Syngas cooler system and method of operation

• US 9,028,571 B2
• Filed: 12/13/2011
• Issued: 05/12/2015
• Est. Priority Date: 04/06/2011
• Status: Active Grant

• Current Assignee: Jupeng Bio (HK) Limited
• Original Assignee: INEOS Bio SA
• Inventors: Bell, Peter S., Vanhecke, Nicolas, Descales, Bernard
• Primary Examiner(s): HANDAL, KAITY V
• Application Number:
  US13/324,299
• Publication Number:
  US 20120256128A1
• Time in Patent Office: 1,246 Days
• Field of Search: 48/61, 481/279, 481/271, 481/97.R, 48/76, 481/983
• US Class Current: 48/198.3
• CPC Class Codes: C01B 2203/0877 by direct injection of fluid
• CPC Class Codes: C01B 2203/0894 Generation of steam
• CPC Class Codes: C01B 2203/142 At least two reforming, decomposition or partial oxidation steps in series
• CPC Class Codes: C01B 2203/143 Three or more reforming, decomposition or partial oxidation steps in series
• CPC Class Codes: C10J 2200/09 Mechanical details of gasifiers not otherwise provided for, e.g. sealing means
• CPC Class Codes: C10J 2200/15 Details of feeding means
• CPC Class Codes: C10J 2300/0956 Air or oxygen enriched air
• CPC Class Codes: C10J 2300/0959 Oxygen
• CPC Class Codes: C10J 2300/1606 Combustion processes
• CPC Class Codes: C10J 2300/1846 Partial oxidation, i.e. injection of air or oxygen only
• CPC Class Codes: C10J 2300/1884 with one stream being synthesis gas
• CPC Class Codes: C10J 3/72 Other features
• CPC Class Codes: C10J 3/721 Multistage gasification, e.g. plural parallel or serial gasification stages
• CPC Class Codes: C10J 3/723 Controlling or regulating the gasification process
• CPC Class Codes: C10J 3/726 Start-up
• CPC Class Codes: C10J 3/84 with means for removing dust or tar from the gas
• CPC Class Codes: C10J 3/86 combined with waste-heat boilers
• CPC Class Codes: C10K 1/02 Dust removal
• CPC Class Codes: C10K 1/04 by cooling to condense non-gaseous materials C10K1/001 takes precedence
• CPC Class Codes: C10K 3/003 Reducing the tar content
• CPC Class Codes: C10K 3/005 : by partial oxidation
• CPC Class Codes: C10K 3/008 : by cracking
• CPC Class Codes: F22B 1/1838 : the hot gas being under a high pressure, e.g. in chemical installations
• CPC Class Codes: Y02E 20/18 : Integrated gasification combined cycle [IGCC], e.g. combined with carbon capture and storage [CCS]
• CPC Class Codes: Y02E 50/10 : Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02E 50/30 : Fuel from waste, e.g. synthetic alcohol or diesel
• CPC Class Codes: Y02E 60/32 : Hydrogen storage
• CPC Class Codes: Y02P 20/10 : Process efficiency
• CPC Class Codes: Y02P 20/129 : Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

A process and system for cooling syngas provides effective syngas cooling and results in reduced levels of fouling in syngas cooling equipment. A process for cooling syngas includes blending syngas with cooled recycled syngas in an amount effective for providing a blended syngas with a temperature at an inlet of a syngas cooler of about 600° F. to about 1400° F. The blended syngas changes direction of flow at least once prior to the inlet of the syngas cooler.

Claims

1. A process for cooling syngas, the process comprising:

blending syngas with cooled recycled syngas in an amount effective for providing a blended syngas with a temperature at an inlet of a syngas cooler of about 600°

F. to about 1400°

F.,

wherein the blended syngas changes direction of flow at least once prior to the inlet of the syngas cooler;

wherein the cooled recycled syngas is supplied to a distal end of a gasification chamber having a diameter DH through a syngas recycle inlet having a diameter Dc; and

wherein the blended syngas is supplied to a gasification outlet having a diameter DM, the gasification outlet is continuous with the distal end of the gasification chamber.

