Gasification Quench Ring Shielding
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Solution Overview
Problem
Prior gasification systems face issues with thermal damage, corrosion, and slag accumulation, leading to premature shutdowns and maintenance challenges due to the vulnerability of metal floors and quench rings to high-temperature syngas and molten slag, which affects the efficiency and longevity of the gasification process.
Innovation Solution
The implementation of a gasification system with a refractory-lined reactor chamber, a widened dip tube with a quench ring for enhanced cooling, and a protective barrier that shields the quench ring from hot syngas and slag, along with a blast nozzle for purging and cleaning, to prevent overheating and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a quench ring is used to cool the dip tube, then cooling efficiency is improved, but the quench ring is vulnerable to thermal damage and corrosion from high-temperature syngas and molten slag
Solution Approach 1:
A protective barrier made of refractory material is introduced as an intermediary between the quench ring and the hot syngas/slag. This barrier shields the quench ring from direct exposure to thermal and chemical damage while allowing it to perform its cooling function through the dip tube wall.
Solution Approach 2:
The system uses composite material construction with the quench ring made of corrosion-resistant alloy (such as Incoloy or nickel-based alloy) combined with a refractory protective barrier. This composite approach provides both thermal protection and structural integrity for effective cooling.
2Temperature
If the quench ring is positioned to cool the dip tube, then cooling performance is improved, but slag accumulates on the quench ring forming plugs that restrict syngas flow
Solution Approach 1:
The harmful function of slag accumulation on the quench ring is eliminated by positioning the quench ring away from the direct slag flow path. The quench ring is located at a position where it cools the dip tube effectively without being in the path of molten slag, thus preventing plug formation.
Solution Approach 2:
The quench ring is positioned in a different spatial dimension relative to the slag flow path. Instead of being directly in the vertical slag flow, it is located at an offset position that allows it to cool the dip tube through thermal conduction while avoiding direct slag contact and accumulation.
3Temperature
If refractory brick is used to line the reactor chamber, then thermal protection is improved, but refractory material erodes or wears off over time
Solution Approach 1:
The protective barrier design changes the thermal and mechanical parameters at the refractory-brick interface by providing an additional protective layer. This reduces the thermal stress and mechanical erosion on the refractory brick, extending its service life while maintaining thermal protection.
4Strength
If the metal floor is made from pressure vessel metallurgy, then structural strength is improved, but the floor is vulnerable to wear from high-temperature corrosive gas
Solution Approach 1:
The metal floor uses composite material construction with pressure vessel steel providing structural strength and a refractory protective layer providing corrosion and erosion resistance. This composite approach allows the metal floor to maintain its mechanical integrity while being protected from chemical attack by hot syngas.
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 configuration significantly reduces wear and corrosion of the quench ring and metal components, extends the lifespan of the gasification system, and minimizes downtime by providing effective thermal and chemical protection, ensuring consistent operation and reduced maintenance needs.
Implementation Method 1
A quench ring may be formed of a corrosion resistant material, such as chrome nickel iron alloy or nickel based alloy such as Incoloy®, and is arranged to spray or inject water as a coolant against the inner surface of the dip tube
Implementation Method 2
The water bath cools the syngas exiting from the reaction chamber and also cools any slag that drops into the water bath
Implementation Method 3
a high temperature reaction chamber surrounded by one or more layers of insulating and refractory material, such as fire clay brick, also referred to as refractory brick or refractory lining
Data Source
AI summary
A gasification system for the partial oxidation of a carbonaceous feedstock to at least provide a synthesis gas, comprising: a reactor chamber for receiving and partially oxidizing the carbonaceous feedstock; a quench chamber below the floor of the reactor chamber for holding a bath of liquid coolant; an intermediate section at said reactor chamber floor, the intermediate section having a reactor outlet opening through which the reactor chamber communicates with the quench chamber to conduct the synthesis gas from the reactor chamber into the bath of the quench chamber; at least one layer of refractory bricks arranged on and supported by the reactor chamber floor, the lower end section of the refractory bricks enclosing the reactor outlet opening and defining the inner diameter thereof; and a dip tube extending from the reactor outlet opening to the bath of the quench chamber, the dip tube having a widened top section.