Multi-Stage Synthesis Gas Cooling Prevents Tar Condensation
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Solution Overview
Problem
The cooling of synthesis gas containing condensable components like tar in gasification plants leads to condensation and deposition on heat exchangers, causing clogging and plant standstill, especially when cooling below the condensation temperature, which is challenging for standard filters and heat exchangers.
Innovation Solution
A multi-stage cooling process where the synthesis gas is initially cooled above the condensation temperature in conventional heat exchangers, followed by admixing cold, cleaned synthesis gas to quench it below the condensation point in subsequent stages, using smoke tube coolers and gas scrubbers to manage condensate dilution and separation effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the synthesis gas is cooled below the condensation temperature of tar, then the separation of condensable components becomes more efficient, but tar condenses and deposits on heat exchangers causing clogging
Solution Approach 1:
The cooling process is divided into multiple stages: first cooling stage (above condensation temperature using conventional heat exchangers), second cooling stage (below condensation temperature using quenching with cold synthesis gas), and third cooling stage (further cooling). This segmentation allows efficient tar separation while preventing condensation damage by separating the cooling functions across different stages and methods.
Solution Approach 2:
Cold cleaned synthesis gas is used as an intermediary medium to quench and cool the synthesis gas below the condensation temperature of tar. This intermediary cooling method achieves the necessary temperature reduction for efficient separation without causing tar condensation on heat exchanger surfaces, as the quenching occurs in a different manner than conventional heat exchange.
2Ease of manufacture
If the synthesis gas is cooled to below 200°C before separation, then standard filters can be used reducing costs, but tar condensation and deposition occurs
Solution Approach 1:
The cooling process is divided into multiple stages: first cooling stage (above condensation temperature using conventional heat exchangers), second cooling stage (below condensation temperature using quenching with cold synthesis gas), and third cooling stage (further cooling). This segmentation allows efficient tar separation while preventing condensation damage by separating the cooling functions across different stages and methods.
Solution Approach 2:
Cold cleaned synthesis gas is used as an intermediary medium to quench and cool the synthesis gas below the condensation temperature of tar. This intermediary cooling method achieves the necessary temperature reduction for efficient separation without causing tar condensation on heat exchanger surfaces, as the quenching occurs in a different manner than conventional heat exchange.
3Device complexity
If conventional heat exchangers are used for cooling, then the design is simple, but tar condenses on the heat exchanger surfaces causing clogging
Solution Approach 1:
The cooling process is divided into multiple stages: first cooling stage (above condensation temperature using conventional heat exchangers), second cooling stage (below condensation temperature using quenching with cold synthesis gas), and third cooling stage (further cooling). This segmentation allows efficient tar separation while preventing condensation damage by separating the cooling functions across different stages and methods.
Solution Approach 2:
Cold cleaned synthesis gas is used as an intermediary medium to quench and cool the synthesis gas below the condensation temperature of tar. This intermediary cooling method achieves the necessary temperature reduction for efficient separation without causing tar condensation on heat exchanger surfaces, as the quenching occurs in a different manner than conventional heat exchange.
4Area of stationary object
If the synthesis gas volume is reduced by cooling, then the required filter area decreases, but condensation occurs on cooling surfaces
Solution Approach 1:
The cooling process is divided into multiple stages: first cooling stage (above condensation temperature using conventional heat exchangers), second cooling stage (below condensation temperature using quenching with cold synthesis gas), and third cooling stage (further cooling). This segmentation allows efficient tar separation while preventing condensation damage by separating the cooling functions across different stages and methods.
Solution Approach 2:
Cold cleaned synthesis gas is used as an intermediary medium to quench and cool the synthesis gas below the condensation temperature of tar. This intermediary cooling method achieves the necessary temperature reduction for efficient separation without causing tar condensation on heat exchanger surfaces, as the quenching occurs in a different manner than conventional heat exchange.
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 method prevents tar condensation in initial cooling stages, allowing the use of standard heat exchangers and filters, reduces filter area and costs, and ensures safe cooling below condensation temperatures without damaging the plant, enabling efficient synthesis gas purification and electricity generation.
Implementation Method 1
The synthesis gas is first cooled in a cooling device to such an extent that the dust-like components can be separated in a filter
Implementation Method 2
the condensable components condense and deposit on the cooling device, in particular the respective heat exchanger
Implementation Method 3
followed by admixing cold, cleaned synthesis gas to quench it below the condensation point in subsequent stages
Implementation Method 4
After separation from the combustion waste gas in a cyclone, the bed material is fed to the stationary fluidized bed of the gasification zone
Implementation Method 5
the fuel is introduced into a gasification zone designed as a stationary fluidized bed, which is fluidized by steam and/or CO2
Data Source
Figure 1
AI summary
The invention relates to a method for cooling a hot synthesis gas containing at least one condensable component, in particular tar, in which the synthesis gas passes in a multi-stage cooling process sequentially a first cooling stage, a second cooling stage and a third cooling stage and in which the synthesis gas, after an at least partial cooling, is subjected to at least one separation step for separating the at least one condensable component. In said method, the synthesis gas is cooled in the first cooling stage to a temperature above the condensation temperature of the at least one condensable component, and the second cooling stage comprises the return of a partial amount of synthesis gas, which has been branched off after the third cooling stage and the at least one separation step, into the synthesis gas stream.