Gasifier Solids Removal via Downflow Combustor and Flow Reversal
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Solution Overview
Problem
Existing integrated gasification combined-cycle (IGCC) systems are complex and costly due to the need for multiple vessels and ancillary equipment to remove solids from syngas, increasing operational complexity and manpower.
Innovation Solution
A gasifier solids removal system featuring a downflow combustor with serial flow passages and multi-stage entrainment separation stages, where products of combustion are reversed and contacted with water to separate particulate components from gaseous components, utilizing a lockhopper and sump for efficient solid removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If three separate vessels and a large radiant cooler are used to gasify bottoms, recover heat and remove solids from syngas, then solids removal effectiveness is improved, but device complexity and capital expense increase
Solution Approach 1:
The patent combines multiple solids removal functions into a single integrated combustor system. The combustor simultaneously performs gasification, heat recovery, and solids removal that would traditionally require separate vessels and a radiant cooler, thereby reducing device complexity while maintaining effectiveness
Solution Approach 2:
The combustor is designed to perform multiple functions: it gasifies the bottoms material, recovers heat from combustion, and removes solids from the syngas stream. This multi-functional design eliminates the need for dedicated separate equipment for each function, reducing overall system complexity
2Reliability
If three separate vessels and a large radiant cooler are used to gasify bottoms, recover heat and remove solids from syngas, then solids removal effectiveness is improved, but operational manpower and system cost increase
Solution Approach 1:
By merging multiple solids removal functions into one integrated combustor system, the operational manpower required to manage and coordinate multiple separate vessels is significantly reduced. The unified system requires fewer operational interventions and simplified control procedures
3Reliability
If products of combustion are channeled in a first direction and then flow direction is reversed, then particulate separation from gaseous components is improved, but device complexity increases
Solution Approach 1:
The flow passage is divided into distinct segments: an initial flow direction section followed by a reversal section and then a separation section. This segmentation allows the system to utilize the change in flow direction to enhance particulate separation efficiency through reduced momentum and improved settling conditions
Solution Approach 2:
The patent intentionally reverses the flow direction of combustion products to enhance separation efficiency. By channeling the flow in the opposite direction after the initial passage, the system creates conditions that favor particulate deposition and separation from the gas stream
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 simplifies the solids removal process, reducing capital expenses and operational complexity while effectively capturing over 90% of fine particulates and converting flowable slag into brittle solids for easier handling, thereby enhancing the efficiency and cost-effectiveness of IGCC systems.
Implementation Method 1
contacting the products of combustion with water to facilitate separating the particulate components of the products of combustion from the gaseous components
Implementation Method 2
separating the particulate components of the products of combustion from the gaseous components
Implementation Method 3
a lockhopper adjacent the sump, the lockhopper configured to transfer solid combustion products from the combustor to an exterior of the pressure vessel
Implementation Method 4
a multi-stage entrainment separator positioned in the outlet passage
Data Source
AI summary
Methods and systems for a gasifier solids removal system are provided. The system includes a down flow combustor including an inlet and an outlet and a combustion zone extending therebetween, the combustor configured to direct a flow of process material including syngas, flowable slag, and particulates in a first downward direction, a plurality of flow passages in serial flow communication including a first flow passage and a second flow passage, wherein the process material flow reverses direction flowing from the first passage to the second passage, and a plurality of entrainment separation stages in serial flow communication with at least one of the plurality of flow passages.