U.S. patent application number 12/494434 was filed with the patent office on 2010-12-30 for cooling chamber assembly for a gasifier.
This patent application is currently assigned to GENERAL ELECTRIC COMPANY. Invention is credited to Judeth Brannon Corry, Constantin Dinu, Denise Marie Rico, James Michael Storey, Richard L. Zhao.
Application Number | 20100325956 12/494434 |
Document ID | / |
Family ID | 43379198 |
Filed Date | 2010-12-30 |
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United States Patent
Application |
20100325956 |
Kind Code |
A1 |
Dinu; Constantin ; et
al. |
December 30, 2010 |
COOLING CHAMBER ASSEMBLY FOR A GASIFIER
Abstract
A gasifier includes a combustion chamber in which a combustible
fuel is burned to produce a syngas and a particulated solid
residue. A cooling chamber having a liquid coolant is disposed
downstream of the combustion chamber. A dip tube is disposed
coupling the combustion chamber to the cooling chamber. The syngas
is directed from the combustion chamber to the cooling chamber via
the dip tube to contact the liquid coolant and produce a cooled
syngas. An asymmetric or symmetric liquid separator is disposed
proximate to an exit path of the cooling chamber and configured to
remove entrained liquid content from the cooled syngas directed
through the annular passage to the exit path.
Inventors: |
Dinu; Constantin; (Katy,
TX) ; Corry; Judeth Brannon; (Manvel, TX) ;
Storey; James Michael; (Houston, TX) ; Rico; Denise
Marie; (Houston, TX) ; Zhao; Richard L.;
(Chicago, IL) |
Correspondence
Address: |
GENERAL ELECTRIC COMPANY;GLOBAL RESEARCH
ONE RESEARCH CIRCLE, BLDG. K1-3A59
NISKAYUNA
NY
12309
US
|
Assignee: |
GENERAL ELECTRIC COMPANY
Schenectady
NY
|
Family ID: |
43379198 |
Appl. No.: |
12/494434 |
Filed: |
June 30, 2009 |
Current U.S.
Class: |
48/85 |
Current CPC
Class: |
C10J 3/84 20130101; C10J
3/485 20130101; C10J 3/74 20130101; C10J 3/76 20130101; C10J
2300/0959 20130101; C10J 2300/0956 20130101; C10J 3/845 20130101;
C10J 3/526 20130101; C10J 2300/093 20130101; C10J 2300/0943
20130101 |
Class at
Publication: |
48/85 |
International
Class: |
C10J 3/20 20060101
C10J003/20 |
Claims
1. A gasifier comprising: a combustion chamber in which a
combustible material is burned to produce a syngas, a cooling
chamber having a liquid coolant disposed downstream of the
combustion chamber, a dip tube coupling the combustion chamber to
the cooling chamber and configured to direct syngas from the
combustion chamber to the cooling chamber to contact the liquid
coolant and produce a cooled syngas; a draft tube disposed
surrounding the dip tube and defining an annular passage there
between; an asymmetric or symmetric liquid separator disposed
proximate to an exit path of the cooling chamber and configured to
remove entrained liquid content from the cooled syngas directed
through the annular passage to the exit path.
2. The gasifier of claim 1, wherein the cooling chamber comprises a
quench chamber for a gasifier.
3. The gasifier of claim 1, wherein the cooling chamber comprises a
scrubber.
4. The gasifier of claim 1, wherein the asymmetric or symmetric
liquid separator comprises a deflector coupled to the dip tube and
configured to redirect the flow of the cooled syngas from the
annular passage.
5. The gasifier of claim 4, wherein the asymmetric or symmetric
liquid separator comprises a plurality of fins provided to the
deflector and configured to remove entrained liquid content from
the cooled syngas directed through the annular passage to the exit
path.
6. The gasifier of claim 4, wherein the asymmetric or symmetric
liquid separator comprises a plurality of holes provided in the
deflector for directing a portion of cooled syngas to a region
upstream of the deflector in the cooling chamber.
7. The gasifier of claim 1, wherein the asymmetric or symmetric
liquid separator comprises a conical shaped faceted or round
separator.
