Method and system for an integrated gasifier and syngas cooler

Abstract

A method and system for an integrated gasifier and syngas cooler are provided. The system includes a gasifier including a reaction chamber, a syngas cooler integrally formed with the gasifier and including at least one heat exchanger element, and a transition portion integrally formed with the reaction chamber and the syngas cooler and extending therebetween, the transition portion further including a throat extending between the reaction chamber and the syngas cooler, the transition portion further including a heat exchanger circumscribing the throat.

1 . An integrated gasifier and syngas cooler comprising:
 a gasifier comprising a reaction chamber;   a syngas cooler integrally formed with said gasifier and comprising at least one heat exchanger element; and   a transition portion integrally formed with said reaction chamber and said syngas cooler and extending therebetween, said transition portion further comprising a throat extending between said reaction chamber and said syngas cooler, said transition portion further comprising a heat exchanger circumscribing said throat.   
   
   
       2 . An integrated gasifier and syngas cooler in accordance with  claim 1  wherein said heat exchanger comprises a steam cooled tube cage positioned radially outward from said throat to facilitate cooling said throat. 
   
   
       3 . An integrated gasifier and syngas cooler in accordance with  claim 1  further comprising:
 a support skirt extending radially inwardly from at least one of said gasifier and said transition portion; and   at least one anchoring ring coupled to said support skirt, said at least one anchoring ring extending radially inwardly from said support skirt, said at least one anchoring ring extending at least partially about a circumference of said support skirt.   
   
   
       4 . An integrated gasifier and syngas cooler in accordance with  claim 3  further comprising a layer of refractory material supported by said at least one anchoring ring, said layer of refractory material supported by said at least one anchoring ring such that adjacent layers of refractory material are slidably engaged to facilitate maintaining contact between layers of refractory material during periods of expansion and contraction. 
   
   
       5 . An integrated gasifier and syngas cooler in accordance with  claim 1  wherein said throat comprises a converging/diverging cross-section. 
   
   
       6 . An integrated gasifier and syngas cooler system comprising:
 a first pressure vessel portion surrounding a gasifier reaction chamber, said first portion extending from a vessel head to a lower end;   a second pressure vessel portion surrounding a gas cooler, said gas cooler configured to cool a hot raw effluent gas stream from said reaction chamber, said second portion extending from an upper end vertically downward towards a solids removal end;   a transition portion extending between said lower end and said upper end, each of said first portion, said second portion, and said transition portion are in substantial vertical coaxial alignment along a central longitudinal axis of each portion;   a throat coaxially aligned with each said portion and extending therebetween for the free passage of the hot raw effluent gas stream from said gasifier reaction chamber to said gas cooler, said throat lined about a radially inner surface with a refractory material;   a concentric coaxial vertical tube cage surrounding said throat along at least a portion of a length of said throat; and   a plurality of annular anchoring rings coupled to at least one of said first portion and said tube cage, said anchoring rings extending radially inward, said anchoring rings configured to support said throat refractory material.   
   
   
       7 . A system in accordance with  claim 6  further comprising a support skirt extending obliquely inward from at least one of said first portion and said tube cage. 
   
   
       8 . A system in accordance with  claim 7  wherein at least one of said plurality of annular anchoring rings is coupled to at least one of said first portion and said tube cage through said support skirt. 
   
   
       9 . A system in accordance with  claim 6  wherein said first portion comprises a first outer diameter and said second portion comprises a second outer diameter, said transition portion extending between said first outer diameter and said second outer diameter. 
   
   
       10 . A system in accordance with  claim 6  wherein said first and second pressure vessel portions comprise respective elongate vertical cylinders. 
   
   
       11 . A system in accordance with  claim 6  wherein said throat is lined about a radially inner surface with a shaped brick refractory material. 
   
   
       12 . A system in accordance with  claim 6  wherein said throat comprises a vertical substantially cylindrical sidewall. 
   
   
       13 . A system in accordance with  claim 6  wherein said throat comprises a diverging sidewall. 
   
   
       14 . A system in accordance with  claim 6  wherein said throat comprises a converging entrance. 
   
   
       15 . A system in accordance with  claim 6  wherein said plurality of annular anchoring rings are positioned such that a first layer of refractory material supported by a first annular anchoring ring slides along a second layer of refractory material supported by a second annular anchoring ring during expansion and contraction of said integrated gasifier and syngas cooler system. 
   
   
       16 . A method of assembling an integrated gasifier and syngas cooler, said method comprising:
 providing a syngas cooler vessel that is integrally formed with a gasification vessel, the gasification vessel including a reaction chamber, the syngas cooler vessel including a heat exchanger;   coupling the reaction chamber and the syngas cooler vessel in flow communication using a throat lined with a refractory material, the refractory material supported in the throat using one or more annular anchoring rings; and   positioning a cooling tube cage surrounding the throat such that during operation the refractory material is cooled using the cooling tube cage.   
   
   
       17 . A method in accordance with  claim 16  further comprising coupling the heat exchanger and the cooling tube cage in flow communication. 
   
   
       18 . A method in accordance with  claim 16  further comprising lining an entrance to the throat with refractory material such that the entrance converges from the reaction chamber to the throat. 
   
   
       19 . A method in accordance with  claim 16  further comprising lining the throat with refractory material such that the throat diverges from the throat to the syngas cooler. 
   
   
       20 . A method in accordance with  claim 16  further comprising lining the throat with refractory material such that the throat is substantially cylindrical.