Methods and systems of producing a particulate free, cooled syngas product

Patent metadata

Field	Value
Publication number	US-9410097-B2
Application number	US-201313833179-A
Country	US
Kind code	B2
Filing date	Mar 15, 2013
Priority date	Mar 15, 2013
Publication date	Aug 9, 2016
Grant date	Aug 9, 2016

Abstract

Methods and systems for gasifier system are provided. The system includes a two-stage particulate separator having a side draw-off connector configured as a first virtual impactor, the first virtual impactor configured to separate a substantially particulate free flow of a reaction product from a particulate laden flow of the reaction product. The two-stage particulate separator also includes a transfer line coupled downstream of said draw-off connector, a second virtual impactor coupled downstream of the transfer line, and a quench chamber coupled downstream from the second virtual impactor, such that the quench chamber is configured to receive at least the particulate laden flow of the reaction product.

First claim

What is claimed is:

1. A two-stage particulate separator for use in a gasifier system, said two-stage particulate separator comprising:
a first virtual impactor including a first flow acceleration nozzle and a side draw-off connector, said first flow acceleration nozzle defining a first throat diameter, said first virtual impactor configured to separate a particulate laden flow of a reaction product into a first flow and a particulate laden second flow, the first flow containing residual particulates;
a first quench chamber coupled downstream from said first virtual impactor configured to receive at least the particulate laden second flow;
a transfer line coupled downstream of said side draw-off connector and configured to receive the first flow;
a second virtual impactor coupled downstream of said transfer line, said second virtual impactor including a second flow acceleration nozzle defining a second throat diameter that is less than said first throat diameter, said second virtual impactor configured to separate the first flow into a third flow and a fourth flow, the fourth flow containing a majority of the residual particulates; and
a second quench chamber coupled downstream from said second virtual impactor, said second quench chamber configured to receive at least the fourth flow from the second virtual impactor.

2. A two-stage particulate separator in accordance with claim 1 wherein said two-stage particulate separator is coupled between a gasifier reaction chamber upstream of said two-stage particulate separator and a syngas cooler downstream of said two-stage particulate separator.

3. A two-stage particulate separator in accordance with claim 1 wherein said two-stage particulate separator is at least one of a portion of a refractory lining of a gasifier and slag separation vessel and a portion of an actively cooled lining of a gasifier and slag separation vessel.

4. A two-stage particulate separator in accordance with claim 2 wherein said syngas cooler is at least one of a fire tube syngas cooler and a partial quench chamber.

5. A two-stage particulate separator in accordance with claim 1 further comprising a reactor comprising a reaction chamber defined therein, said reactor coupled upstream of said first virtual impactor, said two-stage particulate separator further comprising a modified feed injector configured to inject feeds into said reactor with initial trajectories substantially away from the centerline of said reaction chamber.

6. A gasifier system for use with a turbine, said gasifier system comprising:
a reactor comprising a reaction chamber defined therein;
a two-stage particulate separator coupled to said reactor, said two-stage particulate separator comprising:
a first virtual impactor including a first flow acceleration nozzle and a side draw-off connector, said first flow acceleration nozzle defining a first throat diameter, said first virtual impactor configured to separate a particulate laden flow of a reaction product into a first flow and a particulate laden second flow, the first flow containing residual particulates;
a transfer line coupled downstream of said side draw-off connector and configured to receive the first flow; and
a second virtual impactor coupled downstream of said transfer line, said second virtual impactor including a second flow acceleration nozzle defining a second throat diameter that is less than said first throat diameter, said second virtual impactor configured to separate the first flow into a third flow and a fourth flow, the fourth flow containing a majority of the residual particulates; and
a syngas cooler coupled downstream from said two-stage particulate separator.

7. A gasifier system in accordance with claim 6 further comprising a modified feed injector configured to inject feeds into said reactor with initial trajectories substantially away from the centerline of the gasifier reaction chamber.

8. A gasifier system in accordance with claim 6 wherein said two-stage particulate separator further comprises a first quench chamber configured to receive at least the second flow from the first virtual impactor.

9. A gasifier system in accordance with claim 6 wherein said two-stage particulate separator comprises a second quench chamber configured to receive at least the fourth flow from the second virtual impactor.

10. A gasifier system in accordance with claim 6 wherein said syngas cooler is at least one of a fire tube syngas cooler and a partial quench chamber.

11. A gasifier system in accordance with claim 6 wherein at said syngas cooler is at least partially oriented in at least one of a horizontal position and a vertical position.

12. A gasifier system in accordance with claim 9 wherein at least one of said first quench chamber and said second quench chamber comprises an exit for channeling the the corresponding one of the second flow and the fourth flow downstream into said syngas cooler.

13. A gasifier system in accordance with claim 8 wherein said side draw-off extends at least partially upwardly from said reactor, such that particulate contacts said side draw-off and is gravitationally drawn toward said first quench chamber.

14. A gasifier system in accordance with claim 6 wherein said two-stage particulate separator is at least one of a portion of a refractory lining of a gasifier and slag separation vessel and a portion of an actively cooled lining of a gasifier and slag separation vessel.

15. A gasifier system in accordance with claim 6 wherein the inlet to the syngas cooler further comprises an inner membrane comprising a plurality of slots configured to channel a flow of cooling gas across a surface of said membrane such that a film of cooling gas covers at least a portion of the membrane surface.

Assignees

• Gen Electric

Inventors

• Leininger Thomas Frederick

Classifications

• B01D45/08

  by impingement against baffle separators · CPC title

• C10J2300/1678

  with air separation · CPC title

• C10J2300/1603

  with gas treatment · CPC title

• C10J3/485

  Entrained flow gasifiers · CPC title

• C10J2300/0976

  as steam · CPC title