This invention relates to a process for the chemical and/or physical treatment of fluidizable substances in a reactor, in particular in a fluidized-bed reactor, wherein hot gas, in particular the waste gas of a combustion chamber upstream of the reactor, in which fuel and combustion air are burnt at temperatures of 1000 to 1500° C., is introduced into the reactor interior via a gas supply tube. Furthermore, this invention relates to a plant for the thermal treatment of granular solids.
From DE 102 60 741 A1, a process as mentioned above and a respective plant are known, in which hot gas with a temperature of about 1130° C. is generated in a combustion chamber upstream of the reactor and supplied to the reactor. Inside the reactor, this hot gas then can be cooled to about 750° C., for instance by contact with the cooler substances to be treated and/or by mixing with fluidizing gas. However, the hot gas enters the reactor with a comparatively high temperature and in said reactor gets in contact with the solids to be treated, which on the one hand can lead to local overheating and on the other hand also greatly stresses the components of the reactor.
From EP 0 630 683 B1, it is furthermore known to introduce hot gas into a reactor, wherein the hot gas is cooled by solid particles inside the reactor. In addition, cooling panels can be provided in the reactor.
In some applications, for instance when calcining clay, the temperature inside the reactor should not be above 700° C. Therefore, for instance in the processes mentioned above, problems arise in such applications when the fluidizable substances to be treated get in contact with the distinctly hotter waste gas of a combustion chamber. For such applications, such as the calcination of clay, conventional inexpensive fuels such as natural gas, petroleum or coal therefore cannot directly be burnt in the reactor. Thus, only a fuel such as butane, which ignites at lower temperatures, can also be used for a direct combustion inside the reactor space. Such fuels, however, which burn at lower temperatures, are comparatively expensive.
In other applications, hot gases are created and will be used in the downstream process parts as hot as possible, in order to introduce the heat into these process parts.
Furthermore, the above-mentioned plants, in which hot gas is introduced into the reactor interior with temperatures of 500 to 1600° C., in particular 1000 to 1500° C., are expensive to manufacture, as the gas supply tube, through which the waste gas of the combustion chamber or from other processes is passed, must be made of a heat-resistant material, for instance high-temperature resistant steel. Due to the great temperature differences with respect to other components of the plant, high thermal stresses can also occur.
Accordingly, it is the object underlying the invention to provide a process and a plant as mentioned above, which provide for the use of inexpensive fuels or hot waste gases and at the same time a gentle treatment of fluidizable substances in the reactor, wherein the loads acting on the reactor or the components remain limited.
In accordance with the invention, this object substantially is solved with a process, in which the gas and/or the gas supply tube are cooled with a coolant such that the wall of the gas supply tube has a temperature lower by at least 50° C. than the gas at the inlet of the gas supply tube facing away from the reactor interior. In other words, the gas and/or the gas supply tube is cooled with a coolant such that the fluidizable substances in the reactor are sufficiently heated, but the components of the reactor are not exposed to excessive thermal and mechanical loads. By charging the gas supply tube with a coolant, it is therefore possible to use a less expensive material for the gas supply tube despite the very high temperatures of the gas in the gas supply tube, as the same is subjected to lower temperature resistance requirements. This advantageous effect can further be increased in that as a result of cooling, the wall of the gas supply tube has a distinctly lower temperature, in particular lower by at least about 100° C., preferably by about 150° C., than the gas at the inlet of the gas supply tube. By means of cooling, the gas in the gas supply tube itself is hardly cooled, however, and the gas at the reactor-side outlet of the gas supply tube mostly is only cooler by less than 200° C., preferably less than 100° C. than at the inlet.
In accordance with a first embodiment of the invention, the coolant cannot get in direct contact with the gas in the gas supply tube during cooling. This provides for the use of coolants optimized in terms of their cooling properties, without having to consider interactions with the hot gas, for instance the waste gas of the combustion chamber, and/or the substances to be treated in the reactor.
Thus, water can for instance be used as coolant. To simplify the construction of the cooling means, the temperature of the water preferably is up to about 100° C., so that no appreciable pressure is built up. In principle, however, pressure-resistant cooling means are also possible, in which water from a steam system or from upstream regions is used for cooling the gas supply tube and/or the waste gas. Due to the partly only small heat-exchange surfaces, the heat gain for a steam system also is only small, however, when cooling the hot gas and/or the gas supply tube. However, the cooling effect is sufficient to protect the gas supply tube from being damaged and from excessive thermal loads.
