MULTISTAGE METHOD FOR PRODUCING
HYDROGEN-CONTAINING GASEOUS FUEL AND
5 THERMAL GAS-GENERATOR SETUP OF ITS IMPLEMENTATION
(G.G. ARAKELYAN METHOD)
1. Field of technology
The invention relates to energy-saving technologies, mainly to methods and
10 setups for converting water Hz0 in hydrogen-containing gas in combination with
catalyst medium from line of CnH2,,+~ (diesel fuel, residual oil) in continuous heat
flame medium, when a burning temperature above 500°C. Most often such
methods refer to systems, in which gaseous fuel producing and its implementation
by burning are combined into a single cycle, but moreover, such systems may be
15 used for the accumulation of hydrogen-containing gas fuel.
2. Background of technology
Known is a method of hydrogen-containing gas generating (SU Pat No
1144977, 1985), where components are burned in the high temperature mode at
20 producing of hydrogen-containing gas.
The disadvantage of the method is the high power consumption.
Known is a method of gas producing from hydrocarbon raw material (SU
Pat No 939 380, 1982), where water steam, superheated up to 430 degrees, is
mixed with hydrocarbons with following heating of the steam and gas mixture.
25 The disadvantage of the method consists in the necessity to apply an
additional energy source to produce superheated steam and subsequent heating.
Known is application of water steam in its various phase states, all of which
are characterized by different equilibrium states (Soviet encyclopedic dictionary.
30 M.: 1985, - p 962, Ref. "Steam").
Also known is adopted by the applicant as a closest analog "Method of
producing hydrogen-containing gas in the turbo-generator setup), (RU Pat. Nr!
1
2269486, 2006). Known method and device for its implementation have the same
purpose as the claimed technical solution, with all that method is characterized by
sequence of operations by stages, combined in a single closed cycle, and the
device contains sections, corresponding to these stages.
5 As for the method, in the known technical solution realize multistage
method of producing of hydrogen-containing gaseous fuel with closed cycle,
including process start-up in the mode of forced warm-up and realization of a selfheating
process in the normal mode of self-heating, which includes mixing of the
hydrocarbon component and water, their entering by pumping under the pressure,
10 heating, fuel return and ignition.
In the known technical solution the initial mixing in liquid phase of water and
hydrocarbon component at normal (20 degrees) components temperature does
not ensure stability of dispersed composition of the mixture, directed in the further
on heating to produce fuel.
15 After cessation of mixing (i.e, from the moment of arriving the mixture to
heat), reverse process start up - it is the mixture lamination due to different
densities of water and hydrocarbon component. This leads to the heterogeneity of
the mixture on the dispersed composition. During the subsequent heating of the
mixture it is observed also heterogeneity on the temperature.
20 These heterogeneity are saved in the final product - the fuel mixture,
directed to the torch ignition, it causes torch burning instability, due by one side by
forming in the mixture local centers (on composition), where the mixture has no
ability to burn, that causes disruption of ignition and extinction of the torch (which
is typical for heavy hydrocarbon components), on other side, forming in the
25 mixture local centers of rapid burning, which lead to unauthorized flash of flame in
the torch, which is typical for light hydrocarbon components.
As for the known device, it includes relevant elements of the method
realization, inherent also to the claimed technical solution, thermal gas generator
setup is designed as a single device, that has a complex multi-section corps, setup
30 includes a burner system, firing chamber, device for mixing the components,
ignition pulse device, pipes, and start-up system, which includes start-up burner
with a supply of combustible fuel.
The device has disadvantages, inherent to the implemented method,
including failures occurrence in the process of fuel producing due to the
heterogeneity of the mixture.
5 3. Summary of the Invention
3.1. The result of solving of the technical problem
The technical problem consists in eliminating the disadvantages of the
known technical solution, ensuring the stability of process of hydrogen-containing
gaseous fuel producing, decreasing of energy consumption, and hydrocarbon
10 component discharge.
The technical result - is obtaining a homogeneous phase state of the
mixture in the process of fuel producing to ensure the stability and constancy of
the burning of technological firing torch and the working torch, as well as
enhanced security of hydrogen-containing fuel producing, including, due reducing
is hydrocarbon component discharge.
