US20100139581A1 - Vessel for cooling syngas - Google Patents

Abstract

A vessel for cooling syngas comprising

a syngas collection chamber and a quench chamber, wherein the syngas collection chamber has a syngas outlet which is fluidly connected with the quench chamber via a tubular diptube,

wherein the diameter of the diptube at the end nearest to the syngas collection chamber is greater than the diameter of the diptube at the end terminating at the quench chamber.

Description

• This application claims the benefit of European Application No. 08170722.6 filed Dec. 4, 2008 and U.S. Provisional Application No. 61/120,996 filed Dec. 9, 2008, both of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
• The invention is directed to a vessel for cooling syngas comprising a syngas collection chamber and a quench chamber. The syngas outlet of the syngas collection chamber is fluidly connected with the quench chamber via a tubular diptube.
• Such a vessel is described in U.S. Pat. No. 4,828,578. This publication describes a gasification reactor having a reaction chamber provided with a burner wherein a fuel and oxidant are partially oxidized to produce a hot gaseous product. The hot gases are passed via a constricted throat to be cooled in a liquid bath located below the reaction chamber. A diptube guides the hot gases into the bath. At the upper end of the diptube a quench ring is present. The quench ring has a toroidal body fluidly connected with a pressurized water source. A narrow channel formed in said body carries a flow of water to cool the inner wall of the diptube. The quench ring also has openings to spray water into the flow of hot gas as it passes the quench ring.
• U.S. Pat. No. 5,271,243 describes a device for cooling hot gases deriving from incomplete oxidation in a reactor and loaded with solids. A pressurized vessel accommodates a refrigerator made of cooled pipe-slab walls at the top and a water bath for quench cooling at the bottom. The vessel also accommodates a gas-collecting section upstream of a first gas outlet and another gas-collecting section upstream of a second gas outlet. Accommodated in the first gas-collecting section is a shower ring, which is supplied with water from a circulation system. The ring sprays the gas leaving the refrigerator and lowers its temperature further before the gas exits through the gas outlets.
• U.S. Pat. No. 4,808,197 discloses a combination diptube and quench ring, which is communicated with a pressurized source of a liquid coolant such as water and which directs a flow thereof against the diptube guide surfaces to maintain such surfaces in a wetted condition.
• U.S. Pat. No. 5,976,203 describes a synthesis gas generator with combustion and quench chambers for generating, cooling and cleaning gases that are generated by partial oxidation, such generator including quench nozzles for spraying a quenching medium in a finely distributed form into the useful gas stream. The described generator further includes a cone arranged at the outlet of the quench chamber extending into the water bath chamber gas space.
• WO 2008/065184 describes a vessel for cooling syngas wherein the wall of the reaction chamber is made of an arrangement of interconnected parallel arranged tubes resulting in a substantially gas-tight wall. The described vessel further contains a diptube that is partially submerged in a water bath. Preferably at the upper end of the diptube, injecting means are present to add a quenching medium to the, in use, downwardly flowing hot product gas.
SUMMARY OF THE INVENTION
• None of U.S. Pat. No. 5,271,243, U.S. Pat. No. 4,808,197, U.S. Pat. No. 5,976,203 or WO 2008/065184 discloses the improved vessel design disclosed and claimed herein, wherein the diameter of the diptube at the end nearest to the syngas collection chamber is greater than the diameter of the diptube at the end terminating at the quench chamber and which comprises both a quench ring supplying a film of water to the surface of the diptube and water spray nozzles located in the diptube to spray droplets of water into the syngas as it flows downwardly through the diptube.
• The present invention aims to provide an improved design for a vessel for cooling syngas comprising a syngas collection chamber and a quench chamber.
• This is achieved by a vessel for cooling syngas comprising
• a syngas collection chamber and a quench chamber, wherein the syngas collection chamber has a syngas outlet which is fluidly connected with the quench chamber via a tubular diptube,
• wherein the diameter of the diptube at the end nearest to the syngas collection chamber is greater than the diameter of the diptube at the end terminating at the quench chamber,
• wherein a discharge conduit is preferably present having an outflow opening for liquid water directed such that, in use, a film of water is achieved along the inner wall of the diptube, and
• wherein water spray nozzles are located in the diptube to spray droplets of water into the syngas as it flows downwardly through the diptube.
