Two-Stage Gasifier Quench Section for Low Methane Syngas
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Solution Overview
Problem
Gasification processes produce synthesis gas with high methane content, which is detrimental to chemical production processes, requiring expensive pre-treatment to remove methane, thereby necessitating a method to produce low-methane synthesis gas without such treatment.
Innovation Solution
A two-stage gasification reactor process that includes a quench section to extract a methane-depleted gas stream from the synthesis gas produced, reducing methane content to less than 0.6% volume, allowing direct utilization as a feedstock for chemical production without additional processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a two-stage gasification reactor is used to produce synthesis gas, then energy efficiency is improved through heat utilization, but methane content in the synthesis gas increases to unacceptable levels for chemical production
Solution Approach 1:
The gasification process is divided into two distinct stages: a first stage for partial oxidation and heat generation, and a second stage for pyrolysis and synthesis gas production. This segmentation allows the hot synthesis gas from stage one to provide thermal energy to stage two, improving overall energy efficiency while enabling separate control of methane generation and removal
Solution Approach 2:
Methane is extracted from the synthesis gas stream by withdrawing a portion of the hot synthesis gas from the first stage reactor and routing it to a separate methane conversion reactor. This extraction removes the harmful methane component before the gas is combined with the second stage output, solving the methane content problem while preserving the energy-efficient two-stage configuration
2Productivity
If synthesis gas with high methane content is produced, then production volume is maintained, but additional expensive processing equipment is required to remove methane
Solution Approach 1:
The invention merges the methane removal function with the existing two-stage gasification system by integrating a methane conversion reactor that receives a portion of the first stage output. The converted gas is then combined with the second stage synthesis gas, achieving methane removal without requiring separate expensive treatment equipment while maintaining high production volume
3Object-generated harmful factors
If methane removal processes are implemented, then methane content is reduced to acceptable levels, but processing costs increase significantly
Solution Approach 1:
The invention converts the harmful methane component into a beneficial thermal resource by routing a portion of the hot synthesis gas through a methane conversion reactor where methane is converted to additional synthesis gas. This conversion both removes the harmful methane and recovers energy, reducing processing costs while achieving the required methane content reduction
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
The process effectively reduces methane content in synthesis gas to suitable levels for chemical production, eliminating the need for expensive methane removal treatments and enhancing the efficiency of chemical synthesis processes.
Implementation Method 1
partially oxidizing a first carbonaceous feedstock in the at least one reaction zone to produce a product gas comprising H2, CO, and methane
Implementation Method 2
a quench section having a second outlet, wherein the quench section cools molten ash and removes the molten ash via the second outlet
Data Source
Figure 1
AI summary
The present disclosure relates generally to a method for obtaining synthesis gas from a gasifier that has a low methane content. The synthesis gas is obtained as an extraction gas from the quench section of the gasifier, and can be utilized as feedstock for a variety of chemical production processes without the need for expensive pre-treatment to remove methane.