The scrubber tower is carrying water

Water in the syngas at the C1301 outlet 1. Consequences: It causes deactivation and clogging of the shift catalyst; in severe cases, the plant must be shut down for catalyst replacement. 2. Reasons: ① High liquid level in the scrubber tower or low indication ； ②Too much water added to the tray ； ③The syngas flow rate increases ； ④The syngas produced by the gasifier contains a high amount of water, which cannot be removed even through the scrubber tower ； ⑤The internal components of the scrubber tower, such as the tray plates and cyclone separators, are damaged. 3. Measures and precautions: ① Increase the discharge volume of black water from the scrubber tower and gasifier; maintain the liquid level in the gasifier at 50–80% and that in the scrubber tower at 40–65%. ② Reduce the flow rate of condensate on the trays, keeping it between 15–20 m3/h ； ③Add water under the large tray to improve the water quality in the system ； ④Having water present severely affects the temperature of the shift converter; the shift reaction can be stopped by venting ； ⑤Reduce the load; if this does not work, apply to shut down the equipment. After shutdown, inspect the internal components of the gasifier and scrubber. The above are the contents of the Toyoki operation method; it seems there is no mention of the cause of slag port wear you mentioned. However, it is possible that the slag hole expands due to wear, reducing the resistance of the process gas; this leads to an increase in the gas flow rate, with the consequence being water entrainment in the scrubber tower.

When the slag outlet wears out, it becomes larger, which reduces the resistance to the process gas; as a result, the gas flow velocity increases. The consequence of this is water being carried into the scrubber tower. However, this possibility is very low – other possible causes for water ingress should be considered first

Causes of water carryover in the scrubber tower and solutions: Causes                                                     Solutions ⑴ Excessive load                                                     Reduce the load ⑵ Large fluctuations in the system (pressure, temperature, level)    Ensure system stability ⑶ Poor water quality in the system (or changes in separation space)   Control water quality ⑷ Water carryover in the vaporization furnace                     Reduce water inflow and increase water outflow ⑸ Excessively high liquid level in the carbon cleaning tower     Lower the liquid level ⑹ Damaged demister on the tower trays                     Shut down the system for maintenance as appropriate ⑺ Excessive water addition to the tower trays                    Adjust the amount of water added to the tower trays. Wear at the slag outlet is less likely to cause water carryover, as the wear on the slag outlet develops gradually.

The original poster is discussing how severe wear of the slag outlet bricks can cause water to enter the scrubber tower. Should it be considered from the perspective of the correspondence between the two?

What was said on the 2nd floor makes sense: when the wear on the slag outlet bricks is severe, the resistance to the flow of the coarse syngas decreases, resulting in an increase in the gas velocity; this in turn causes water to be carried into the scrubber tower.

Has the slag hole becoming smaller caused the air flow velocity to increase? Isn’t there a downcomer coming out of the slag outlet? The diameter of the slag outlet is about 400 units smaller than that of the downcomer. The speed change should not be very significant either. Besides, there is a downcomer, so I think this shouldn’t have much impact on the water content