8. The gasifier of claim 7, wherein the faceted baffle comprises a
plurality of splash plates.
9. The gasifier of claim 7, wherein the asymmetric or symmetric
liquid separator comprises a plurality of baffle elements provided
to the conical shaped faceted or round separator and configured to
remove entrained liquid content from the cooled syngas directed
through the annular passage to the exit path.
10. The gasifier of claim 9, wherein the baffle elements are
v-shaped.
11. The gasifier of claim 10, wherein the asymmetric or symmetric
liquid separator comprises a channel between mutually adjacent
baffle elements; wherein the channel is configured to drain the
removed entrained liquid.
12. The gasifier of claim 11, wherein the asymmetric or symmetric
liquid separator comprises a pipe coupled to the channel and
configured to transfer the removed entrained liquid from the
channel to the cooling chamber.
13. A gasifier comprising: a combustion chamber in which a
combustible material is burned to produce a syngas, a cooling
chamber having a liquid coolant disposed downstream of the
combustion chamber, a dip tube coupling the combustion chamber to
the cooling chamber and configured to direct syngas from the
combustion chamber to the cooling chamber to contact the liquid
coolant and produce a cooled syngas; a draft tube disposed
surrounding the dip tube and defining an annular passage there
between; a finned asymmetric or symmetric liquid separator disposed
proximate to an exit path of the cooling chamber and configured to
remove entrained liquid content from the cooled syngas directed
through the annular passage to the exit path.
14. The gasifier of claim 13, wherein the finned asymmetric or
symmetric liquid separator comprises a deflector coupled to the dip
tube and configured to redirect the flow of the cooled syngas from
the annular passage.
15. The gasifier of claim 14, wherein the deflector is elliptical
shaped, or rectangular shaped, or trapezoidal shaped.
16. The gasifier of claim 14, wherein the finned asymmetric or
symmetric liquid separator comprises a plurality of fins provided
to the deflector and configured to remove entrained liquid content
from the cooled syngas directed through the annular passage to the
exit path.
17. The gasifier of claim 16, wherein the plurality of fins
comprises straight fins, curved fins, angled fins, or combinations
thereof.
18. The gasifier of claim 16, wherein the plurality fins are
arranged in a circular direction, polygonal direction, radial
direction, tangential direction, or combinations thereof.
19. The gasifier of claim 16, wherein the plurality of fins are
arranged in a single row, or a multi-row, or slanted-row, or
staggered form.
20. The gasifier of claim 14, wherein the finned asymmetric or
symmetric liquid separator comprises a plurality of holes provided
in the deflector for directing a portion of cooled syngas to a
region upstream of the deflector in the cooling chamber.
21. A gasifier comprising: a combustion chamber in which a
combustible material is burned to produce a syngas, a cooling
chamber having a liquid coolant disposed downstream of the
combustion chamber, a dip tube coupling the combustion chamber to
the cooling chamber and configured to direct syngas from the
combustion chamber to the cooling chamber to contact the liquid
coolant and produce a cooled syngas; a draft tube disposed
surrounding the dip tube and defining an annular passage there
between; a asymmetric or symmetric faceted or round liquid
separator disposed proximate to an exit path of the cooling chamber
and configured to remove entrained liquid content from the cooled
syngas directed through the annular passage to the exit path.
22. The gasifier of claim 21, wherein the asymmetric or symmetric
faceted or round liquid separator comprises a conical shaped
faceted or round separator.
23. The gasifier of claim 22, wherein the faceted baffle comprises
a plurality of splash plates.
24. The gasifier of claim 22, wherein the asymmetric or symmetric
faceted or round liquid separator comprises a plurality of baffle
elements provided to the conical shaped faceted or round separator
and configured to remove entrained liquid content from the cooled
syngas directed through the annular passage to the exit path.
25. The gasifier of claim 24, wherein the baffle elements are
v-shaped.
26. The gasifier of claim 25, wherein the asymmetric or symmetric
faceted or round liquid separator comprises a channel between
mutually adjacent baffle elements; wherein the channel is
configured to drain the removed entrained liquid.