Alternatively, heat transfer oils or other coolants are of course also possible, which preferably are advantageously used in other parts of the plant, e.g. for heating up other substances or as a secondary circuit for heat recovery.
Preferably, the coolant is passed through an annular and/or helical cooling duct formed on the inside and/or outside of the gas supply tube. Thus, not only the gas in the gas supply tube, but in particular the wall of the gas supply tube can be cooled to such an extent that no expensive, high-temperature resistant material must be used for the gas supply tube.
In a special embodiment, the material of the gas supply tube consists of a radiation-reflecting material or has a reflecting coating, e.g. tinplate, so that heating up by radiation is reduced.
In accordance with a further embodiment of the invention, the coolant gets in direct contact with the hot gas during cooling. The objective is to keep the flow of the hot gases away from the wall of the gas supply tube by selective and metered supply of the coolant.
The resulting thorough mixing of the hot gas, e.g. the waste gas of the combustion chamber, with the coolant, should be minimized and can effect a more efficient cooling of the gas at the edges of the gas supply tube. Thus, the gas generally enters the reactor with a slightly lower temperature, but the temperatures at the edge of the gas supply tube are much lower than the average temperature of the gas at the inlet of the gas supply tube.
In accordance with a development of this invention it is provided that the coolant is introduced into the gas supply tube and/or a portion of the reactor adjoining the gas supply tube and is mixed there with the hot gas. Thus, the coolant can be introduced into the gas supply tube or the reactor for instance from a perforated tube, a membrane and/or via an orifice plate. This allows a uniform cooling of the gas supply tube without the occurrence of temperature gradients generating thermal stresses. The supply of the coolant is effected such that there is only a minimum intermixture with the gas in the gas supply tube, and a boundary layer of cold coolant substantially is built up on the inside of the gas supply tube.
The gas supply tube can be shielded particularly efficiently from the gas passed through with high temperature, when the coolant is introduced into the gas supply tube such that a coolant layer enveloping the gas is at least partly formed. Preferably, the coolant flows along the inner wall of the gas supply tube or along a cooling means provided in the same and thus forms a cooler gas cushion between the hot gas and the gas supply tube.
In a further embodiment of the invention the coolant is introduced into the gas supply tube, e.g., by an orifice plate in which the orifices are distributed around the supply tube. It is preferred, that these orifices are formed in a way so that the coolant enters the gas supply tube in a tangential direction. In this case a very good and small film of coolant is formed around the wall of the supply tube.
As coolant which can also get in contact with the gas, ambient air is preferably used. However, any other gas can be used for this purpose, e.g., cooled and cleaned waste gas from other processes or process stages. What can be used in particular are gases which have a much higher viscosity or which must be supplied additionally for the reaction in the fluidized-bed reactor. In accordance with the invention, the coolant, for instance cooling gas, has a rather low temperature, preferably between about 0 and 400° C., particularly preferably below 200° C.
In another embodiment, the coolant is delivered in liquid or even solid form to the inner wall of the gas supply tube, where it is then preferably evaporated or sublimed and thereby forms a gas cushion or a liquid layer which protects the inner wall of the gas supply tube against the heat. Water is particularly useful here as coolant. In a further embodiment, this liquid or solid coolant is introduced within a gas stream, e.g., as droplets or line particles.
In accordance with the invention, the hot gas introduced into the reactor through the gas supply tube can come from another process, e.g. also from a heat exchanger. In this case, the gases in the gas supply tube have a temperature of about 600 to 1000° C. In the reactor, an internal combustion can take place, but due to the thermal loads caused by the gas supplied, the gas supply tube must be cooled. Depending on the temperature of the gas in the gas supply tube, far less heat-resistant and hence less expensive materials can also be used, e.g. steel which only is heat-resistant up to 600° C., preferably up to 500° C., particularly preferably only up to 450° C. (e.g. boiler plate, H2 steel).
As an alternative to heating the substances to be treated by a combustion directly inside the reactor or by supplying hot gas from another process, the waste gas of a combustion chamber upstream of the reactor, in which fuel and combustion air is burnt at temperatures of about 1000 to about 1500° C., can also be supplied to the reactor as hot gas. This leads to particularly high temperatures in the gas supply tube, which require a particularly efficient cooling and/or the use of heat-resistant materials, but this inventive decoupling of the combustion in the combustion chamber and the treatment of substances in the reactor provides for also using inexpensive fuels. Due to the interposed cooling, natural gas, petroleum or coal as well as biomass or waste materials thus can also be used as fuel, which require a distinctly higher ignition temperature or combustion temperature than is necessary or desirable for the treatment inside the reactor at a temperature of e.g. 500 to 700° C.
