The pressure difference in the syngas cooler section of the SHELL gasification process is continuously increasing
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In the SHELL gasification process, the pressure difference of the syngas cooler (SGC), indicated by parameter 13PDI0077, has been increasing continuously since coal feeding began; its maximum value has now exceeded the allowable range. Could everyone please analyze the reasons for this?
Excluding instrument-related issues, if the pressure difference is indeed high, it indicates that the channel is not unobstructed. The possible causes include the following: 1. Severe dust accumulation, which narrows the channel; 2. Leaks in the water wall, resulting in a cement-like mixture formed by dust that blocks the channel. (The main locations are at the cross supports.) ）
The instruments should not have any major problems. If there were a leak in the water wall, that would be a serious issue, but I don’t think the possibility of a leak there is high, as it hasn’t been very long since the last inspection. Moreover, the temperature in that area remains below 750 degrees at most. The main concern at present is the severe ash accumulation in that section; it is necessary to find solutions related to the quenching air, the composition of the coal ash, and the impact devices, in order to address this issue of excessive ash accumulation which leads to a high pressure difference in 13PDI0077. If the situation becomes severe, it will be necessary to shut down the equipment.
Try using a different type of coal and check the backflow here.
It is recommended to consider the following points: 1. Analysis of the coal type’s composition, to determine whether there is a possibility of ash scaling. 2. Inspect the instruments and check the value of the total pressure difference 13PDT-0067 to determine whether there is an issue with the instruments. 3. Adjust the frequency of the striker and observe whether there is a reduction in the pressure difference; if so, it indicates that there is a blockage at the cross-hanger area. 4. Other comprehensive parameter analyses related to the gasification furnace system. . . .
The probability of such a possibility seems quite high. There are shims between several tubes in the SGC; it has been observed that the manufacturer welds both ends of these shims shut, and stress then causes the tube bundle to be damaged as a result. It depends on luck – perhaps with good luck the shims can be pulled out without damaging the tube bundle, but it’s not guaranteed:@
Support coal quality analysis and check whether 13TI0018 is on the high side. If it is high, it is likely due to severe dust accumulation at the cross hanger.
What is the range for 77 points? How high does it rise at 67 points? Was the dust accumulation on the crosshead and gas delivery ducts checked when the machine was stopped?