Dry Bottom Reactor Vessel for Coal Gasification
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Solution Overview
Problem
Reactor vessels in coal gasification systems generate excess quench water containing slag and byproducts, leading to inefficiencies and waste in the quench-cooling process, as existing systems require full water quenching to manage hot slag, resulting in 'black' water production.
Innovation Solution
A dry bottom reactor vessel design that uses a dry solids material as a receiving bed to catch and cool hot slag, reducing the need for full water quenching by employing a dry bed zone with a dry solids material and optional cooler to manage heat and prevent damage to the reactor vessel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If full water quenching is used to manage hot slag, then the reactor vessel is protected from hot slag damage, but excess quench water containing slag and byproducts is generated causing waste and inefficiency
Solution Approach 1:
The invention extracts the water quenching function from the slag cooling process, replacing it with a dry bed zone that directly receives and cools slag without introducing water. This eliminates the generation of waste black water while maintaining slag damage protection.
Solution Approach 2:
A dry bed zone filled with dry solids material serves as an intermediary between the slag and the reactor vessel walls. This intermediate layer absorbs and distributes the thermal energy from slag, preventing direct contact with the vessel while avoiding water quenching.
2Loss of substance
If a dry bed zone with dry solids material is used to catch and cool slag, then the need for full water quenching is reduced minimizing black water generation, but the complexity of the reactor vessel structure increases
Solution Approach 1:
The dry bed zone is implemented locally at the bottom of the reactor vessel where slag accumulates, rather than modifying the entire reactor structure. This localized approach minimizes structural complexity while achieving the goal of reducing black water generation.
Solution Approach 2:
The invention changes the physical state parameter of the cooling medium from liquid water to dry solids material. This parameter change fundamentally alters the cooling mechanism to eliminate water consumption and black water generation without requiring complex additional systems.
3Loss of substance
If quench water is vaporized into steam instead of forming liquid droplets, then waste black water is minimized, but the quenching efficiency may be reduced
Solution Approach 1:
The invention replaces the mechanical water spray quenching system with a thermal conduction-based dry cooling system. The dry solids material conducts heat away from slag through direct contact, eliminating the need for water vaporization and associated quenching efficiency concerns.
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
This approach minimizes the generation of waste 'black' water by vaporizing quench water into steam, eliminating the need for full water quenching and allowing for the recycling of slag and solids, thus enhancing operational efficiency and reducing waste.
Implementation Method 1
The cooler 60 is a heat exchanger in which a relatively cool working fluid circulates
Implementation Method 2
a dry solids material as a receiving bed to catch and cool hot slag
Implementation Method 3
vaporizing quench water into steam, eliminating the need for full water quenching
Data Source
AI summary
A reactor vessel includes an entrained-flow gasifier and a dry solids discharge beneath the gasifier.