Systems and methods for reducing corrosion in a reactor system using corrosion protection layers

Abstract

Systems and methods for reducing or eliminating corrosion of components of a reactor system, including a supercritical water gasification system, are described. Corrosion protection layers may be configured to provide a physical barrier between component surfaces and subcritical fluid present in one or more subcritical zones during operation of the reactor system. The corrosion protection layers may include glass and silicon carbide, and may be positioned within the one or more subcritical zones to prevent the subcritical fluid from contacting component surfaces susceptible to corrosion from corrosive ions present in the subcritical fluid.

1 . A reactor system configured to reduce or eliminate corrosion thereof, the system comprising:
 a system vessel comprising an inner surface, and having a subcritical zone configured to receive fluid at subcritical conditions; and   at least one corrosion protection layer comprising silicon carbide at least partially encapsulated in glass, the at least one corrosion protection layer being positioned within the subcritical zone to provide a physical barrier that protects at least a portion of the inner surface from corrosion by the fluid.   
     
     
         2 . The system of  claim 1 , wherein the reactor system is a supercritical water reactor system. 
     
     
         3 . (canceled) 
     
     
         4 . The system of  claim 1 , further comprising a pump configured to pump the fluid through the system vessel. 
     
     
         5 .- 6 . (canceled) 
     
     
         7 . The system of  claim 1 , further comprising a pre-heater. 
     
     
         8 . The system of  claim 1 , further comprising a heat exchanger. 
     
     
         9 . The system of  claim 1 , wherein the system vessel is configured as one of a reactor vessel, a pre-heater, and a heat exchanger. 
     
     
         10 . The system of  claim 1 , wherein the reactor system is configured as a supercritical coal water gasifier. 
     
     
         11 .- 13 . (canceled) 
     
     
         14 . The system of  claim 1 , wherein water within the subcritical zone is configured to a temperature below about 647 Kelvin. 
     
     
         15 . The system of  claim 1 , wherein water within the subcritical zone is configured to a temperature between about 570 Kelvin and about 647 Kelvin. 
     
     
         16 . The system of  claim 1 , wherein water within the subcritical zone is configured to a pressure of about 25 MPa. 
     
     
         17 . (canceled) 
     
     
         18 . The system of  claim 1 , wherein the glass comprises borosilicate glass. 
     
     
         19 . The system of  claim 18 , wherein the borosilicate glass comprises at least one of the following: SiO 2 , B 2 O 3 , Na 2 O, Al 2 O 3 , Fe 2 O 3 , CaO, MgO, and Cl. 
     
     
         20 . (canceled) 
     
     
         21 . The system of  claim 18 , wherein the borosilicate glass comprises about 80.6% SiO 2  by weight, about 12.6% B 2 O 3  by weight, about 4.2% Na 2 O by weight, about 2.2% Al 2 O 3  by weight, about 0.04% Fe 2 O 3  by weight, about 0.1% CaO by weight, about 0.05% MgO by weight, and about 0.1% Cl by weight. 
     
     
         22 . (canceled) 
     
     
         23 . The system of  claim 1 , wherein the at least one corrosion protection layer comprises less than about 40% glass by volume. 
     
     
         24 . The system of  claim 1 , wherein the at least one corrosion protection layer comprises at least about 20% glass by volume. 
     
     
         25 . (canceled) 
     
     
         26 . The system of  claim 1 , wherein the at least one corrosion protection layer comprises at least about 60% silicon carbide by volume. 
     
     
         27 . The system of  claim 1 , wherein the at least one corrosion protection layer comprises about 60% silicon carbide by volume to about 80% silicon carbide by volume. 
     
     
         28 .- 71 . (canceled) 
     
     
         72 . A method for reducing or eliminating corrosion in a reactor system, the method comprising:
 providing a reactor system having a system vessel, the system vessel comprising an inner surface and having a subcritical zone configured to receive fluid at subcritical conditions;   providing at least one corrosion protection layer comprising silicon carbide at least partially encapsulated by glass; and   positioning the at least one corrosion protection layer within the subcritical zone to provide a physical barrier that protects at least a portion of the inner surface from corrosion by the fluid at subcritical conditions.   
     
     
         73 . (canceled) 
     
     
         74 . The method of  claim 72 , wherein providing the reactor system comprises providing a supercritical water reactor system. 
     
     
         75 .- 78 . (canceled) 
     
     
         79 . The method of  claim 72 , further comprising a pump configured to move the fluid through the system vessel. 
     
     
         80 . The method of  claim 72 , wherein receiving the fluid at subcritical conditions comprises receiving the fluid at a subcritical temperature less than about 647 Kelvin. 
     
     
         81 . (canceled) 
     
     
         82 . The method of  claim 72 , wherein receiving the fluid at subcritical conditions comprises receiving the fluid at a subcritical pressure of about 25 MPa. 
     
     
         83 . The method of  claim 72 , wherein receiving the fluid at subcritical conditions comprises receiving the fluid at a subcritical temperature of about 620 Kelvin and a subcritical pressure of about 25 MPa. 
     
     
         84 . (canceled)