The solution of the technical problem is provided by multistage character of
the fuel producing process, every stage of process corresponds the most secure,
stable and homogeneous phase state of the components and mixture, that is
achieved by changing the direction of technological flows with separation of
20 entering for hydrocarbon components and water, and mixing hydrocarbon components
with water, phase state of which is changed.
3.2. List of drawings
Fig.1 shows block-diagram of the algorithm, realizing this method:
a) generalized block-diagram of the algorithm b) detailed block-diagram with basic
s elements; fig.2 - shows the scheme of three-section thermal gas-generator setup;
fig.3 shows profile 1-1 in FIG. 2; fig.4 - profile 11-11 in FIG. 2; fig.5 shows scheme of
injection type mixer; fig.6 shows thermal temperature regime in the technological
cylinder,
where: 1 - discharge water container; 2 - discharge container for hydrocarbon
10 component S,Hzn+2; 3 - working burner; 4 - startup burner; 5 - external
independent source-generator with pulsed spark igniter; 6 - turbocharger unit; 7 -
induction (pin) heater of turbo generator startup; 8 - injection type mixer; 9 - fire
chamber; 10 - first section of the technological cylinder; 11 - second section of
the technological cylinder; 12 - third section of technological cylinder; 13 - zone
is of ignition; inflammation and fire torch formation; 14 - zone of technological
burning of firing torch; 15 - unit for forming the working torch, 16 - working torch
zone, 17 - technological pipe for water supply by pumping from the discharge
water container (1) into the first section (10) of technological cylinder; 18 -
technological pipe for supply hydrocarbon component SnH2,+2 by pumping from
20 the discharge hydrocarbon container (2) into the injection type mixer (8); 19 -
technological pipe for steam supply from ine first section (10) of technological cylinder into the
injection type mixer (8); 20 - technological pipe for steam and hydrocarbons mixture
supply from the mixer (8) into the second section (11) of technological cylinder; 21 -
technological pipe for steam and hydrocarbons mixture supply from the second section (1 1)
25 into the third section (12) of the technological cylinder; 22 - technological pipe for steam
and hydrocarbons mixture supply from the second section (11) into the start-up
burner (4) (return of fuel in the forced heating mode); 23 - technological pipe for
fuel supply from the third section (12) of technological cylinder into working burner (3)
(return of the fuel in the normal mode of self-heating); 24 - pipe of fuel take-off for
30 external fuel consumer; 25 - control valve; 26 - the place of water loading into the
discharge container (1); 27 - the place of hydrocarbon fuel loading into the
discharge container (2); 28 - devices for control the head and the pressure in the
technological pipes; 29 - water steam generation; 30 - fire torch formation; 31 -
mixing and heating of the water steam and hydrocarbon mixture; 32 - heating of
the steam and hydrocarbon mixture for fuel producing; 33 - inner cylinder of
thermal gas generator ; 34 - outer cylinder of thermal gas generator: a) - supply of
5 steam and hydrocarbon mixture from the second section (1 1) of the technological cylinder
for running process, b) - supply of combustible mixture from an external source for running
process, c - supply of hydrocarbon component for running process; 35 -
technological cylinder heating.
3.3. Distinctive features
In the method, by contrast to the known, fuel producing is realized as a multi
stages process with separate entering of the hydrocarbon component and water
into the heated by firing torch technological cylinder, divided on isolated sections,
number of which corresponds to the number of fuel producing stages, in the first
is stage water is introduced and heated up to water steam formation, at later stages
hydrocarbon component is introduced and mixed with water steam, then water
steam and hydrocarbon mixture is additionally heated up to a temperature of forming
of hydrogen-containing gaseous fuel, flow of which is directed to return into ignition
zone to ensure firing torch burning.