• Applicants found that by a diptube as claimed a more efficient vessel for cooling is provided. Preferably the diptube comprises a tubular part with the larger diameter and a tubular part with the smaller diameter which parts are fixed together by a frusto conical part. The diptube may also comprise a tubular part with the larger diameter connected with only a frusto conical part at the end terminating at the quench chamber. Preferably the ratio between the larger diameter and the smaller diameter is between 1.25:1 and 2:1.
BRIEF DESCRIPTION OF THE DRAWINGS
• The invention and its preferred embodiments will be further described by means of the following figures.
• FIG. 1 is a cooling vessel according to the invention.
• FIG. 2 is a side-view of detail A ofFIG. 1.
• FIG. 3 is a top view of detail A ofFIG. 1.
• FIG. 4 is a gasification reactor according to the invention.
• FIG. 4ashows an alternative design for a section of the reactor ofFIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
• Syngas has the meaning of a mixture comprising carbon monoxide and hydrogen. The syngas is preferably prepared by gasification of an ash comprising carbonaceous feedstock, such as for example coal, petroleum coke, biomass and deasphalted tar sands residues. The coal may be lignite, bituminous coal, sub-bituminous coal, anthracite coal and brown coal. The syngas as present in the syngas collection chamber may have a temperature ranging from 600 to 1500° C. and a pressure of between 2 and 10 MPa. The syngas is preferably cooled, in the vessel according the present invention, to below a temperature which is 50° C. higher than the saturation temperature of the gas composition. More preferably the syngas is cooled to below a temperature which is 20° C. higher than the saturation temperature of the gas composition.
• FIG. 1 shows avessel1 comprising asyngas collection chamber2 and aquench chamber3. In use it is vertically oriented as shown in the Figure. References to vertical, horizontal, top, bottom, lower and upper relate to this orientation. Said terms are used to help better understand the invention but are by no means intended to limit the scope of the claims to a vessel having said orientation. Thesyngas collection chamber2 has asyngas outlet4, which is fluidly connected with thequench chamber3 via atubular diptube5. Thesyngas collection chamber2 and thediptube5 have a smaller diameter than thevessel1 resulting in an upper annular space2abetweensaid chamber2 the wall ofvessel1 and a lower annular space2bbetween thediptube5 and the wall ofvessel1. Annular space2aand2bare preferably gas tight separated by sealing2cto avoid ingress of ash particles from space2binto space2a.
• Thesyngas outlet4 comprises atubular part6 having a diameter, which is smaller than the diameter of thetubular diptube5. Thetubular part6 is oriented co-axial with thediptube5 as shown in the Figure. Thevessel1 as shown inFIG. 1 is at its upper end provided with a syngas inlet7 and a connectingduct8 provided with apassage10 for syngas. The passage for syngas is defined by walls9. Connectingduct8 is preferably connected to a gasification reactor as described in more detail in WO-A-2007125046.
• Thediptube5 is open to the interior of thevessel1 at itslower end10. Thislower end10 is located away from thesyngas collection chamber2 and in fluid communication with agas outlet11 as present in thevessel wall12. The diptube is partially submerged in awater bath13. Around the lower end of the diptube5 adraft tube14 is present to direct the syngas upwardly in theannular space16 formed betweendraft tube14 anddiptube5. At the upper discharge end of theannular space16deflector plate16ais present to provide a rough separation between entrained water droplets and the quenched syngas.Deflector plate16apreferably extends from the outer wall of thediptube5. The lower part5bof thediptube5 has a smaller diameter than the upper part5aas shown inFIG. 1. This is advantageous because the layer of water in the lower end will increase and because the annular area for thewater bath13 will increase. This is advantageous because it enables one to use a more optimized, smaller, diameter forvessel1. The quenchzone3 is further provided with anoutlet15 for water containing for example fly-ash.
• Thetubular part6 is preferably formed by an arrangement of interconnected parallel arranged tubes resulting in a substantially gas-tight tubular wall running from a cooling water distributor to a header. The cooling oftubular part6 can be performed by either sub-cooled water or boiling water.
• The walls of thesyngas collection chamber2 preferably comprise an arrangement of interconnected parallel arranged tubes resulting in a substantially gas-tight wall running from a distributor to a header, said distributor provided with a cooling water supply conduit and said header provided with a discharge conduit for water or steam. The walls of the diptube are preferably of a simpler design, like for example a metal plate wall.