27. The gasifier of claim 26, wherein the asymmetric or symmetric
liquid separator comprises a pipe coupled to the channel and
configured to transfer the removed entrained liquid from the
channel to the cooling chamber.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application is related to the following co-pending
United States patent applications having Serial No. {Attorney
Docket No. 235585-1}, entitled "QUENCH CHAMBER ASSEMBLY FOR A
GASIFIER" and Serial No. {Attorney Docket No. 236150-1}, entitled
"GASIFICATION SYSTEM FLOW DAMPING" assigned to the same assignee as
this application and filed concurrently herewith, each of which is
hereby incorporated by reference.
BACKGROUND
[0002] The invention relates generally to gasifiers, and more
particularly to a cooling chamber assembly for a gasifier.
[0003] In a normal coal gasification process, wherein a
particulated carbonaceous fuel such as coal or coke or a
carbonaceous gas is burned, the process is carried out at
relatively hot temperatures and high pressures in a combustion
chamber. When injected fuel is burned or partially burned in the
combustion chamber, an effluent is discharged through a port at a
lower end of the combustion chamber to a cooling chamber disposed
downstream of the combustion chamber. The cooling chamber contains
a liquid coolant such as water. The effluent from the combustion
chamber is contacted with the liquid coolant in the cooling
chamber, so as to reduce the temperature of the effluent. In
certain applications, the cooling chamber may be used as a quench
chamber for syngas. In certain other applications, the cooling
chamber may be used as a scrubber for removing entrained solids
from the generated syngas. In certain applications, a gasifier may
be provided with both a quench system and a scrubber.
[0004] When the fuel is a solid such as coal or coke, the gasifier
arrangement permits a solid portion of the effluent, in the form of
ash, to be retained in the liquid pool of the cooling chamber, and
subsequently to be discharged as slag slurry. A gaseous component
of the effluent is discharged from the cooling chamber for further
processing. The gaseous component, however, in passing through the
cooling chamber, will carry with it a substantial amount of the
liquid coolant. A minimal amount of liquid entrained in the exiting
gas is not considered objectionable to the overall process.
However, excessive liquid carried from the cooling chamber and into
downstream equipment, is found to pose operational problems.
[0005] There is a need for an improved cooling chamber assembly for
both quench and scrubber applications configured to remove
entrained liquid content substantially from an effluent gas
generated in a gasifier.
BRIEF DESCRIPTION
[0006] In accordance with one exemplary embodiment of the present
invention, a gasifier includes a combustion chamber in which a
combustible fuel is burned to produce a syngas and a particulated
solid residue. A cooling chamber having a liquid coolant is
disposed downstream of the combustion chamber. A dip tube is
disposed coupling the combustion chamber to the cooling chamber.
The syngas is directed from the combustion chamber to the cooling
chamber via the dip tube to contact the liquid coolant and produce
a cooled syngas. An asymmetric or symmetric liquid separator is
disposed proximate to an exit path of the cooling chamber and
configured to remove entrained liquid content from the cooled
syngas directed through the annular passage to the exit path.
[0007] In accordance with another exemplary embodiment of the
present invention, a finned asymmetric or symmetric liquid
separator is disposed proximate to an exit path of the cooling
chamber and configured to remove entrained liquid content from the
cooled syngas directed through the annular passage to the exit
path.
[0008] In accordance with another exemplary embodiment of the
present invention, an asymmetric or symmetric faceted or round
liquid separator is disposed proximate to an exit path of the
cooling chamber and configured to remove entrained liquid content
from the cooled syngas directed through the annular passage to the
exit path.