In the process of the invention, an ash-producing fuel can also be used as fuel, wherein a gas cleaning possibly is provided between the combustion chamber and the fluidized-bed reactor. The combustion can for instance be effected e.g. in a horizontal cyclone, in which ash of the fuel is separated from the hot waste gas and precipitated. This allows the use of inexpensive and locally available fuels. The choice of the fuel also is dependent on the requirements of the substance to be treated. Substances which have no increased requirements concerning the freedom from impurities can be calcined by ash-containing fuels, whereas substances which must remain free from impurities, e.g. white paper filler, must be treated with ash-free fuels.
Another alternative for heating the substances is the use of a waste gas, e.g., from an electric furnace. In this case the hot gases have a temperature of 1000° C. to 1900° C.
In accordance with one embodiment of the invention, the reactor is a fluidized-bed reactor, in which a stationary fluidized bed is annularly formed around the gas supply tube. In this case, a gas can be passed as coolant through a cooling tube provided around the gas supply tube and can subsequently be guided into a gas distributor provided below the stationary fluidized bed, so that the cooling gas can be introduced into the stationary fluidized bed as fluidizing gas via a tuyère bottom. To maintain the temperature inside the reactor within the temperature limits optimal for the treatment of substances, for instance in the case of clay calcination below about 700° C., the supplied quantity of the hot gas in the gas supply tube preferably is controlled and/or regulated on the basis of the temperature in the reactor.
The object underlying the invention furthermore is solved by a plant for the thermal treatment of granular solids, which includes a fluidized-bed reactor, in which the solids are introduced via a solids supply conduit and in which they are thermally treated substantially at a temperature of about 300° C. to about 1200° C., preferably of about 500° C. to about 700° C., and a gas supply tube, which for supplying process gas substantially centrally opens into the fluidized bed reactor from below. Preferably, a combustion chamber is provided upstream of the fluidized-bed reactor, in which fuel is burnt at a temperature of for instance 1000 to 1500° C. and which is connected with the fluidized-bed reactor via the gas supply tube. In accordance with the invention, a for instance annular cooling duct for cooling the gas supply tube and the process gas is at least partly associated to the gas supply tube, which is connected with a coolant source for supplying coolant with a temperature of below about 400° C., in particular below about 100° C. The flow cross-section of the cooling duct preferably is smaller than the flow cross-section of the gas supply tube, so that the coolant is strongly heated by the gas supply tube or the process gas. Due to the configuration of the plant of the invention with a cooling duct, e.g. simple steels can be used for the gas supply tube, which are heat-resistant up to about 800° C., preferably only up to about 700° C., particularly preferably up to about 650° C. (e.g. 16Mo3 steel). The use of expensive, highly heat-resistant chrome-nickel steels therefore can he avoided. At the same time, the temperature inside the reactor can be kept low, without having to renounce the use of inexpensive fuels, which require a higher ignition temperature and/or combustion temperature.
In another embodiment of the invention the plant comprises an electric furnace, and the waste gases of the electric furnace are supplied to a reactor, preferably a fluidized-bed reactor, in which solids are treated with at least a part of this waste gas.
In accordance with a preferred embodiment of the invention, the gas supply tube of the fluidized-bed reactor is annularly surrounded by a stationary fluidized bed, and the plant includes a gas distributor provided below the stationary fluidized bed, from which fluidizing gas is introduced into the stationary fluidized bed via a tuyère bottom. Above the gas supply tube and the stationary fluidized bed, a turbulence mixing chamber can be provided for the intensive mixing of the solids. The cooling duct of the invention at least partly constitutes an annular space between the gas distributor and the gas supply tube, wherein the cooling duct is connected with the gas distributor formed below the stationary fluidized bed of the fluidized-bed reactor. The gaseous coolant flowing through the cooling duct thus can also be used for fluidizing the stationary fluidized bed, and the heat dissipated from the gas supply tube is introduced into the reactor. By means of the configuration in accordance with the invention, according to which the cooling duct constitutes an annular space between the gas distributor and the gas supply tube, an increased flow velocity is achieved inside the cooling duct, so that a more efficient cooling of the gas supply tube or the gases flowing through the same is achieved.
In accordance with a development of this invention it is provided that the cooling duct includes a plurality of outlet openings distributed around the periphery, which open into the gas distributor. Alternatively, it is also possible that the cooling duct includes an outlet opening annularly formed around its periphery, which opens into the gas distributor. The at least one outlet opening can open into the gas distributor directly below the tuyère bottom.