20 In the normal mode of self-heating processes of forming of hydrogencontaining
gaseous fuel can be carried out with heating in at least three stages,
corresponding to the process of water steam forming in the first stage, where
water is injected by pumping under pressure 0,3-0,5 MPa and heated up to water
steam formation with a temperature of 500-550 O C, corresponding to the process
25 of mixing and further heating in the second stage, where hydrocarbon component
is injected by pumping under pressure of 0.3-0.5 MPa and mixed it with water by
water steam injecting under pressure of 0,06-0,25 MPa, at a ratio of water to the
hydrocarbon component from 10,5:1 to 8.1, and the mixture is heated up to a
temperature of 1000-1 100 O C, at third and subsequent stages, corresponding to
30 the process of producing of hydrogen-containing gaseous fuel, the mixture is
heated up to a temperature of 1300-2000 C.
In the normal mode of self-heating ignition can be carried with firing torch
andlor ignition pulse device with external source - sparking generator, running with
a frequency of 1-2 Hz, fuel flow to return for ignition and firing torch formation can
be partially directed to storage andlor external consumption, and process of
formation and maintenance of firing torch can be carried with turbo charging to
improve the firing quality and efficiency.
When starting of the process in the mode of forced heating, it is reasonable
to carry out preliminary water injection in amount of 40-50% of the largest
allowable normal working volume under the pressure of 0.3-0.5 MPa, changing of
the water phase state - to carry out by heating up to forming of water steam with a
temperature 450-500 O C, heating to realize from independent source of heat, for
example, an inductive heater, and ignition of steam and of hydrocarbon mixture or
the other fuel component - to carry out with independent source by ignition spark
pulse device with an independent source of sparking, operating with a frequency
of 40 - 50 Hz.
Thermal gas generator setup is made as a single device, which has a
complex multi section corpus, in contrast to the known device it has a complex
corpus, made as two embedded in one another cylindrical tubes with a gap,
forming the technology cyl~nder, divided on isolated sections, with sections
number, corresponding to number of stage of fuel mixture producing, inner tube
space forms the firing chamber, device for mixing is made as an injector with separate
inlets for water as a water steam and hydrocarbon components, the outlet of
the technological cylinder last section is connected via pipe to inlet of firing
chamber, where burner system is installed, this system includes ignition device
with spark-ignition pulse source of ignition, a working burner, start up burner, on
the firing chamber outlet is installed working torch formation element, as a
constrict unit, the setup is supplied with fuel tanks, realized as a separate sealed
discharge containers for water and hydrocarbon components.
The device can be made as a three section's technological cylinder, where
the I-st section realizes the vaporization stage, section is made with an
independent induction source of heat, 2-nd section realizes stages of the
components mixing, and steam and gas mixture heating, 3-d section provides a
additional heating stage for the fuel mixture producing, with all that, discharge
container for water in the setup is connected via a pipe with inlet of the I-st section
of the technological cylinder, outlet of which is connected via a pipe to the first
s inlet of injector, the injector second inlet is connected via a pipe to discharge
container of hydrocarbon component, the injector outlet is connected via a pipe to
I the technological cylinder second section, which is connected via a pipe with third
I
I section of the technological cylinder.
10 The ratio of the tubes radii, forming the technological cylinder for making the
fuel mixture is:
0,3> (r2/RI)> 0,l;
where R1 - outer diameter of the inner tube,
r2 - inner diameter of the outer tube,
is and on the inlet of turbine burner system a turbo charging unit is installed, it is
reasonable to maintain constant overpressure 0.3-0.5 MPa in the discharge
containers.
3.4. Description of the method and setup of its realization
20 The method and the setup realizes the dependence of Hz0 + SnHzn+2= HZ +
C02 in high-temperature multi-stage mode. The thermal ability of carbon is best
utilized at water gas.
On the vaporization of water gas of carbon it is requires 8% of its own
resources, with all that the water gas consists mainly of CO (40-60%) and H2 (30-
25 50%).
Water gas formation is a complex, at least two-stage process - at 500°C is
a complete decomposition on hydrogen and carbon dioxide (C+2H20 = 2H2 +
C02, at 1000-1200 OC - decomposition on hydrogen and carbon monoxide (C02
+ C = 2CO), If the water is taken in a steam state, the decomposition of water
30 steam (C + H20 = CO + HZ) is accompanied by heat loss, and therefore leads to a
cooling, in relation to these, to compensate heat losses, temperature of the first
stage of heating must be higher, than temperature of final stage - it must be not
less than 1300°C.