DRAWINGS
[0009] These and other features, aspects, and advantages of the
present invention will become better understood when the following
detailed description is read with reference to the accompanying
drawings in which like characters represent like parts throughout
the drawings, wherein:
[0010] FIG. 1 is a diagrammatical representation of a gasifier
having an exemplary cooling chamber with a liquid separator in
accordance with an exemplary embodiment of the present
invention;
[0011] FIG. 2 is a diagrammatical representation of a liquid
separator in accordance with an exemplary embodiment of the present
invention;
[0012] FIG. 3 is a diagrammatical representation of a portion of a
cooling chamber having a liquid separator in accordance with an
exemplary embodiment of the present invention;
[0013] FIG. 4 is a diagrammatical representation of a portion of a
cooling chamber having a liquid separator in accordance with an
exemplary embodiment of the present invention;
[0014] FIG. 5 is a diagrammatical representation of a portion of a
cooling chamber having a liquid separator in accordance with an
exemplary embodiment of the present invention;
[0015] FIG. 6 is a diagrammatical representation of a portion of a
cooling chamber having a liquid separator in accordance with an
exemplary embodiment of the present invention;
[0016] FIG. 7 is a diagrammatical representation of a fin
arrangement in accordance with an exemplary embodiment of the
present invention;
[0017] FIG. 8 is a diagrammatical representation of a fin
arrangement in accordance with an exemplary embodiment of the
present invention;
[0018] FIG. 9 is a diagrammatical representation of a fin
arrangement in accordance with an exemplary embodiment of the
present invention;
[0019] FIG. 10 is a diagrammatical representation of a portion of a
cooling chamber having a liquid separator with a single row fin
arrangement in accordance with an exemplary embodiment of the
present invention;
[0020] FIG. 11 is a diagrammatical representation of a portion of a
cooling chamber having liquid separator with a multi-row fin
arrangement in accordance with an exemplary embodiment of the
present invention;
[0021] FIG. 12 is a diagrammatical representation of a portion of a
cooling chamber having a liquid separator with a slanted fin
arrangement along a row in accordance with an exemplary embodiment
of the present invention;
[0022] FIG. 13 is a diagrammatical representation of a liquid
separator with a staggered fin arrangement in accordance with an
exemplary embodiment of the present invention;
[0023] FIG. 14 is a diagrammatical representation of a scrubber
having a liquid separator in accordance with an exemplary
embodiment of the present invention;
[0024] FIG. 15 is a diagrammatical representation of a faceted or
round liquid separator in accordance with an exemplary embodiment
of the present invention;
[0025] FIG. 16 is a diagrammatical representation of a faceted
liquid separator in accordance with an exemplary embodiment of the
present invention; and
[0026] FIG. 17 is a diagrammatical representation of a round liquid
separator in accordance with an exemplary embodiment of the present
invention.
DETAILED DESCRIPTION
[0027] In accordance with the exemplary embodiments disclosed
herein, a gasifier having a cooling chamber assembly configured to
reduce temperature of syngas downstream of a combustion chamber is
disclosed. The gasifier includes a cooling chamber containing a
liquid coolant disposed downstream of the combustion chamber. A
syngas generated from the combustion chamber is directed via a dip
tube to the cooling chamber to contact the liquid coolant and
produce a cooled syngas. The gasifier also includes a dip tube
coupling the combustion chamber to the cooling chamber and
configured to direct syngas from the combustion chamber to the
cooling chamber to contact the liquid coolant and produce a cooled
syngas. A draft tube is disposed surrounding the dip tube and
defining an annular passage there between. A liquid separator is
disposed proximate to an exit path of the cooling chamber and
configured to remove entrained liquid content from the cooled
syngas directed through the annular passage to the exit path. In
one embodiment, the liquid separator is a symmetric liquid
separator. In another embodiment, the liquid separator is an
asymmetric liquid separator. In some embodiments, the cooling
chamber is used for quench applications. In certain other
embodiments, the cooling chamber is used for scrubbing
applications. The cooled syngas is directed through the annular
passage and impacted against the liquid separator so as to remove
entrained liquid content from the cooled syngas before the cooled
syngas is directed through the exit path. The features used to
accomplish the removal of the entrained liquid are referred to
herein as the "liquid separator". The liquid separator may be a
single component or an assembly. In some embodiments, the liquid
separator includes a finned deflector coupled to the dip tube. In
other embodiments, the liquid separator includes a conical shaped
faceted or round separator. The provision of the exemplary liquid
separator substantially reduces entrainment of liquid content in
the syngas directed through the exit path to the downstream
components. Specific embodiments are discussed in greater detail
below with reference to the FIGS. 1-15.
[0028] Referring to FIG. 1, an exemplary gasifier 10 is disclosed.