• At the end of thediptube5 which is nearest to the syngas collection chamber2 adischarge conduit19 is preferably present having an outflow opening for liquid water directed such that, in use, a film of water is achieved along the inner wall of the diptube. Dischargeconduit19 is connected towater supply conduit17. Dischargeconduit19 will be described in detail by means ofFIGS. 2 and 3.
• FIG. 1 also shows preferredwater spray nozzles18 located in thediptube5 to spray droplets of water into the syngas as it flows downwardly through thediptube5. Thenozzles18 are preferably sufficiently spaced away in a vertical direction from thedischarge conduit19 to ensure that any non-evaporated water droplets as sprayed into the flow of syngas will contact a wetted wall of thediptube5. Applicants have found that if such droplets would hit a non-wetted wall ash may deposit, thereby forming a very difficult to remove layer of fouling. It is preferred that thenozzles18 are positioned in the larger diameter part5aof thedipleg5. More residence time is achieved by the larger diameter resulting in that the water as injected has sufficient time to evaporate.
• FIG. 2 shows detail A ofFIG. 1.
• FIG. 2 shows that thetubular part6 terminates at a point within the space enclosed by thediptube5 such that anannular space20 is formed between thetubular part6 and thediptube5. In the annular space20 adischarge conduit19 for a liquid water is present having adischarge opening21 located such to direct theliquid water22 along the inner wall of thediptube5.Conduit19 andtubular part6 are preferably not fixed to each other and more preferably horizontally spaced away from each other. This is advantageous because this allows both parts to move relative to each other. This avoids, when the vessel is used, thermal stress as both parts will typically have a different thermal expansion. The gap19aas formed betweenconduit19 andpart6 will allow gas to flow from thesyngas collection chamber2 to the space2abetween the wall of thechamber2 and the wall ofvessel1. This is advantageous because it results in pressure equalization between said two spaces. Thedischarge conduit19 preferably runs in a closed circle along the periphery of thetubular part6 and has a slit like opening21 as the discharge opening located at the point where thedischarge conduit19 and the inner wall of thediptube5 meet. In use,liquid water22 will then be discharged along the entire inner circumference of the wall of thediptube5. As shownconduit19 does not have discharge openings to direct water into the flow of syngas, which is discharged viasyngas outlet4.
• FIG. 2 also shows that thedischarge conduit19 is suitably fluidly connected to acircular supply conduit23. Saidsupply conduit23 runs along the periphery of thedischarge conduit19. Bothconduits19 and23 are fluidly connected bynumerous openings24 along said periphery. Alternatively, not shown inFIGS. 2 and 3, is an embodiment wherein thedischarge conduit19 is directly fluidly connected to one ormore supply lines17 for liquid water under an angle with the radius of the closed circle, such that in use a flow of liquid water results in the supply conduit.
• Preferably thedischarge conduit19 orconduit23 are connected to a vent. This vent is intended to remove gas, which may accumulate in said conduits. The ventline is preferably routed internally in thevessel1 through the sealing2cto be fluidly connected to annular space2b.The lower pressure in said space2bforms the driving force for the vent. The size of the vent line, for example by sizing an orifice in said ventline, is chosen such that a minimum required flow is allowed, possibly also carrying a small amount of water together with the vented gas into the annular space2b.Preferablyconduit19 is provided with a vent as shown inFIG. 2, wherein thedischarge conduit19 has an extendingpart26 located away from thedischarge opening21, which extendingpart26 is fluidly connected to avent conduit27.
• Thecircular supply conduit23 ofFIG. 3 is suitably fluidly connected to one ormore supply lines17 for liquid water under an angle α, such that in use a flow of liquid water results in thesupply conduit23. Angle α is preferably between 0 and 45°, more preferably between 0 and 15°. The number ofsupply lines17 may be at least 2. The maximum number will depend on the dimensions of for example theconduit23. Theseparate supply lines17 may be combined upstream and within thevessel1 to limit the number of openings in the wall ofvessel1. The discharge end ofsupply line17 is preferably provided with a nozzle to increase the velocity of the liquid water as it enters thesupply conduit23. This will increase the speed and turbulence of the water as it flows inconduit23, thereby avoiding solids to accumulate and form deposits. The nozzle itself may be an easy to replace part having a smaller outflow diameter than the diameter of thesupply line17.
