Gas Shift Reactor Steam Generation for IGCC Efficiency
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Solution Overview
Problem
In integrated gasification combined-cycle (IGCC) power generation plants, the high temperatures in the water-gas shift reactor lead to uncontrolled heat release, reducing electrical generation efficiency due to steam injection, which also necessitates larger reactors and additional moisture removal apparatus.
Innovation Solution
A method and apparatus that include a gas shift reactor configured to receive boiler feedwater and syngas, producing a high-pressure steam stream, which is then used to optimize temperature control and reduce steam usage, thereby enhancing electrical generation efficiency and reducing equipment needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If steam is injected into the shift reactor to control temperature, then temperature control is improved, but electrical generation efficiency deteriorates due to reduced steam availability for turbines
Solution Approach 1:
The shift reactor is designed to generate its own steam through the exothermic water-gas shift reaction (CO + H2O → CO2 + H2). The reactor utilizes the heat released during the reaction to convert water into steam, which is then directly available for turbine generation without requiring external steam injection or consumption. This self-service mechanism eliminates the trade-off between temperature control and energy loss.
2Temperature
If steam injection is used to mitigate temperature rise, then temperature control is improved, but plant electrical generation deteriorates
Solution Approach 1:
The invention converts the harmful effect of uncontrolled temperature rise into a beneficial outcome by utilizing the exothermic heat of the water-gas shift reaction to generate steam. Instead of needing to inject steam to control temperature (which would reduce power generation), the reactor design allows the reaction heat to directly produce steam that is then fed to the turbine, thereby converting potential thermal runaway into useful energy production.
3Temperature
If larger shift reactor is used to accommodate steam injection, then temperature control is improved, but device complexity increases
Solution Approach 1:
The shift reactor is designed to generate its own steam through the exothermic water-gas shift reaction, eliminating the need for external steam injection systems, larger reactor volumes, and additional moisture removal apparatus. The reactor operates with standard sizing and configuration while achieving effective temperature control through the inherent thermodynamics of the reaction and proper heat integration with the turbine system.
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 improves thermal efficiency by controlling reactor temperatures, reducing capital costs, and increasing steam availability for turbines, while minimizing the need for additional heat transfer apparatus and associated hardware.
Implementation Method 1
the scrubbed and quenched syngas is typically channeled to at least one water-gas shift reactor to convert the CO and water into hydrogen (H2) and carbon dioxide (CO2) via at least one exothermic chemical reaction. The heat released via the exothermic reactions facilitates a temperature rise in the shift reactor.
Implementation Method 2
The at least one gas shift reactor is further configured to produce a high pressure steam stream
Implementation Method 3
The at least one steam turbine engine is configured to receive at least a portion of the high pressure steam stream
Data Source
AI summary
A method of producing substitute natural gas (SNG) includes providing at least one steam turbine engine. The method also includes providing a gasification system that includes at least one gas shift reactor configured to receive a boiler feedwater stream and a synthesis gas (syngas) stream. The at least one gas shift reactor is further configured to produce a high pressure steam stream. The method further includes producing a steam stream within the at least one gas shift reactor and channeling at least a portion of the steam stream to the at least one steam turbine engine.