In accordance with a further embodiment of the invention, the plant of the invention includes a cooling tube in the gas supply tube such that between the gas supply tube and the cooling tube an annular cooling duct is formed. Therefore, the gas supply tube is cooled on its inside by the coolant flowing in the annular cooling duct.
Particularly preferably, outlet openings are provided in the cooling tube for connecting the cooling duct with the reactor interior or the interior of the gas supply tube. In this way, a coolant layer enveloping the waste gas of the combustion chamber and flowing along the inner wall of the gas supply tube or of the cooling tube can be formed, which as a gas cushion prevents an excessive heating of the gas supply tube or of the, cooling tube.
When the fluidized-bed reactor constitutes a Venturi reactor, the cooling tube can open into a flared portion with outlet openings for connecting the cooling duct with the reactor interior. Preferably, the portion of the cooling tube adjoining the gas supply tube extends substantially parallel to the likewise flared bottom of the reactor. In this way, not only the gas supply tube, but also the bottom of the reactor can be cooled.
A particularly efficient cooling can be achieved by using water as coolant. Preferably, on the inside or outside of the gas supply tube, a cooling duct is at least partly provided, which is connected with a coolant source containing water as coolant with a temperature of up to about 100° C. The cooling duct can for instance be formed helically and extend around the gas supply tube in the manner of a cooling coil.
To additionally protect the material of the gas supply tube against an excessive thermal load due to the waste gases of the combustion chamber, a studding made of gunned concrete or some other suitable thermal insulating coating can be provided on the inside of the gas supply tube. Even at temperatures of the waste gas of the combustion chamber of 1300° C. and more, the loads of the gas supply tube thus can be minimized.
Preferably, a gas cleaning means is associated to the combustion chamber in the plant of the invention. The combustion chamber can constitute a horizontal cyclone.
Furthermore, the invention relates to the use of a material with low heat resistance for instance in the gas supply tube of a plant or of a method as mentioned above.
The invention will subsequently be explained in detail by means of embodiments and with reference to the drawings. All features described and/or illustrated per se or in any combination form the subject-matter of the invention, independent of their inclusion in the claims or their back-reference.
In the drawing:
a is a sectional view along line A-A in
The plant for the thermal treatment of granular solids, such as for clay calcination, which is shown in
A gas supply tube (central tube) 3, which is connected with a combustion chamber 4, opens into the reactor interior 2. As indicated by the arrows in
In the reactor 1, a tuyère bottom 5 is provided, which is associated to a gas distributor 6. Through a conduit 7, fluidizing gas is introduced into the gas distributor 6, which reaches the reactor 1 via the tuyère bottom 5. Above the tuyère bottom 5, the gas supply tube 3 is surrounded by an annular stationary fluidized bed, which is intermixed by the fluidizing gas. Furthermore, a recirculation cyclone 8 is schematically indicated in
The formation of the gas distributor 6 and of the gas supply tube 3 of the plant as shown in
Another embodiment of the invention is shown in
In this embodiment, the cooling tube 9 in turn is arranged annularly, surrounding the central gas supply tube 3, so that an annular cooling duct 10 is formed between the gas supply tube 3 and the cooling tube 9. The gas supply tube 3 partly is provided with outlet openings 12, so that a coolant flowing through the annular cooling duct 10 can get into the interior of the central gas supply tube 3. In doing so, the coolant can form a coolant layer flowing along the inner surface of the gas supply tube 3 and thus protect the material of the gas supply tube 3 against an inadmissibly high heating.
a show an alternative to the embodiment according to
In the embodiment of
The embodiment shown in
In the embodiment shown in
By means of the cooling of the central gas supply tube 3 as described above, it is achieved that the waste gas from the combustion chamber 4 is cooled considerably from a temperature of about 1000 to 1500° C., so that the waste gas heats the solids treated in the reactor 1 to a temperature of about 500 to about 700° C.
In a reactor as shown in
In a reactor as shown in
In a reactor as shown in
1 fluidized-bed reactor
1′ Venturi reactor
2 reactor interior
3 gas supply tube (central tube)
4 combustion chamber
5 tuyère bottom
6 gas distributor
7 conduit
8 recirculation cyclone
9 cooling tube
10 cooling duct
11 outlet opening
12, 12′ outlet opening
13 cooling duct
14 studding
Number | Date | Country | Kind |
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10 2007 041 427.9 | Aug 2007 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2008/007047 | 8/28/2008 | WO | 00 | 10/4/2010 |