Presence of the turbo pumping (air, oxygen or other additional oxidant)
gives a possibility to obtain so-called generator gas with a temperature of
5 mixture burning of 1935OC, at actual absence on the output environmentally
harmful components.
The essence of method is shown in the block-diagram of algorithm its
realization (Figure 1). The method includes (Fig.la) fire torch formation and
10 providing of technological burning (30) for heating components and mixture in the
technological cylinder (35).
To provide the process realization, and claimed technical problem decision
it is envisage separation of the technological streams with separate supply (17-1 8)
components (water (1) and the hydrocarbon component (2)). Water is supplied for
15 heating and vaporization (29) for subsequent steam supply (19) for mixing with the
hydrocarbon component and subsequent heating of the steam and hydrocarbon
mixture (31), which already at this stage may be a flammable mixture.
This mixture is used during start-up of system (22). Then, the mixture is
sent to the next stages of processing (32) - for additional warm-up (20-21). The
20 resulting fuel is sent to the system inlet for ignition (23), it used also to create a
working torch at the setup outlet.
Heating of components and mixture (35) in normal mode is carried out by
means of technological cylinder, having several sections, according to the stages
number for implementing of the method.
25 Components - water and hydrocarbon component are loaded into sealed
containers (1, 2) under the constant pressure of 0.3-0.5 MPa to ensure their
uninterrupted supply to the system by pumping through control valves (25), (Figure
la, Figure 2). Loading can be carried out periodically, as fast, as component
discharge, as well as continuously.
30 Because as a basis is taken a three-stage process, on the first stage in the
normal mode of self-heating, water is heated up to superheated steam with
temperature of 500-550°C; and in the start-up mode with forced heating - up to
temperature of 450-500°C.
The resultin'g superheated steam is directed to the mixing with the
I hydrocarbon components. Mixing is provided by injection (8) of steam (Fig. 5).
I
s Then the steam and hydrocarbon mixture is additionally heated in the second
section of the technological cylinder (11) and in the third section (12) mixture is
I heated up to a temperature of formation of gaseous fuel, which in the normal
1
I mode of self-heating is directed to return (23) for igniting and flame torch
I formation.
10 In the start-up mode with forced heating (7) the steam and hydrocarbon
mixture is directed (22) for ignition from the second section (1 1).
The setup includes appropriate elements of the method realizing, it is made
as a single device, which has a complex multi section corpus, it is includes a
is burner system (30), the firing chamber (9), injection type unit for mixing the
components (8), the pulse ignition unit (5), pipes and start-up system, including
start-up burner (4) with a supply of combustible fuel (a, b, or c).
The corpus is made single as two cylindrical tubes, imbedded in one
another (33, 34), with a gap, forming technological cylinder.
20 Technological cylinder is heated by the firing torch, it is divided on
hermetically isolated sections (10, 1-1, 12) - the section number corresponds to the
stages number of the fuel mixture making process, the first section (10)
corresponds to stage of vaporization, section is equipped with an independent
induction source of heat (7) for realizing the start-up process, second setup
25 section, corresponding to stage of components mixing and heating of a water
steam and gas mixture, includes a section 11 of technological cylinder,
injection type mixer (8), and the third section (12), which serves for final warmingup
of mixture and producing of fuel. inner tube cavity (9) with an inner diameter r l
forms the firing chamber of firing torch formation (13, 14) for the technological
30 cylinder heating, unit for mixing (8), of the second stage, is made as an injector
with a separate entries (19) for water, in the steam form, and hydrocarbon
component (18), the setup is equipped with fuel tanks, which is made as
separate, sealed, discharge containers for water (1) and the hydrocarbon
component (2), discharge water container (1) is connected via pipe (17) to the
inlet of the first section of the technological cylinder of vaporization chamber (lo),
the outlet of vaporization chamber is connected via pipe to the injector first inlet, i s the second inlet of which is connected to the hydrocarbon component discharge
1 container, the injector outlet is connected via pipe to a camera (1 1) for heating a
I
steam and gas mixture, camera (11) for heating a steam and gas mixture is
3
2 connected via pipe (21) with a additional heating chamber (12) to form a fuel
b mixture, outlet this chamber is connected via pipe (23) to the inlet of the firing
10 chamber (9 ), where the turbine burner system is installed, this system has ignition
device with spark-ignition pulse source (5), working burner (3) start-up burner (4), on the
firing chamber outlet is installed the working torch formation element (16), as a constrict
unit, (15).
