Synthesis Gas Cooling via Segmented Heat Recovery
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Solution Overview
Problem
Existing methods for cooling raw synthesis gas in thermochemical synthesis gas or hydrogen production are economically inefficient due to the need for expensive acid-resistant materials and increased pressure loss, as well as loss of stripping steam when degassing demineralized water, leading to suboptimal heat utilization and increased costs.
Innovation Solution
A method involving indirect cooling of the first fluid containing acid gases and water vapor in two successive steps using a chemically neutral second fluid, allowing heat transfer without the need for additional heat exchangers, and utilizing an intercooler to generate stripping steam for degassing, thus reducing material costs and improving heat utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If additional heat exchangers are arranged downstream of the BFW preheater to efficiently use low temperature heat of the raw synthesis gas, then heat utilization is improved, but pressure loss increases and device complexity increases
Solution Approach 1:
The cooling process is divided into two successive steps: first cooling the raw synthesis gas from approximately 100°C to just below boiling temperature, then further cooling to condense water. The intercooler is integrated into the degasifier sump chamber, creating a segmented heat recovery system that reduces pressure loss while maintaining efficient heat utilization.
Solution Approach 2:
The intercooler is nested within the degasifier structure, specifically in the sump chamber where stripping steam is generated. This nesting eliminates the need for separate additional heat exchangers downstream, reducing both pressure loss and device complexity while maintaining efficient heat recovery for low temperature heat utilization.
2Use of energy by moving object
If additional heat exchangers are arranged downstream of the BFW preheater, then heat utilization is improved, but device complexity and manufacturing cost increase due to acid-resistant material requirements
Solution Approach 1:
The intercooler is nested within the degasifier structure, utilizing the existing acidic environment infrastructure. This eliminates the need for separate additional heat exchangers that would require expensive acid-resistant materials, significantly reducing manufacturing cost while maintaining efficient heat recovery.
Solution Approach 2:
The system uses the acidic condensate already present in the process to cool the raw synthesis gas in the intercooler. The acidic condensate serves dual purposes: it absorbs heat from the raw synthesis gas and simultaneously strips volatile components from the BFW. This self-service approach eliminates the need for additional acid-resistant heat exchangers, reducing manufacturing cost.
3Ease of operation
If stripping steam is lost to the atmosphere during DMW degassing, then degassing function is achieved, but energy efficiency deteriorates
Solution Approach 1:
The stripping steam that would normally be lost to the atmosphere is redirected to serve as a heat source in the intercooler. The 'waste' steam now provides useful heat for cooling the raw synthesis gas and condensing water, converting an energy loss into a beneficial heat recovery opportunity that improves overall energy efficiency.
Solution Approach 2:
Instead of discarding the stripping steam to the atmosphere, the system recovers its thermal energy in the intercooler. The stripping steam condenses in the intercooler, releasing heat that is used to cool the raw synthesis gas and condense water vapor. This recovery process transforms waste energy into useful thermal energy, improving energy efficiency.
4Reliability
If raw synthesis gas is cooled to condense water for acid gas removal, then gas purification is improved, but heat loss increases
Solution Approach 1:
The cooling process is made continuous and useful through two successive cooling steps with heat recovery. The heat extracted from the raw synthesis gas during cooling is continuously recovered in the intercooler to generate stripping steam and condense water. This continuous heat recovery eliminates waste heat loss while maintaining effective gas purification through water condensation and acid gas removal.
Solution Approach 2:
The heat that would normally be lost during the cooling and condensation process is converted into a beneficial resource. The intercooler captures this heat and uses it to generate stripping steam for degassing and to condense water vapor. The harmful heat loss is transformed into useful thermal energy that supports other process functions, improving overall energy efficiency while maintaining gas purification.
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 more efficient heat use and reduces material costs by eliminating the need for expensive acid-resistant equipment, while optimizing the use of stripping steam, thereby enhancing the economic efficiency of synthesis gas or hydrogen production.
Implementation Method 1
heat is transferred between the two fluids via a heat-conductive wall, which separates both fluids from one another and prevents mass transfer
Implementation Method 2
a first fluid, which arises in the process and contains acid gases and water vapor, is cooled indirectly against a second fluid, an acidic condensate thus being formed
Implementation Method 3
utilizing an intercooler to generate stripping steam for degassing
Implementation Method 4
heat for use in the heat-consuming process step is indirectly drawn from the second fluid
Data Source
AI summary
The invention relates to a method and to a device for performing a process (P) having at least one heat-consuming process step (F). A first fluid (2), which arises in the process and contains acid gases and water vapor, is cooled indirectly against a second fluid (7), an acidic condensate thus being formed. The invention is characterized in that the first fluid (2) is cooled in at least two successive steps (E1, E2), between which heat for use in the heat-consuming process step (V) is indirectly drawn from the second fluid (10).