The gasifier 10 includes an outer shell 12 housing a combustion
chamber 14 at an upper end and a cooling chamber 16 at a lower end.
Combustion chamber 14 is provided with a refractory wall 18 capable
of withstanding the normal operating temperatures. A burner 20 is
coupled via a path 22 to a fuel source 24. A fuel stream including
pulverized carbonaceous fuel such as coal, coke or the like, is fed
into the combustion chamber 12 via the burner 20 removably disposed
on an upper wall of the combustion chamber 14. The burner 20 is
further coupled via a path 26 to a combustion supporting gas source
28 configured to supply gas such as oxygen or air.
[0029] The combustible fuel is burned in the combustion chamber 14
to produce an effluent including syngas and a particulated solid
residue. Hot effluent is fed from the combustion chamber 14 to the
cooling chamber 16 provided at the lower end of the shell 12. The
cooling chamber 16 is coupled to a pressurized source 30 and
configured to supply a pool of liquid coolant 32, preferably water
to the cooling chamber 16. The level of the liquid coolant in the
cooling chamber 16 is maintained at a desired height to assure an
efficient operation depending on the conditions of the effluent fed
from the combustion chamber 14 into the cooling chamber 16. The
lower end of the gasifier shell 12 is provided with a discharge
port 34 through which water and fine particulates are removed from
the cooling chamber 16 in the form of a slurry.
[0030] In the illustrated embodiment, a constricted portion 36 of
the combustion chamber 14 is coupled to the cooling chamber 16 via
a dip tube 38. The hot effluent is fed from the combustion chamber
14 to the liquid coolant 32 in the cooling chamber 16 via a
passageway 40 of the dip tube 38. A ring 42 is disposed proximate
to the dip tube 38 and coupled to the pressurized source 30 so as
to sustain a dip tube inner wall in a wetted condition to best
accommodate the downward effluent flow. A lower end 44 of the dip
tube 38 may be serrated, and positioned below the surface of the
liquid coolant 32 to efficiently achieve cooling of the
effluent.
[0031] A draft tube 46 is positioned in the cooling chamber 16. The
draft tube 46 includes an elongated cylindrical body 48 fixedly
supported in the gasifier shell 12. A lower portion of the draft
tube 46 is submerged in the liquid coolant 32. The cylindrical body
48 terminates adjacent to, but spaced at its upper end, from the
ring 42. The cylindrical body 48 is also spaced from the dip tube
38 to define an annular passage 50. The syngas is contacted with
the liquid coolant 32 to produce a cooled syngas. The cooled syngas
is then passed through the annular passage 50 towards an exit path
52 of the cooling chamber 16.
[0032] As discussed above, the gaseous component of the effluent is
discharged for further processing via the exit path 52 from the
cooling chamber 16. In the illustrated embodiment, the cooling
chamber 16 is a quench chamber. In certain other embodiments, the
cooling chamber is a scrubber configured to remove entrained solids
from the syngas. It is known conventionally that the gaseous
component, however, in passing through a quench chamber, will carry
with it a substantial amount of the liquid coolant. Excessive
liquid carried from the cooling chamber and into downstream
equipment, is found to pose operational problems.
[0033] In the illustrated embodiment, a liquid separator 54 is
disposed proximate to the exit path 52 of the cooling chamber 16.
It should be noted herein that in the illustrated embodiment, the
liquid separator 54 is a symmetric liquid separator. The liquid
separator 54 includes a deflector 56 coupled to the dip tube 38 and
configured to redirect the flow of the cooled syngas from the
annular passage 50 in a downward direction. In the illustrated
embodiment, the deflector 56 may be spherical shaped. In other
embodiments, other shapes of the deflector are also envisaged. A
plurality of fins 58 are provided to the deflector 56. The cooled
syngas redirected by the deflector 56 is forced to flow through a
series of blockages, in other words the fins 58. As a result, the
momentum of flow of the syngas is dissipated and available flow
area is used more efficiently. The flow of syngas is more evenly
distributed at an exit of the deflector 56. In the normal course of
quench cooling, the cooled gas stream would convey with it a
certain amount of liquid coolant. However, as the cooled gas stream
impinges against the deflector 56 and the fins 58, flow velocity of
the syngas is reduced, and the entrained liquid content is removed
from the syngas. The deflector 56 also prevents sloshing of liquid
coolant 32 to the exit path 52 of the cooling chamber 16.