• Theopenings24 preferably have an orientation under an angle β with theradius25 of the closed circle, such that in use a flow of liquid water results in thedischarge conduit19 having the same direction has the flow in thesupply conduit23. Angle β is preferably between 45 and 90°.
• FIG. 3 also showstubular part6 as an arrangement of interconnected parallel arrangedtubes28 resulting in a substantially gas-tighttubular wall29.
• FIG. 4 shows avessel30 according to the invention wherein thesyngas collection chamber2 is areaction chamber31 provided with4 horizontally firingburners32. The number of burners may suitably be from 1 to 8 burners. To said burners the carbonaceous feedstock and an oxygen containing gas are provided viaconduits32aand32b.Thewall33 of thereaction chamber31 is preferably an arrangement of interconnected parallel arrangedtubes34 resulting in a substantially gas-tight tubular wall. Only part of the tubes are drawn inFIG. 4. Thetubes34 run from a lower arrangedcooling water distributor37 to a higher arrangedheader38. Theburners32 are arranged inFIG. 4 as described in for example WO-A-2008110592, which publication is incorporated by reference. The burners or burner may alternatively be directed downwardly as for example described in WO-A-2008065184 or in US-A-2007079554. In use a layer of liquid slag will be present on the interior ofwall33. This slag will flow downwards and will be discharged from the reactor viaoutlet15.
• The reference numbers inFIG. 4, which are also used inFIGS. 1-3, relate to features having the same functionality. Detail A inFIG. 4 refers toFIGS. 2 and 3.
• Thesyngas outlet4 consists of a frusto-conical part35 starting from the lower end of thetubular wall33 and converging to anopening36. Preferablypart35 has a tubular part35aconnected to the outlet opening of saidpart35 to guide slag downwards into thediptube5. This is advantageous because one then avoids slag particles to foul thedischarge conduit19. If such a tubular part35awould not be present small slag particles may be carried to theconduit19 by recirculating gas. By having a tubular part of sufficient length such recirculation in the region ofconduit19 is avoided. Preferably the length of35ais such that the lower end terminates at or below thedischarge conduit19. Even more preferably the lower end terminates below thedischarge conduit19, wherein at least half of the vertical length of the tubular part35aextends belowdischarge conduit19.
• The frusto-conical part35 and the optionaltubular part35aand35bcomprise one or more conduits, through which in use boiling cooling water or sub-cooled cooling water, flows. The design of the conduits ofparts35,35aand35bmay vary and may be for example spirally formed, parallel formed, comprising multiple U-turns or combinations. Theparts35,35aand35bmay even have separate cooling water supply and discharge systems. Preferably the temperature of the used cooling water or steam make of theseparts35 and35aare measured to predict the thickness of the local slag layer on these parts. This is especially advantageous if the gasification process is run at temperatures, which would be beneficial for creating a sufficiently thick slag layer for a specific feedstock, such as low ash containing feedstocks like certain biomass feeds and tar sand residues. Or in situations where a coal feedstock comprises components that have a high melting point. The danger of such an operation is thatoutlet4 may be blocked by accumulating slag. By measuring the temperature of the cooling water or the steam make one can predict when such a slag accumulation occurs and adjust the process conditions to avoid such a blockage. The invention is thus also directed to a process to avoid slag blockage at the outlet of the reaction chamber in a reactor as illustrated byFIG. 4 by measuring the temperature of the cooling water or the steam make of theseparts35 and35ain order to predict when a slag blockage could occur and adjust the process conditions to avoid such a blockage. Typically a decrease in temperature of the used cooling water or a decrease in steam make are indicative of a growing layer of slag. The process is typically adjusted by increasing the gasification temperature in the reaction chamber such that the slag will become more fluid and consequently a reduction in thickness of the slag layer onparts35 and35awill result. The supply and discharge conduits for this cooling water are not shown inFIG. 4.
• The frusto-conical part35 is connected to thetubular part6 near its lower end.Opening36 has a smaller diameter than the diameter of thetubular part6 such that liquid slag will less easily hit the wall of thetubular part6 and or of thediptube5 when it drops down into thewater bath13 and solidifies. Inwater bath13 the solidified slag particles are guided by means of an inverted frusto-conical part39 tooutlet15.
• InFIG. 4aa preferred embodiment for tubular part35ais shown, wherein the lower end of tubular part35ais fixed by aplane35bextending to the lower end of the nexttubular part6. This design is advantageous because less stagnant zones are present where solid ash particles can accumulate.

