Gasification Reactor Blaster Slag Removal
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Solution Overview
Problem
Existing gasification reactors face issues with large slag deposits forming at the point where quench gas is mixed into the hot gas flow, leading to uneven cooling and fouling on heat exchangers, which can disrupt the gas flow and prevent effective solidification of slag droplets.
Innovation Solution
A gasification reactor equipped with a blaster system that uses pressurized blast gas to actively remove slag deposits by directing blast nozzles in line with the quench gas flow, with adjustable angles and periodic operation to ensure complete removal of slag without residue, and a continuous purge flow to maintain nozzle integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If quench gas is supplied into the hot syngas stream to cool and solidify slag droplets, then the syngas is cooled to below slag softening temperature, but large slag deposits form at the mixing point disrupting gas flow
Solution Approach 1:
The blaster system is activated before or during the quench gas injection to pre-clean the discharge channel of any incipient slag deposits. This preliminary cleaning action prevents the formation of large slag deposits that would otherwise disrupt the quench gas flow and mixing process.
Solution Approach 2:
The blaster acts as an intermediary device between the quench gas supply and the syngas stream. By introducing a high-velocity gas jet, it creates a cleaning effect that removes slag deposits without directly interfering with the cooling function of the quench gas.
2Productivity
If the blaster is operated to remove slag deposits, then the quench gas flow is restored, but the blaster nozzles are exposed to heat radiation and potential clogging
Solution Approach 1:
The blaster operates with a continuous purge flow between periodic cleaning cycles. This continuous action maintains nozzle openness by preventing slag accumulation and simultaneously cools the nozzle surface through the flowing gas, protecting against heat radiation damage.
Solution Approach 2:
The blaster is operated periodically in cycles of intense cleaning followed by continuous purge flow. This periodic operation allows the system to alternately perform aggressive slag removal and gentle nozzle maintenance, optimizing both cleaning effectiveness and nozzle protection.
3Object-generated harmful factors
If the blaster directs gas flow at high velocity to remove deposits, then slag beards are effectively blasted away, but the blast impulse may affect the center of the syngas stream
Solution Approach 1:
The blaster system employs an asymmetric configuration where nozzles are positioned and angled to direct the blast impulse specifically at the peripheral regions where slag deposits form. This asymmetric targeting concentrates the cleaning effect where it is most needed while minimizing disruption to the central syngas flow.
Solution Approach 2:
The blaster nozzles are positioned to create localized high-velocity gas jets that affect only specific regions of the discharge channel where slag deposits are most likely to form. This localized action removes deposits without creating large-scale disturbances in the overall syngas stream symmetry.
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 blaster system effectively prevents large slag deposits from forming, ensuring uniform quench gas mixing and efficient cooling of syngas, thereby maintaining the integrity of the gas flow and heat exchanger operation by completely removing slag deposits and preventing new growth.
Implementation Method 1
A gasification reactor equipped with a blaster system that uses pressurized blast gas to actively remove slag deposits by directing blast nozzles in line with the quench gas flow
Implementation Method 2
a quench gas supply unit (5) arranged to mix cool quench gas into the stream A of discharged hot syngas to cool down the syngas to below the softening point of the slag particles
Implementation Method 3
it is necessary to solidify the liquid slag droplets that are entrained in the gas leaving the gasifier, and to cool the liquid slag droplets to a temperature at which they are not sticky
Implementation Method 4
the blaster tips are cooled and protected against heat radiation from the syngas
Data Source
AI summary
A gasification reactor (1) and a process for the production of syngas by gasification of a carbonaceous feed. The reactor comprises a gasifier unit with a discharge channel (4) for discharging a stream of slag-loaded hot syngas and a quencher (5) for supplying a flow of quench gas into the discharge channel (4). At least one blaster (10) is arranged comprising at least one blast nozzle (12), such as a blast lance, in line with the flow direction of the quench gas. The blaster (10) can be connected to a source of pressurized gas, such as syngas, nitrogen, carbon dioxide, steam or the like. The blaster can be actuated periodically to blast away slag deposits.