[0034] In the illustrated embodiment, the deflector 56 may include
a plurality of holes 57 for directing a portion of the cooled
syngas to a region upstream of the deflector 56 in the cooling
chamber 16. This facilitates to enhance syngas flow uniformity and
also reduced entrainment of liquid content in the syngas. In
certain embodiments, the deflector 56 may employ holes 56 and may
not have fins 58. It should be noted herein that the illustrated
gasifier is an exemplary embodiment and other configurations of
gasifiers are also envisaged. It should noted herein that the term
"cooling chamber" will refer to a quench system or a scrubber
regardless of the gasifier configuration. Other embodiments of the
liquid separator are discussed below with reference to subsequent
figures.
[0035] Referring to FIG. 2, a liquid separator 54 is disclosed. As
discussed above, the liquid separator 54 is disposed proximate to
the exit path of the cooling chamber. The liquid separator 54
includes the spherical deflector 56 coupled to the dip tube and
configured to redirect the flow of the cooled syngas from the
annular passage between the dip tube and the draft tube in a
downward direction. The plurality of fins 58 are disposed on the
deflector 56. In the illustrated embodiments, ten fins 58 are
provided to the deflector 56. The fins 58 are disposed along a
circular direction 60. As the cooled gas stream impinges against
the deflector 56 and the fins 58, the momentum of flow is
dissipated and the flow velocity is reduced resulting in removal of
entrained liquid content from the syngas.
[0036] Referring to FIG. 3, a portion of the cooling chamber 16 is
disclosed. A liquid separator 62 is disposed proximate to the exit
path 52 of the cooling chamber 16. In the illustrated embodiment,
the liquid separator 62 is a symmetrical liquid separator. The
liquid separator 62 includes an elliptical deflector 64 coupled to
the dip tube 38 and configured to redirect the flow of the cooled
syngas from the annular passage 50 between the dip tube 38 and the
draft tube 46 in a downward direction.
[0037] Referring to FIG. 4, a portion of the cooling chamber 16 is
disclosed. A liquid separator 66 is disposed proximate to the exit
path 52 of the cooling chamber 16. In the illustrated embodiment,
the liquid separator 66 is a symmetric liquid separator. The liquid
separator 66 includes a rectangular deflector 68 coupled to the dip
tube 38 and configured to redirect the flow of the cooled syngas
from the annular passage 50 between the dip tube 38 and the draft
tube 46 in a downward direction.
[0038] Referring to FIG. 5, a portion of the cooling chamber 16 is
disclosed. A liquid separator 67 is disposed proximate to the exit
path 52 of the cooling chamber 16. In the illustrated embodiment,
the liquid separator 67 is an asymmetric liquid separator. The
liquid separator 67 includes a deflector 69 coupled to the dip tube
38 and configured to redirect the flow of the cooled syngas from
the annular passage 50 between the dip tube 38 and the draft tube
46 in a downward direction.
[0039] Referring to FIG. 6, a portion of the cooling chamber 16 is
disclosed. A liquid separator 70 is disposed proximate to the exit
path 52 of the cooling chamber 16. The liquid separator 70 is a
symmetric liquid separator. The liquid separator 70 includes a
trapezoidal deflector 72 coupled to the dip tube 38 and configured
to redirect the flow of the cooled syngas from the annular passage
50 between the dip tube 38 and the draft tube 46 in a downward
direction.
[0040] Referring to FIG. 7, a plurality of fins 74 provided to a
deflector (not shown) are disclosed. In the illustrated embodiment,
the fins 74 include straight fins and are arranged in the shape of
a polygon.
[0041] Referring to FIG. 8, a plurality of fins 76 provided to a
deflector (not shown) are disclosed. In the illustrated embodiment,
the fins 76 include curved fins and are arranged in the shape of a
circle.
[0042] Referring to FIG. 9, a plurality of fins 78 provided to a
deflector (not shown) are disclosed. In the illustrated embodiment,
one set of fins 78 may be disposed along a radial direction 80 and
another set of fins 78 may be disposed along a tangential direction
82.
