142—Multi-factor swirl separator for mother-son separation and vane separation technologies in the gas-liquid-solid dynamic separation design of gasifier units in coal gasification projects
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This post was last edited by luoli519 on 2020-3-15 at 10:50. Based on the multi-factor cyclone mother-separator and vane separators provided by NOVEL Company for the gas-liquid-solid separation stage in gasification units for domestic and international coal gasification projects, this article provides a detailed overview of the design and application of such dynamic separation technologies and equipment in coal gasification processes.
In the coal chemical industry, coal gasification is one of the fundamental and crucial aspects of coal chemical projects. From the perspective of energy conversion chemistry, it is the controlled combustion of carbon-containing substances with oxygen. The key word is “controlled”. Currently, the coal gasification units used domestically and internationally, in terms of those applied on an industrial scale, mainly include slurry coal gasification, moving bed gasification, and powder coal gasification. The approaches that actively and urgently pursue advancements in separation technology mainly focus on water-coal slurry gasification and pulverized coal gasification. This article also primarily analyzes and discusses these two types of gasification.
In the water-coal slurry gasification process, kinetic separators are mainly used in the purification system and the slag treatment system. In purification systems, the multi-factor cyclone mother-son separator technology can be used to upgrade and replace traditional cyclone separators, while vane separators can replace the traditional wire mesh separators at the top of wash towers. In the slag treatment system, a feather leaf separator is used to replace the traditional wire mesh separator at the top of the evaporative hot water tower. The attached figure is a schematic diagram of the conventional configuration of a multi-nozzle opposed water-coal slurry gasification unit, provided for reference:
In the powder coal gasification process, kinetic separators are mainly used in the purification system and the slag treatment system as well. In purification systems, the multi-factor cyclone mother-son separator technology can be used to upgrade and replace traditional cyclone separators. In the slag treatment system, a feather leaf separator is used to replace the traditional wire mesh separator at the top of the evaporative hot water tower. The attached figure is a schematic diagram of the conventional configuration of a pulverized coal gasification unit, provided for reference:
Novel’s multi-factor swirl separator for mother-son separation and vane separation belongs to the category of dynamic separation technologies. It requires not only the use of patented internal components but also a system platform based on Novel’s precise dynamic gas-solid separation process calculation software in order to carry out accurate configuration design; both are essential. The data and information required for our precision dynamics gas-solid separation process calculation and design system platform are as follows: 1. Operating temperature ； 2. Operating pressure ； 3. Vapor phase composition (v%) ； 4. Accurate density of the gas phase under operating conditions (if this data is not available, it will be calculated by our platform and provided accordingly). 5. Viscosity of the gas phase (if this data is not available, it will be retrieved from our database and provided) ； 6. Gas flow rate (it must be specified whether the volume flow rate refers to the flow rate under standard conditions or under actual operating conditions) ； 7. Description of the types and approximate contents of solid/liquid phases carried by the airflow (particle size distribution data, if available, would be preferable) ； 8. Apparent density of solid/liquid phases carried by the airflow ； 9. It is necessary to clarify the technical upgrade: is it intended to reuse the existing tank, with only our side providing the internal components? Should we still design and manufacture a completely new separator? If the existing tank is to be reused and only our side needs to provide the internal components, please provide the internal dimension drawings of the original container shell, so that we can design the internal component system based on these constraints and ensure its smooth and easy installation. 10. Material, size, pressure rating, and connection method of the original gas-phase process transmission pipelines ； 11. Recommendations and requirements for the material of new separators.
Some customers have reported that for their powder gas gasifiers, the original configuration of the raw gas purification system consisted of two dust removal stages: a traditional cyclone separator followed by a filter. However, due to the low separation efficiency and unstable operation of the original cyclone separator, a large amount of dust escapes to the downstream filters, overloading them and causing frequent clogging. This leads to high frequencies of filter element replacement and maintenance, resulting in elevated operational and maintenance costs. They turned to NOVEL Company to seek technical upgrades for their existing cyclone separators by employing the multi-factor cyclone parent-separation technology.
The actual operating condition data provided by the customer are shown in the attached diagram below:
Based on the actual operating condition data provided by the customer, the information regarding the G54 multi-factor cyclone parent-child separator solution, which is developed through NOVEL’s precise dynamics separation calculations and the configuration system platform, is as follows: 1. Type of separation technology: Multi-factor cyclone parent-child separation technology (NOVEL patented technology)； II. Model: G54-71-243.66; III. Inlet separation assembly: G50B-24/70; IV. Material: CS ； V. Separation efficiency: 100% separation and removal of particulate matter with a size of 5.93 microns and above ； VI. Overall operating pressure drop: 2.32 psi.
This post was last edited by luoli519 on 2020-3-19 at 17:51. Here, the tables showing the output data of the G54 multi-factor cyclone parent-child separator, which are derived from the actual operating conditions provided by the customer through NOVEL’s precise dynamics separation calculations and configuration system platform, are attached below:
Due to the low operating pressure of the customer’s process, by adopting the water washing dust removal process, the advantages in terms of equipment modification costs, operational flexibility, operating expenses, and smooth operation become more evident. At this time, a vaned separation internals set can be installed on the inner side of the top of the water scrubber tower. The customer decided to install an independent vane separator in series on the gas outlet pipeline at the top of the water wash tower for its own specific reasons.
Based on the actual operating condition data provided by the customer and taking into account its specific process requirements, the information regarding the G50 type vane separator solution developed by NOVEL through precise dynamic separation calculations and its configuration system platform is as follows: 1. Type of separation technology: Vane separation technology (NOVEL’s patented technology)； II. Model: G50-63-243.66; III. Primary pre-condensation separation internal component assembly: G50D63; IV. Material: Internal components, S31603 ； Housing, CS ； V. Separation efficiency: 99.99% – removal of liquid droplets, mist, and particulate matter with a size of 5.16 microns or larger, as well as any heavy-phase contaminants ； VI. Overall operating pressure drop: 0.842 psi.