2. The process of claim 1 wherein the cooled recycled syngas has a temperature of about 350°

F. to about 450°

F.

3. The process of claim 1 wherein cooled recycled syngas is blended with syngas at a ratio of about 0.1 to about 20.

4. The process of claim 1 wherein the blended syngas has a temperature of about 600°

F. to about 900°

F.

5. The process of claim 4 wherein the blended syngas has a temperature of about 750°

F. to about 825°

F.

6. The process of claim 1 wherein the syngas recycle inlet enters the distal end of the gasification chamber tangentially at an outer circumference of the gasification chamber.

7. The process of claim 1 wherein the syngas recycle inlet enters the distal end of the gasification chamber at an angle of about 15 to about 165°

.

8. The process of claim 1 wherein L(distance syngas recycle inlet is away from gasifier outlet)/D_H is about 1 to about 10.

9. The process of claim 1 wherein D_C/D_H is about 0.25 to about 0.75.

10. The process of claim 1 wherein D_H/D_M is about 0.5 to about 2.0.

11. A syngas mixing system comprising:

a gasification chamber having a diameter D_H;

a syngas recycle inlet having a diameter D_C, the syngas recycle inlet entering the gasification chamber at a distal end of the gasification chamber; and

a gasification outlet having a diameter D_M, the gasification outlet continuous with the distal end of the gasification chamber, the gasification outlet including at least one change of direction prior to entering a syngas cooler; and

wherein the blended syngas is supplied to the gasification outlet.

12. The gas mixing system of claim 11 wherein the syngas recycle inlet enters the distal end of the gasification chamber tangentially at an outer circumference of the gasification chamber.

13. The gas mixing system of claim 11 wherein the syngas recycle inlet enter the distal end of the gasification chamber at an angle of about 15 to about 165°

.

14. The gas mixing system of claim 11 wherein L(distance syngas recycle inlet is away from gasifier outlet)/D_H is about 1 to about 10.

15. The gas mixing system of claim 11 wherein D_C/D_H is about 0.25 to about 0.75.

16. The gas mixing system of claim 11 wherein D_H/D_M is about 0.5 to about 2.0.

17. A process for cooling syngas, the process comprising:

blending syngas with cooled recycled syngas in an amount effective for providing a blended syngas with a temperature at an inlet of a syngas cooler of about 600°

F. to about 1400°

F.,

wherein cooled recycled syngas is supplied to a distal end of a gasification chamber having a diameter D_H through a syngas recycle inlet having a diameter D_C, and D_C/D_H is about 0.25 to about 0.75;

wherein the blended syngas changes direction of flow at least once prior to the inlet of the syngas cooler; and

wherein blended syngas is supplied to a gasification outlet having a diameter DM, the gasification outlet is continuous with the distal end of the gasification chamber.

18. The process of claim 17 wherein the cooled recycled syngas has a temperature of about 350°

F. to about 450°

F.

19. The process of claim 17 wherein cooled recycled syngas is blended with syngas at a ratio of about 0.1 to about 20.

20. The process of claim 17 wherein the blended syngas has a temperature of about 600°

F. to about 900°

F.

21. The process of claim 20 wherein the blended syngas has a temperature of about 750°

F. to about 825°

F.

22. The process of claim 17 wherein D_H/D_M is about 0.5 to about 2.0.

23. The process of claim 17 wherein the syngas recycle inlet enters the distal end of the gasification chamber tangentially at an outer circumference of the gasification chamber.

24. The process of claim 17 wherein the syngas recycle inlet enters the distal end of the gasification chamber at an angle of about 15 to about 165°

.

25. The process of claim 17 wherein L(distance syngas recycle inlet is away from gasifier outlet)/D_H is about 1 to about 10.