15 Ratio of radii of tubes, forming the technological cylinder for fuel mixture
producing is:
0,3 <(r2/R1)> 0,l;
where R1 - outer diameter of the inner tube,
r2 - inner diameter of outer tube,
20 At the turbine burner system inlet is installed turbocharger unit (6), and into
the discharge containers (1.2) is maintained constant overpressure of 0.3-0.5 MPa
The graph of FIG 6 shows dependence of the temperature in the technological
cylinder on its sections.
4. Possibility of the method implementation
The table below shows the comparative characteristics of the known
technical solutions and proposed method, these characteristics confirms, that
implementation of the method solves the claimed technical problem -take place
increasing of stability of process of hydrogen-containing gaseous fuel producing
(a significant reduction of failures number), reduction of power consumption and
hydrocarbon component discharge (rising the value of indicator of water I diesel
fuel ratio).
Table
Example of a concrete implementation of the method and the technical
characteristics thermal gas generator setups, realizing the Arakelyan GG method
Technical
characteristic
discharge of Water
Unit of
measur
ement
liters per
Setup "Grantstroy"
type
VTPGU-1 series of
2009
(implementation of the . ~
prototype)
20-25
Setup
"Grantstroy" type
VTTGU-700 series of
201 1
(implementation of the
claimed solution)
in normal mode
Water / diesel fuel
ratio
Setup outer
diameter
Thermal power
Average frequency of
the flame failure on
an operating time of
1,000 hours
hour
mm
Gcal
Flame
failure
Per
hour
(6,5:1) - (8,O:l)
Average (7,25 : 1)
(87,9:12,1)0?
203
1 ,o
0,1
(8,O:l) - (10,4:1)
Average (9,5 : 1)
(90,5:9,5)%
203
1 ,o
0,Ol
CLAIMS
1. Multistage method for producing hydrogen-containing gaseous fuel with
5 closed cycle, including start-up of process in the forced heating mode and realizing
of process in the normal mode of self-heating, that includes entering hydrocarbon
component and water by pumping under pressure, heating, fuel return into ignition
zone for firing torch forming, characterized in that the fuel producing is realized as
a multi stages process with separate entering of the hydrocarbon component and
10 water into the heated by firing torch technological cylinder, divided on isolated sections,
number of which corresponds the number of fuel producing stages, in the
first stage water is introduced and heated up to water steam formation, at later
stages hydrocarbon component is introduced and mixed with water steam, then
water steam and hydrocarbon mixture is additionally heated up to a temperature of
15 forming of hydrogen-containing gaseous fuel, flow of which is directed to return
into ignition zone, to ensure firing torch burning.
2.The method according lo claim 1, characterized in that in the normal
mode of self-heating processes of formation of hydrogen-containing gaseous fuel
20 is carried out with heating in three stages, in the first stage water is introduced by
pumping under the pressure of 0.3-0.5 MPa and it is heated up to the forming of
water steam with a temperature of 500-550 O C, in the second stage hydrocarbon
component is introduced into the mixer by pumping under pressure of 0.3-0.5
MPa, this component is mixed with water steam in the mixer by injection under
25 pressure of 0,06-0,25 MPa, at a ratio of water to hydrocarbon component from
10,5:1 to 8.1, and the mixture is heated up to a temperature of 1000-1100 O C, at
the third stage the mixture is heated up to a temperature of 1300-2000 O C.
3.The method according to claim 1, characterized in that in the normal
30 mode of self-heating ignition is carried out by the ignition pulse unit with an external
source -sparking generator, running with a frequency of 1-2 Hz.
