Gasification Reactor Slag Tap Cooling Conduits
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Solution Overview
Problem
Gasification reactors face blockages due to slag formation when processing ash-containing feedstocks, requiring operation at elevated temperatures to prevent blockages, which is inefficient.
Innovation Solution
A reactor design featuring a tubular syngas collection chamber, quench chamber, and dipleg with a frusto-conical slag tap and separate cooling conduits allows for monitoring of cooling medium temperature to predict and prevent slag blockages by maintaining optimal gasification temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the reactor operates at elevated gasification temperature to prevent slag blockage, then the reliability of the reactor is improved, but the energy efficiency deteriorates
Solution Approach 1:
The patent applies preliminary action by monitoring the temperature of cooling water in the slag tap conduits before actual blockage occurs. The cooling water temperature serves as an early warning indicator of slag layer thickness, allowing operators to adjust gasification temperature proactively to prevent blockage rather than reacting after blockage occurs, thus avoiding unnecessary high-energy operation.
Solution Approach 2:
The patent implements feedback control by using the cooling water temperature from the slag tap conduits as a feedback signal to monitor slag layer conditions. This temperature feedback allows the control system to adjust the gasification temperature dynamically, maintaining reliable operation while minimizing energy consumption by operating at the lowest necessary temperature.
2Loss of energy
If the reactor operates at optimal gasification temperature for efficiency, then the energy efficiency is improved, but the reliability deteriorates due to slag blockage risk
Solution Approach 1:
The system performs preliminary monitoring of slag layer thickness through cooling water temperature measurement in the slag tap conduits. This early detection capability allows the reactor to operate at optimal low temperatures for efficiency, with the understanding that blockage can be detected and addressed before it actually blocks the system.
Solution Approach 2:
The cooling water temperature provides continuous feedback on slag layer conditions, enabling the reactor to maintain optimal gasification temperature while having real-time awareness of blockage risk. This feedback loop ensures reliability is maintained through monitoring rather than through conservative high-temperature operation.
3Temperature
If a constricted throat is used to cool hot gases, then the cooling efficiency is improved, but the reliability deteriorates due to blockage by slag
Solution Approach 1:
The patent introduces an intermediary monitoring system using the cooling water in the slag tap conduits as a mediator to detect slag layer thickness. This intermediary measurement method allows the constricted throat to maintain its efficient cooling geometry while the cooling water temperature serves as an indirect indicator of slag accumulation, enabling early warning before blockage occurs.
Solution Approach 2:
The patent replaces direct mechanical monitoring of the throat condition with a thermal field-based monitoring method. Instead of mechanically measuring slag thickness in the constricted throat, the system uses temperature measurement of cooling water in adjacent conduits to infer slag layer conditions, substituting a mechanical measurement problem with a thermal measurement solution.
4Reliability
If continuous monitoring of slag layer thickness is implemented, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The cooling water conduits in the slag tap serve multiple functions: they provide necessary cooling to the slag tap structure and simultaneously serve as sensors for monitoring slag layer thickness through temperature measurement. This multi-functionality eliminates the need for separate monitoring devices, maintaining reliability improvement while avoiding additional system complexity.
Solution Approach 2:
The cooling water system serves itself by providing both its primary cooling function and the secondary monitoring function. The cooling water temperature automatically reflects the thermal conditions and slag layer thickness, providing self-diagnostic capability without requiring external sensors or complex monitoring infrastructure.
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 operation closer to optimal gasification temperatures while minimizing slag blockage risks, allowing for efficient syngas production and monitoring of slag layer thickness.
Implementation Method 1
the frusto-conical part comprises one or more conduits having an inlet for cooling medium and an outlet for used cooling medium
Implementation Method 2
measuring the temperature of the used cooling water or steam make in the conduits of the frusto-conical part
Implementation Method 3
The hot gases are passed via a constricted throat to be cooled in a liquid bath located below the reaction chamber
Implementation Method 4
The syngas outlet of the syngas collection chamber is fluidly connected with the quench chamber via a tubular diptube
Data Source
Figure 1
Figure 1a~3
AI summary
Reactor vessel for preparing a syngas comprising a tubular syngas collection chamber, a quench chamber and a dipleg connecting the syngas collection chamber with the quench chamber, wherein the syngas collection chamber is connected to the dipleg via a slag tap, comprising of a frusto-conical part starting from the lower end of the tubular wall of the syngas collection chamber and diverging to an opening fluidly connected to the interior of the dipleg, wherein the diameter of said opening is smaller than the diameter of the dipleg, and wherein the frusto-conical part comprises one or more conduits having in inlet for cooling medium and an outlet for used cooling medium wherein the slag tap also comprises of a first tubular part connected to the opening of the frusto- conical part and extending in the direction of the dipleg, wherein a second tubular part is connected to the frusto-conical part or to the tubular part and extending in the direction of the dipleg and having a diameter smaller than the diameter of the diptube and larger than the diameter of the opening of the frusto-conical part and wherein the second tubular part is spaced away from the dipleg to provide an annular space and wherein in said annular space a discharge conduit for liquid water is present having a liquid water discharge opening located such to direct the liquid water along the inner wall of the diptube, and wherein at least half of the vertical length of the first tubular part extends below the liquid water discharge opening.