Hot Gas Cleaner for High-Temperature DRI Synthesis Gas
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Solution Overview
Problem
The production of direct reduced iron (DRI) using hot synthesis gas from petroleum refinery bottoms or petroleum coke gasifiers is inefficient due to the need for cooling to below 200 C for conventional sulfur and dust removal, resulting in high equipment costs and energy inefficiency.
Innovation Solution
A process utilizing a high or low pressure petroleum refinery bottoms or petroleum coke gasifier and a hot gas cleaner to desulfurize and dedust the synthesis gas at elevated temperatures (>350 C), with a recycle gas stream and heat management system to optimize gas usage in a direct reduction shaft furnace.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If synthesis gas is cooled to below 200 C for conventional sulfur and dust removal, then sulfur and dust can be removed effectively, but energy consumption increases and equipment costs rise
Solution Approach 1:
The patent changes the temperature parameter from conventional low-temperature (below 200 C) cooling to high-temperature (>350 C) processing. The hot gas cleaner operates at elevated temperatures to desulfurize and dedust synthesis gas, eliminating the need for extensive cooling while maintaining effective impurity removal through thermal processes
2Object-affected harmful factors
If synthesis gas is cooled to below 200 C for conventional sulfur and dust removal, then sulfur and dust can be removed effectively, but equipment costs increase
Solution Approach 1:
The patent changes the temperature parameter from conventional low-temperature (below 200 C) cooling to high-temperature (>350 C) processing. The hot gas cleaner operates at elevated temperatures to desulfurize and dedust synthesis gas, eliminating the need for extensive cooling while maintaining effective impurity removal through thermal processes
Solution Approach 2:
The patent extracts the sulfur and dust removal process from the conventional cooling sequence and performs it independently at high temperature in the hot gas cleaner. This separates the impurity removal function from the temperature reduction requirement, allowing simultaneous high-temperature operation and effective desulfurization/dedusting
3Object-affected harmful factors
If synthesis gas is cooled to below 200 C for conventional sulfur and dust removal, then sulfur and dust can be removed effectively, but process efficiency decreases
Solution Approach 1:
The patent changes the temperature parameter from conventional low-temperature (below 200 C) cooling to high-temperature (>350 C) processing. The hot gas cleaner operates at elevated temperatures to desulfurize and dedust synthesis gas, eliminating the need for extensive cooling while maintaining effective impurity removal through thermal processes
Solution Approach 2:
The patent maintains continuous high-temperature processing through the hot gas cleaner, eliminating the interruption and energy loss associated with cooling the synthesis gas. The continuous high-temperature operation sustains process efficiency while achieving effective sulfur and dust removal
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
Enables efficient production of DRI by maintaining high temperature processing, reducing energy consumption, and lowering equipment costs through effective desulfurization and dedusting of synthesis gas, while maintaining the integrity of the reducing gas stream for direct reduction.
Implementation Method 1
a hot gas cleaner operable for desulfurizing and dedusting the synthesis gas stream
Implementation Method 2
a hot gas cleaner operable for desulfurizing and dedusting the synthesis gas stream
Implementation Method 3
a cooler/scrubber and a compressor collectively operable for cooling, scrubbing, and compressing the top gas stream
Implementation Method 4
a cooler/scrubber and a compressor collectively operable for cooling, scrubbing, and compressing the top gas stream
Implementation Method 5
a carbon dioxide removal unit operable for removing carbon dioxide from the top gas stream
Implementation Method 6
a waste heat boiler operable for removing heat from a portion of the synthesis gas stream
Implementation Method 7
a recycle gas heater operable for heating the recycle gas stream
Implementation Method 8
a turbine generator operable for decreasing the pressure of the synthesis gas stream
Implementation Method 9
a reducing gas heater operable for heating the reducing gas stream
Data Source
AI summary
Methods and systems for producing DRI utilizing a petroleum refinery bottoms (i.e. heavy fuel oil, vacuum residue, visbreaker tar, asphalt, etc.) or petroleum coke gasifier and a hot gas cleaner. Cooling of the hot synthesis gas generated by the petroleum refinery bottoms or petroleum coke gasifier to <200 C is not necessary. Rather, the synthesis gas from the petroleum refinery bottoms or petroleum coke gasifier is desulfurized and dedusted at high temperature (>350 C) using a hot gas cleaner, well known to those of ordinary skill in the art, although not in such an application. This hot gas cleaner may be high pressure or low pressure.