Integrated Syngas Cooler and Shift Reactor for IGCC Efficiency
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Solution Overview
Problem
Existing IGCC systems require an external heat source for pre-heating gasification feed, leading to the production of medium and intermediate pressure steam with limited usefulness and reduced overall plant efficiency.
Innovation Solution
Incorporating a syngas cooler that transfers heat from the gasifier reaction zone to a shift reactor, generating high pressure steam through an exothermic shift reaction, and using a heat exchanger to produce high pressure steam, eliminating the need for separate startup shift pre-heaters and optimizing heat transfer within the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate shift heat recovery system with feed product exchangers is used, then pre-heating of gasification feed can be achieved, but medium pressure and intermediate pressure steam is produced which has limited usefulness and reduces total plant efficiency
Solution Approach 1:
The patent combines the syngas cooler and shift reactor into an integrated unit where the syngas cooler is positioned inside the shift reactor. This merging eliminates the need for separate feed product exchangers and external pre-heating systems, allowing direct heat transfer from syngas cooling to drive the exothermic shift reaction and produce only high pressure steam, thereby improving plant efficiency
2Ease of manufacture
If an external heat source is used for pre-heating gasification feed, then the exothermic reaction in the shift reactor can be started, but the configuration requires additional equipment and reduces overall system efficiency
Solution Approach 1:
The integrated design allows the syngas cooler to serve dual purposes: cooling the syngas and providing the necessary heat for the shift reaction. The system uses its own internal heat resources rather than requiring external heat sources, eliminating additional equipment while maintaining startup capability through the exothermic shift reaction
3Ease of operation
If separate startup shift pre-heaters are used, then pre-heating can be achieved, but the system complexity increases and cost-effectiveness decreases
Solution Approach 1:
The syngas cooler is designed to perform multiple functions simultaneously: it cools the hot syngas exiting the gasifier and provides the necessary heat for the exothermic shift reaction in the shift reactor. This multi-functionality eliminates the need for separate startup pre-heaters and feed product exchangers, reducing equipment count and improving cost-effectiveness
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 allows for the generation of only high pressure steam, enhancing overall efficiency and eliminating the need for separate pre-heaters, thereby improving the reliability and cost-effectiveness of IGCC power generation systems.
Implementation Method 1
a syngas cooler configured to transfer heat from a reaction zone of the gasifier to a flow of fluid through the syngas cooler
Implementation Method 2
generating heat in a flow of shift effluent using an exothermic shift reaction in the shift reactor
Implementation Method 3
a heat exchanger coupled in flow communication with the reaction vessel wherein the heat exchanger is adapted to produce relatively high pressure steam using the generated heat
Data Source
AI summary
Methods and systems for a gasifier system are provided. The gasifier system includes a gasifier including a syngas cooler configured to transfer heat from a reaction zone of the gasifier to a flow of fluid through the syngas cooler, a reaction vessel coupled in flow communication with the syngas cooler wherein the reaction vessel is adapted to receive the flow of fluid and generate heat in an exothermic shift reaction. The system also includes a heat exchanger coupled in flow communication with the reaction vessel, the heat exchanger adapted to produce relatively high pressure steam using the generated heat.