Claims (20)

1. A vessel for cooling syngas comprising:

a syngas collection chamber and a quench chamber, wherein the syngas collection chamber has a syngas outlet which is fluidly connected with the quench chamber via a tubular diptube,

wherein the diameter of the diptube at the end nearest to the syngas collection chamber is greater than the diameter of the diptube at the end terminating at the quench chamber,

wherein the syngas outlet comprises a tubular part, co-axial with the diptube, having a diameter which is smaller than the diameter of the tubular diptube at the end nearest to the syngas collection chamber,

wherein the tubular part terminates at a point within the diptube such that an annular space is formed between the tubular part and the diptube, and

wherein in the annular space a discharge conduit for liquid water is present having a discharge opening located such to direct the liquid water along the inner wall of the diptube, and

wherein nozzles are positioned in the larger diameter part of the diptube such that in use droplets of water are sprayed via these nozzles into the syngas as it flows downwardly through the diptube.

2. A vessel according toclaim 1, wherein the diptube comprises a tubular part with the larger diameter and a tubular part with the smaller diameter which parts are fixed together by a frusto conical part.

3. A vessel according toclaim 1, wherein the ratio between the larger diameter and the smaller diameter of the diptube is between 1.25:1 and 2:1.

4. A vessel according toclaim 1, wherein at the end of the diptube which is nearest to the syngas collection a discharge conduit is present having an outflow opening for liquid water directed such that, in use, a film of water is achieved along the inner wall of the diptube.

5. A vessel according toclaim 1, wherein the syngas collection chamber comprises an arrangement of interconnected parallel arranged tubes resulting in a gas-tight tubular wall running from a distributor to a header, said distributor provided with a cooling water supply conduit and said header provided with a steam/water discharge conduit.

6. A vessel according toclaim 1, wherein the diptube is partly submerged in a water bath at the end terminating at the quench chamber.

7. A vessel according toclaim 1, wherein a draft tube is present around the lower end of the diptube forming an annular space between the draft tube and the diptube.

8. A vessel according toclaim 7, wherein a deflector plate extends from the outer wall of the diptube at the upper discharge end of the annular space.

9. A vessel according toclaim 2, wherein a tubular part is connected to the bottom of the frusto conical part, such that the lower end of the tubular part terminates below the discharge conduit.

10. A vessel according toclaim 9, wherein at least half of the vertical length of the tubular part extends below the discharge conduit.

11. A vessel for cooling syngas comprising:

a syngas collection chamber and a quench chamber, wherein the syngas collection chamber has a syngas outlet which is fluidly connected with the quench chamber via a tubular diptube,

wherein the diameter of the diptube at the end nearest to the syngas collection chamber is greater than the diameter of the diptube at the end terminating at the quench chamber,

wherein the ratio between the larger diameter and the smaller diameter of the diptube is between 1.25:1 and 2:1,

wherein the syngas outlet comprises a tubular part, co-axial with the diptube, having a diameter which is smaller than the diameter of the tubular diptube at the end nearest to the syngas collection chamber,

wherein the tubular part terminates at a point within the diptube such that an annular space is formed between the tubular part and the diptube, and

wherein in the annular space a discharge conduit for liquid water is present having a discharge opening located such to direct the liquid water along the inner wall of the diptube, and

wherein nozzles are positioned in the larger diameter part of the diptube such that in use droplets of water are sprayed via these nozzles into the syngas as it flows downwardly through the diptube.

12. A vessel according toclaim 11, wherein the diptube comprises a tubular part with the larger diameter and a tubular part with the smaller diameter which parts are fixed together by a frusto conical part.

13. A vessel according toclaim 11, wherein a draft tube is present around the lower end of the diptube forming an annular space between the draft tube and the diptube.

14. A vessel according toclaim 13, wherein a deflector plate extends from the outer wall of the diptube at the upper discharge end of the annular space.

15. A vessel according toclaim 12, wherein a tubular part is connected to the bottom of the frusto conical part, such that the lower end of the tubular part terminates below the discharge conduit.

16. A vessel according toclaim 15, wherein at least half of the vertical length of the tubular part extends below the discharge conduit.

17. A vessel for cooling syngas comprising:

a syngas collection chamber and a quench chamber, wherein the syngas collection chamber has a syngas outlet which is fluidly connected with the quench chamber via a tubular diptube,

wherein the diameter of the diptube at the end nearest to the syngas collection chamber is greater than the diameter of the diptube at the end terminating at the quench chamber,

wherein the syngas outlet comprises a tubular part, co-axial with the diptube, having a diameter which is smaller than the diameter of the tubular diptube at the end nearest to the syngas collection chamber,

wherein the tubular part terminates at a point within the diptube such that an annular space is formed between the tubular part and the diptube, and

wherein in the annular space a discharge conduit for liquid water is present having a discharge opening located such to direct the liquid water along the inner wall of the diptube,

wherein nozzles are positioned in the larger diameter part of the diptube such that in use droplets of water are sprayed via these nozzles into the syngas as it flows downwardly through the diptube, and

wherein at the end of the diptube which is nearest to the syngas collection a discharge conduit is present having an outflow opening for liquid water directed such that, in use, a film of water is achieved along the inner wall of the diptube.

18. A vessel according toclaim 17, wherein the diptube comprises a tubular part with the larger diameter and a tubular part with the smaller diameter which parts are fixed together by a frusto conical part.

19. A vessel according toclaim 18, wherein a tubular part is connected to the bottom of the frusto conical part, such that the lower end of the tubular part terminates below the discharge conduit.

20. A vessel according toclaim 19, wherein at least half of the vertical length of the tubular part extends below the discharge conduit.

Images