Gasification Reactor Floor Cooling and Refractory Shielding
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Solution Overview
Problem
Prior gasification systems face issues with thermal damage, corrosion, and slag accumulation, leading to premature wear and maintenance needs in the quench ring and metal floor of gasifiers, especially when handling high-temperature, corrosive syngas and molten slag from carbonaceous feedstocks.
Innovation Solution
A gasification system with a protective barrier and cooling conduit system, including refractory bricks and spirally arranged halved tubes on the reactor chamber floor, along with a quench ring that provides liquid coolant to the dip tube, effectively shields the quench ring and metal parts from hot syngas and slag, maintaining a stable temperature and preventing corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the quench ring is exposed to hot syngas and molten slag, then the gasification process can proceed, but the quench ring experiences thermal damage and corrosion leading to premature wear
Solution Approach 1:
A refractory protective ring is introduced as an intermediary barrier between the hot syngas/slag environment and the quench ring. This protective ring absorbs the thermal and corrosive effects, allowing the quench ring to maintain its cooling function while being shielded from direct exposure to harmful conditions.
Solution Approach 2:
The protective barrier changes the thermal environment parameters around the quench ring by providing thermal insulation. This reduces the temperature exposure of the quench ring material, preventing thermal damage and extending its operational lifespan while maintaining the high-temperature gasification process.
2Temperature
If the quench ring is used to cool syngas, then the syngas temperature is reduced, but slag accumulates on the quench ring reducing cooling efficiency
Solution Approach 1:
The harmful slag accumulation is prevented from adhering to the quench ring surface by the protective refractory barrier. The barrier extracts or prevents the deposition of slag on the cooling surface, maintaining the quench ring's cooling efficiency over extended periods and reducing maintenance frequency.
3Temperature
If refractory bricks are used to protect the reactor chamber floor, then thermal protection is provided, but the structure becomes more complex
Solution Approach 1:
The refractory protective ring serves multiple functions simultaneously: it protects the reactor chamber floor from thermal damage, prevents slag accumulation on the quench ring, and provides structural support. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in structural complexity.
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 solution significantly extends the lifespan of the quench ring and metal components by reducing thermal and corrosive damage, minimizing downtime for maintenance and ensuring continuous operation by maintaining a stable temperature and preventing slag accumulation.
Implementation Method 1
a pump system communicating with a source of a liquid coolant for circulating the liquid coolant through the at least one coolant conduit
Implementation Method 2
at least one coolant conduit arranged on an outer surface of the reactor chamber floor
Implementation Method 3
at least one layer of refractory bricks arranged on and supported by the reactor chamber floor, the refractory bricks enclosing the reactor outlet opening
Implementation Method 4
a quench ring that provides liquid coolant to the dip tube
Implementation Method 5
quench ring for providing liquid coolant against the inner surface of the dip tube
Data Source
AI summary
A gasification system for the oxidation of a carbonaceous feedstock to provide a synthesis gas comprising: a reactor chamber for oxidizing the carbonaceous feedstock; a quench section for holding a bath of liquid coolant; an intermediate section having a reactor outlet opening through which the synthesis gas is conducted from the reactor chamber into the bath of the quench section; at least one layer of refractory bricks arranged on the reactor chamber floor, the lower end section of the refractory bricks enclosing the reactor outlet opening and defining the inner diameter thereof; the intermediate section including a number of halved tubes for liquid coolant arranged onto at least part of the reactor chamber floor on a side thereof opposite to the lower end section of the refractory bricks; and a pump system for circulating the liquid coolant through the halved tubes on the reactor chamber floor.