CCS and Power Systems

Advanced Energy Systems - Gasification Systems

Mitigation of Syngas Cooler Plugging and Fouling

Performer: Reaction Engineering International

Project No: FE0007952

Project Description

The project consists of three main areas: laboratory scale experimentation, modeling work, and field testing for validation of the selected technology developed under this project.

The laboratory scale testing will be conducted by the University of Utah. The experiments will consist of generating ash deposits from both the pilot scale gasifier and the Laminar Entrained Flow Reactor (LEFR), which will be used to evaluate deposit strength at a range of temperatures, surface materials, and fuel properties. The impinging jet experiments will determine the energy requirements for removal of ash material deposits that adhere to metallic and refractory surfaces. This work will evaluate the adhesion strength of ash deposits to the surface in tests using coal-derived syngas from the LEFR over a range of temperatures (700-1050 °C). An impinging jet blowing nitrogen will be used to dislodged the ash deposits and thus, determine the adhesion strength.

Modeling will be performed by the recipient, Reaction Engineering International (REI). Process and engineering model calculations will assist in development of the test design and data interpretation. Computational fluid dynamic (CFD) modeling of commercial syngas cooler designs will be done to determine the conditions that cause plugging and fouling in the syngas cooler. In addition, by using CFD modeling, REI will evaluate methods to mitigate and better manage syngas cooler plugging and fouling. This will be accomplished by CFD modeling of alternative process conditions, syngas cooler geometry changes that could reduce fouling/plugging, and equipment changes (e.g., filters, traps, baffles, flow area expansions) upstream of the syngas cooler. Potential syngas cooler geometry changes include using larger diameter tubes and/or varying syngas cooler orientation (up, down, horizontal). 

After the experimental testing, modeling, and economic evaluation for the proposed mitigation technology for syngas cooler improvements is completed, the last part of the project is to conduct testing at a commercial IGCC plant to test the applicability of the chosen technology. A reactor will be constructed with shakedown testing done at the University of Utah to then install at the plant to withstand a particulate syngas stream at high pressure and temperature.

From left to right: Laminar Entrained Flow Reactor, Pilot Scale Entrained Flow Reactor, Syngas Cooler CFD Model

Project Details