IGCC Gas Removal System with Start-Up Absorber

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Solution Overview

Problem

Existing integrated gasification combined cycles (IGCCs) face challenges in meeting emissions requirements during all operating conditions, particularly during system shutdowns, equipment failures, or sulfur recovery unit trips, as current acid gas removal systems are unable to effectively capture emissions at these times, leading to atmospheric releases.

Innovation Solution

The proposed solution involves a gas removal system with a first rich solvent tank, a stripper, and an absorber configured to store and process emissions-rich solvents, allowing for the recirculation of emissions-free solvents and the storage of emissions-rich gases during start-up and shutdown conditions, utilizing variable pressure absorbers and additional solvent streams like methyl diethanol amines to minimize atmospheric emissions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a traditional acid gas removal system is used, then emissions can be captured during normal operation, but emissions are released into the atmosphere during system shutdowns, equipment failures, or sulfur recovery unit trips

Engineering Contradiction:

Improveemissions capture capabilityVSAvoidatmospheric emissions

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by adding a start-up absorber that can immediately absorb syngas emissions during start-up conditions before the main acid gas removal system is fully operational. This preliminary absorption capability ensures emissions are captured from the outset, preventing atmospheric releases during critical transition periods when traditional systems would fail to meet emissions requirements

Inventive Principle:

Principle #10Preliminary action

2Object-affected harmful factors

If low sulfur start-up fuels or methanol are used, then emissions can be reduced, but additional inventory and handling equipment are required, increasing system costs

Engineering Contradiction:

ImproveemissionsVSAvoidinventory and handling equipment

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent uses an intermediary approach by introducing a start-up absorber as a mediating component between the gasifier and the main acid gas removal system. This intermediary device captures emissions during start-up without requiring fundamental changes to fuel composition or the introduction of complex additional handling equipment, thus reducing emissions while avoiding the cost and complexity penalties of alternative approaches

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If a start-up absorber is added, then emissions upstream from the acid gas removal system can be reduced, but the system can only handle low temperature syngas and cannot address emissions downstream from the acid gas removal system

Engineering Contradiction:

Improveupstream emissionsVSAvoidtemperature range and emission coverage

Core Design Contradiction:

Object-affected harmful factorsVSAdaptability or versatility

Solution Approach 1:

The patent applies universality by designing a integrated system where the start-up absorber is coupled with the main acid gas removal system and sulfur recovery unit, creating a multi-functional configuration. This universal system can handle both upstream emissions during start-up and downstream emissions during normal operation, while accommodating various syngas temperature conditions through proper heat integration and solvent selection across the entire process train

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 enables the IGCC to start up with minimal emissions and reduces emissions during equipment failures or shutdowns by storing emissions in solvent tanks until systems stabilize, ensuring no emissions are released into the atmosphere, thereby improving compliance with emissions regulations.

Implementation Method 1

The absorber contains a solvent capable of absorbing hydrogen sulfide and carbonyl sulfide from the syngas

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 2

The sulfur-rich solvent is delivered to a stripper, wherein acid gases are removed from the solvent

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 3

use gasification to breakdown biomass feedstock to create synthetic gas

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Data Source

PatentUS8038779B2Methods and apparatus for reducing emissions in an integrated gasification combined cycle

Publication Date: 2011.10.18 AIR PROD & CHEM INC

AI summary

A method of assembling a gas removal system for an integrated gasification combined cycle is provided. The method includes coupling a first rich solvent tank in flow communication with the integrated gasification combined cycle to store a first emissions-rich solvent discharged from the integrated gasification combined cycle and coupling a first stripper in flow communication with the first rich solvent tank to facilitate removing gases from the first emissions-rich solvent. The method also includes coupling an absorber in flow communication with the first stripper to receive gases from the first stripper and create a second emissions-rich solvent and coupling a second rich solvent tank in flow communication with the absorber to store the second emissions-rich solvent.