Annular Wall Segmentation for Slag Separation in Gasification Coolers

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Solution Overview

Problem

Incorporation of slag in syngas entering a radiant syngas cooler can damage heat exchanger tubing, and current methods for separating slag from syngas complicate optimal cooling by increasing syngas velocity, which affects heat exchange efficiency.

Innovation Solution

A gasification cooling system with an annular wall featuring an annular step and regions of constant and increasing diameter to separate slag from syngas, allowing for decoupling of the slag stream and facilitating diffusion of syngas towards heat exchanger tubing, enabling improved heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the diameter of the throat is limited to separate slag from syngas, then slag separation is improved, but the velocity of syngas flow increases which complicates optimal cooling design

Engineering Contradiction:

Improveslag separationVSAvoidsyngas flow velocity

Core Design Contradiction:

ReliabilityVSSpeed

Solution Approach 1:

The throat is segmented into multiple regions with different diameter characteristics (annular step, region of constant diameter, region of increasing diameter) to perform different functions: initial separation, maintained flow control, and velocity reduction for optimal cooling

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sections of the throat have different geometric properties tailored to specific functions: the annular step provides separation, the constant diameter region maintains flow, and the increasing diameter region reduces velocity for effective heat exchange

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If slag is incorporated in syngas entering the radiant syngas cooler, then the cooling system can handle variable feedstock, but heat exchanger tubing may be damaged without sufficient separation

Engineering Contradiction:

Improvefeedstock flexibilityVSAvoidheat exchanger tubing damage

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The throat structure performs preliminary separation of slag from syngas before the syngas reaches the heat exchanger tubing, preventing damage while maintaining the ability to handle variable feedstocks with different slag contents

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system effectively separates slag from syngas, reducing the risk of damage to heat exchanger tubing and enhancing heat transfer efficiency by diffusing the syngas flow, thus optimizing cooling performance.

Implementation Method 1

one or more drip points circumferentially disposed about the annular wall and adapted to separate a high density stream from a mixed density fluid stream

Methodology Applied

Scientific EffectDensity separation: Density Gradient

Implementation Method 2

a plurality of heat exchanger tubes downstream of the one or more annular steps and adapted to cool a syngas in the gas passage as the syngas flows in the flow direction

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Data Source

PatentUS9045705B2Systems and methods for cooling gasification products

Publication Date: 2015.06.02 AIR PROD & CHEM INC

AI summary

Gasification cooling systems provided herein may include a housing having a fluid passage extending in a flow direction lengthwise along the housing and an annular wall disposed about the fluid passage and having one or more annular steps. Such systems may also include a plurality of heat exchanger tubes downstream of the one or more annular steps and adapted to cool a syngas in the gas passage as the syngas flows in the flow direction.