fluid flows and mixed according to a method indicated in claim 6 and further brought to react in a reaction chamber.
Applications Claiming Priority (2)
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NO20074651A NO328141B1 (en) | 2007-09-12 | 2007-09-12 | Apparatus and method for mixing at least two fluid streams |
NO20074651 | 2007-09-12 |
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WO2009035334A1 true WO2009035334A1 (en) | 2009-03-19 |
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PCT/NO2008/000315 WO2009035334A1 (en) | 2007-09-12 | 2008-09-04 | Device and method for mixing at least two fluid flows for combustion |
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WO (1) | WO2009035334A1 (en) |
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CN105107401A (en) * | 2015-08-17 | 2015-12-02 | 江苏大学 | Cross micromixer of symmetrical fan shaped annular baffle |
CN106090917A (en) * | 2016-08-04 | 2016-11-09 | 珠海格力电器股份有限公司 | Burner and induction tunnel assembly, gas-cooker |
EP3650753A1 (en) * | 2018-11-12 | 2020-05-13 | WS Wärmeprozesstechnik GmbH | Method and device for flameless staged combustion |
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GB2595907A (en) * | 2020-06-11 | 2021-12-15 | Csk Inc | Dry gas scrubber |
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