[0043] Referring to FIG. 10, a portion of the cooling chamber 16 in
accordance with the embodiment of FIG. 1 is disclosed. The liquid
separator 54 includes the spherical deflector 56 coupled to the dip
tube 38 and configured to redirect the flow of the cooled syngas
from the annular passage 50 between the dip tube 38 and the draft
tube 46 in a downward direction. The plurality of fins 58 are
provided to the deflector 56. In the illustrated embodiment, the
fins 58 are disposed along a single row.
[0044] Referring to FIG. 11, a portion of the cooling chamber 16 in
accordance with the embodiment of FIG. 1 is disclosed. In the
illustrated embodiment, the plurality of fins 58 are provided to
the deflector 56 and are disposed along multi-rows.
[0045] Referring to FIG. 12, a portion of the cooling chamber 16 in
accordance with the embodiment of FIG. 1 is disclosed. In the
illustrated embodiment, the plurality of fins 58 are provided to
the deflector 56 and are disposed slanted along a row.
[0046] Referring to FIG. 13, a liquid separator 84 is disclosed. In
the illustrated embodiment, the liquid separator 84 includes two
sets of fins 86, 88 provided to a deflector 90. The two sets of
fins 86, 88 are disposed along two rows respectively along a
circular direction. In one embodiment, the set of fins 86 along one
row is disposed staggered with respect to the set of fins 88 of the
other row.
[0047] Referring to FIG. 14, an exemplary cooling chamber 85 is
disclosed. In the illustrated embodiment, the cooling chamber 85 is
a scrubber. A draft tube 87 is disposed surrounding a dip tube 89
in the cooling chamber 85. A lower portion of the draft tube 87 is
submerged in a liquid coolant 91. An annular passage 93 is defined
between the draft tube 87 and the dip tube 89. The syngas is
contacted with the liquid coolant 91 to cool and remove entrained
solid particles from the syngas.
[0048] In the illustrated embodiment, a liquid separator 95 is
disposed proximate to an exit of the annular passage 93. The liquid
separator 95 includes a deflector 97 coupled to the dip tube 89 and
configured to redirect the flow of the cooled syngas from the
annular passage 93 in a downward direction. A plurality of fins
(not shown) may be provided to the deflector 97. The cooled syngas
redirected by the deflector 97 may forced to flow through a series
of fins. As a result, the momentum of flow of the syngas is
dissipated and available flow area is used more efficiently. The
syngas then flows through a space 99 between the draft tube 87 and
a wall 101 of the cooling chamber 85 in an upward direction and is
exited from an upper side.
[0049] In accordance with the embodiments discussed herein, the
provision of the deflector, fins, or combinations thereof
facilitates to reduce cooled syngas flow velocity, and also to
increase gas flow path distance between the liquid coolant and the
exit path of the cooling chamber. This results in increased
residence time of the gas and liquid coolant mixture in the cooling
chamber leading to enhanced removal of entrained liquid content
from the cooled syngas. In general, the deflector and the fins may
create a tortuous path for the flow of syngas within the cooling
chamber.
[0050] It should be noted herein that with reference to FIG. 1-14,
that the shape of the deflector may vary depending on the
application. The number, shape, and arrangement of fins may also be
varied and optimized depending on the application. The various
permutations and combinations of the various embodiments discussed
above may also be envisaged.
[0051] Referring to FIG. 15, a cooling chamber 92 is disclosed. In
the illustrated embodiment, a draft tube 94 is positioned
surrounding a dip tube 96 in the cooling chamber 92. The cooled
syngas is passed through an annular passage 98 formed between the
dip tube 96 and the draft tube 94 towards an exit path 100 of the
cooling chamber 92. A liquid separator 102 is disposed proximate to
the exit path 100 and surrounding the dip tube 96 and the draft
tube 94 in the cooling chamber 92. The syngas is cooled by
contacting a liquid coolant 104 in the cooling chamber 92. The
liquid separator 102 may be a faceted or round liquid separator. In
the illustrated embodiment, the liquid separator 102 is a conical
shaped liquid separator. In one embodiment, the liquid separator
102 may be an asymmetric liquid separator. In another embodiment,
the liquid separator 102 may be a symmetric liquid separator. The
liquid separator is explained in greater detail with reference to
subsequent figures.
