Integrated Quench Chamber Scrubber System
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Solution Overview
Problem
Existing gasification systems face operational instability and increased costs due to the exposure of quench units to hot, dirty syngas, which requires separate scrubber units for cooling and cleaning, leading to inefficiencies and higher overall system costs.
Innovation Solution
A gasifier with an integrated quench chamber and scrubber system that includes a dip tube and scrubber trays, where hot syngas is cooled in a quench pool and counterflowed with water through the scrubber trays, eliminating the need for a separate gas scrubber unit and reducing the risk of solids plugging and instability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate gas scrubber unit is used to cool and clean syngas, then syngas quality is improved, but system complexity and cost increase
Solution Approach 1:
The patent combines the quench chamber and gas scrubber unit into a single integrated system. The quench chamber serves dual functions: cooling the syngas and removing undesirable components through integrated scrubber trays that eliminate the need for a separate downstream gas scrubber unit, thereby reducing system complexity while maintaining syngas quality
2Reliability
If a separate gas scrubber unit is used, then syngas cleaning is improved, but overall system cost increases
Solution Approach 1:
The integrated design merges the quench chamber and gas scrubber unit into one system, eliminating the need for duplicate high-pressure vessels and reducing overall system cost while maintaining effective syngas cleaning through the scrubber trays
3Temperature
If quench unit is exposed to hot dirty syngas, then cooling function is performed, but operational stability decreases
Solution Approach 1:
The integrated scrubber system is positioned within the quench chamber to simultaneously perform cooling and cleaning functions. The scrubber trays remove undesirable components including slag and ash during the cooling process, preventing accumulation that would otherwise reduce operational stability
4Temperature
If quench unit is exposed to syngas components, then cooling occurs, but efficiency and operating range reduce
Solution Approach 1:
The integrated scrubber trays are positioned within the quench chamber to remove undesirable components during the cooling process. This simultaneous cleaning prevents buildup on heat transfer surfaces and maintains the quench unit's efficiency and operating range over time
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 integrated scrubber system enhances operational stability, reduces system costs, and minimizes the footprint by integrating cooling and scrubbing within a single pressure vessel, improving syngas quality and reducing the need for duplicate high-pressure vessels.
Implementation Method 1
flowing hot syngas down a dip tube, cooling the hot syngas in a quench pool
Implementation Method 2
cooling the hot syngas in a quench pool
Implementation Method 3
counterflowing water along the number of the scrubber trays so as to scrub the rising syngas
Implementation Method 4
flowing the cooled syngas through a number of scrubber trays, and counterflowing water along the number of the scrubber trays so as to scrub the rising syngas
Data Source
AI summary
The present application provides a gasifier for creating a flow of a syngas. The gasifier may include a reaction chamber and a quench chamber. The quench chamber may include a number of integrated scrubber trays therein such that the syngas first enters a quench pool via a dip tube and then passes through the scrubber trays before leaving the quench chamber.