4. The method according to claim 1, characterized in that in the normal
mode of self-heating the flow of gaseous fuel is separated to return into igniting
zone to form the fire torch and for storage and I or external consumption.
5 5. The method according to claim 1, characterized in that the process of
formation and maintenance of the fire torch is carried out with a turbo charging.
6. The method according to claim 1, characterized in that at the process
start-up in a mode of forced heating it is carried out preliminary pumping of wa-
10 ter in an amount of 40-50% of maximum amount of normal working volume under
pressure 0.3-0.5 MPa, heating in the first stage is carried out until formation of
water steam at a temperature 450-500°C, heating is carried out from an independent
source of heat, such as, for example, induction heater.
15 7. The method according to claim 1, characterized in that at start-up of the
process in a forced heating mode it is carried out ignition of the steam and hydrocarbon
mixture or other fuel component from an independent source by ignition
spark pulse device with an independent sparking source, which operate with a
frequency of 40 - 50 Hz.
20
8. A thermal gas setup for hydrogen-containing gaseous fuel producing with
closed cycle, is made as a single device, which has a complex multi section corpus,
includes a burner system, firing chamber, unit for components mixing, pulse
ignition unit, pipes and start-up system, including independent induction heat
25 source, start-up burner with a supply of combustible fuel, characterized in that the
complex corpus is made as single, as a two cylindrical tubes, imbedded in one
another with a gap, forming technological cylinder, divided on isolated sections, so
the section number correspond to number of stages of the process of making of
fuel mixture, the inner tube cavity forms the firing chamber, unit for mixing is made
30 as injector with separate inlets for water as a steam, and hydrocarbon component,
outlet of the last section of the technological cylinder is connected via pipe to the
inlet of firing chamber, where is installed the burner system with ignition device
with spark ignition pulse source, a working burner, start-up burner, at the firing
chamber outlet is installed working torch forming element, as a restriction device, ,
the setup is equipped with fuel tanks, made as separate sealed discharge containers
for water and hydrocarbon component, technological cylinder is made as
5 three section device, so the section number correspond to number of stages of the
process of fuel mixture making, the cylinder concludes the I-st section with an
independent induction source of heat, section corresponds to vaporization stage,
I 2-nd section of stage of components mixing and heating a steam and gas mixture,
3-d section of the additional heating stage for the fuel mixture producing, dis-
10 charge water container is connected via pipe to the inlet of a first section of the
. .
technological cylinder, outlet of which is connected via pipe to I-st inlet of injector,
the second inlet of injector is connected via ,p~ihp e to discharge container of hydrocarbon
component, Injector outlet is connected via pipe to the technological cylinder
second section, connected via pipe to third section of technological cylinder.
15
9. The setup according to claim 8, characterized in that, ratio of radii of
tubes, forming the technological cylinder for fuel mixture producing is:
0,3 >(r2/R1)> 0,l;
Where R1 - outer diameter of the inner tube,
20 r2 - inner diameter of outer tube
10. The setup according to claim 8, characterized in that the turbo charging
u"it IS installed on the inlet of the burner system.
11. The setup according to claim 8, characterized in that the constant overpressure
of 0,3-0,5 MPa is supported in the discharge containers.
25
Dated this 11/07/2014 [RANJNA MEHTA-DUTT]
OF REMFRY & SAGAR
ATTORNEY FOR THE APPLICANT[S]
The invention relates to a method for producing a hydrogen-containing gaseous fuel in a
turbogenerator plant. The multi-stage method for producing a hydrogen-containing gaseous
fuel (G.G. Arakelyan method) is implemented in a turbogenerator plant which performs at
least three stages of separation of process flows and comprises separation of the supply of
water and hydrocarbon component, wherein, in the first stage, water is fed for heating and
steam generation, in the second stage, the hydrocarbon component is fed and is then mixed
with the steam by an injection method, and the mixture is heated and passed on to the third
and subsequent steps of heating to produce fuel, and then the fuel produced is passed on from
the latter step to the inlet of a firing system for forming a fving flare which heats a process
cylinder for the multi-step formation of fuel, and a working flare, and some of the fuel is
directed for external use.