[0052] Referring to FIG. 16, a liquid separator 102 in accordance
with the embodiment illustrated in FIG. 15 is disclosed. In the
illustrated embodiment, the separator 102 is a symmetric faceted
separator. The illustrated separator 102 includes a plurality of
splash plates 105 and a plurality of v-shaped baffle elements 106
provided to the splash plates 105. The baffle elements 106 are
arranged in a converging pattern with channels 108 formed between
the baffle elements 106. The baffle elements 106 restrict the flow
area along a radial direction in the separator 102. A pipe 110 is
coupled to each channel 108. The cooled syngas exiting the annular
passage between the dip tube and the draft tube is directed through
the separator 102. The cooled syngas is directed against inner
walls of splash plates 105 due to inertial forces. The baffle
elements 106 are configured to separate the liquid content from
cooled syngas stream. In other words, due to the converging flow
area in the separator 102, the syngas flow would stratify due to
difference in density between liquid and gas. The gas phase is
displaced inwards along a radial direction in the separator 102 due
to flow stratification. The liquid content will tend to coalesce on
the baffle elements 106. The removed entrained liquid content is
drained via the channels 108 into the pipes 110 and then directed
into the cooling chamber. In some embodiments, the baffle elements
106 may be provided normal to the surface of the splash plates 105.
In certain other embodiments, the baffle elements 106 may be
disposed angle upwards to the surface of the splash plates.
[0053] In accordance with the embodiments discussed herein, the
provision of the splash plates 105 and baffle elements 106
facilitates to reduce cooled syngas flow velocity, and also to
increase gas flow path distance between the liquid coolant and the
exit path of the cooling chamber. This results in increased
residence time of the gas and liquid coolant mixture in the cooling
chamber leading to enhanced removal of entrained liquid content
from the cooled syngas. The amount of entrained liquid content in
the syngas exiting the separator 102 is reduced as radial velocity
is smaller than axial velocity of flow of syngas. In general, the
splash plates 105 and baffle elements 106 may create a tortuous
path for the flow of syngas within the cooling chamber. The
separator also prevents re-entrainment of liquid content in the
syngas.
[0054] Referring to FIG. 17, a round liquid separator 112 is
disclosed. In the illustrated embodiment, the separator 112 is an
asymmetric liquid separator. The illustrated liquid separator 112
includes a plurality of v-shaped baffle elements 114. The baffle
elements 114 are arranged in a converging pattern with channels 116
formed between the baffle elements 114. It should be noted herein
that the baffle elements 114 are not provided uniformly in the
round liquid separator 112. The baffle elements 114 restrict the
flow area along a radial direction in the separator 112. A pipe 118
is coupled to each channel 116.
[0055] The entrainment mitigation mechanisms depicted in FIGS. 1-17
may be employed separately or in combination with one another.
Moreover, as may be appreciated, the relative sizes, shapes, and
geometries of the entrainment mitigation mechanisms may vary.
Although certain embodiments employ symmetric geometries for the
liquid separator, it should be noted herein that asymmetric
constructions could be employed as well in certain applications.
For example by removing one or more fins from a given arrangement
one could achieve cost savings while still preserving functionality
of the liquid separator. The entrainment mitigation mechanisms may
be employed in a cooling chamber during the initial manufacturing,
or the entrainment mitigation mechanisms may be retrofit into
existing cooling units and/or scrubbers. Further, the entrainment
mitigation mechanisms may be adjusted based on operational
parameters, such as the type of carbonaceous fuel, the system
efficiency, the system load, or environmental conditions, among
others to achieve improved system operability and control.
[0056] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they have structural elements that do not differ
from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal languages of the claims.
[0057] While only certain features of the invention have been
illustrated and described herein, many modifications and changes
will occur to those skilled in the art. It is, therefore, to be
understood that the appended claims are intended to cover all such
modifications and changes as fall within the true spirit of the
invention.
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