Determination of slag tap blockage

Abstract: A method for determining blockage of a coal gasification slag tap by observing changes in the sound pressure across the slag tap.

Description: The invention relates to a process for monitoring the open cross sectional area of the slag tap of a gasifier for the gasification of coal to detect changes therein, while carrying out a process for the partial oxidation of coal in the gasifier. This invention relates in particular to the monitoring of a slagging process for the partial oxidation of carbon-containing fuel, particularly coal, with an oxygen-containing gas in a reactor under high pressures and temperatures in which the gas formed is removed at the top of the reactor and slag at the bottom of the reactor. Many carbon-containing fuels are of mineral origin, and often contain, in addition to carbon and hydrogen, varying quantities of inorganic incombustible material. This material is a by-product of the process of oxidation, and, depending on characteristics such as density and size of the particular particle, and the reactor configuration and conditions, may undergo a rough separation in the reactor into particles called "flyash" (lighter) and "slag" (denser). The flyash particles are removed overhead, while the denser materials collect as a molten slag, often including separated iron, in the hearth of the reactor from which it is discharged downward through an outlet or orifice in the hearth, referred to as a slag tap, into a water bath. A real concern in slagging processes is that the molten slag and iron may solidify within the slag tap orifice to such an extent that the slag tap becomes blocked. Blockage of the slag tap requires shutdown of the process, an obviously unsatisfactory result. The invention is directed to overcoming this problem. This problem was solved in a different way by US-A-4834778. According to this document the blockage of the slag tap is prevented by measuring the change in pressure differential across a diaphragm seal. Accordingly, it is an object of the invention to provide a procedure or process for monitoring the open cross-sectional area to detect changes therein, or of detecting the blockage, or partial blockage, of a slag tap of a gasifier operated under elevated temperature and pressure for partially oxidizing coal. By identifying the early existence of a partial blockage, operating conditions may be changed to prevent or inhibit further deposition or even stimulate the removal of some or all of the blockage. Also, the monitoring technique of the invention may allow identification of conditions which lead to the origination of the partial blockage, so that these conditions may be avoided in subsequent operations. The invention therefore provides a process for monitoring the open cross sectional area of the slag tap of a gasifier for the gasification of coal to detect changes therein, while carrying out a process for the partial oxidation of coal in the gasifier, applying first and second pressure transducers, characterized by the steps of: a) providing at least one first acoustical pressure transducer in said gasifier; b) providing at least one second acoustical pressure transducer at a locus proximate the slag tap outside the gasifier; c) utilizing characteristics of sound emanating from the gasifier, whether endemic or supplied by an inserted source, concomitantly receiving sound pressure generated in said gasifier in both the at least one first pressure transducer and the at least one second pressure transducer, and transmitting from each of said transducers a time domain electrical signal proportionate to the amplitude of the sound pressure received by each of said respective transducers; d) converting said time domain signals respectively to mathematically complex signals in the frequency domain proportional to their pressure magnitude and/or pressure phase; e) comparing the frequency domain signal from the at least one transducer below the slag tap to the frequency domain signal from the at least one transducer in the gasifier at a preselected frequency, and deriving a frequency response function from the comparison; and f) comparing the magnitude and/or the phase of said function with a predetermined value. According to the invention, advantageously, in response to a deviation of the function produced in step e) from the predetermined value, the process for the partial oxidation of coal in the gasifier is discontinued. In another advantageous case, the partial oxidation process conditions may be changed or varied, such as the oxygen to coal ratio. For example, the oxygen to coal ratio may be decreased (or increased) depending on other factors. In another advantageous case, in response to a deviation of the value produced in step e) from the predetermined value, a flux is added to coal fed to the gasifier. As will be apparent, the invention utilizes characteristics of sound emanating from the gasifier or gasification zone, whether endemic or supplied by an inserted source. It is remarked that US-A-4,834,778 discloses determination of slag tap blockage by observing changes in the pressure differential across a diaphragm seal located in a pressurized vessel between the gasifier wall and the vessel wall. However, the use of characteristics of sound emanating from the gasifier, whether endemic or supplied by an inserted source, has not been disclosed therein. The partial combustion of coal to produce synthesis gas, which is substantially carbon monoxide and hydrogen, and particulate flyslag, is well known, and a survey of known processes is given in "Ullmanns Enzyklopadie Der Technischen Chemie", vol. 10 (1958), pp. 360-458. Several such processes for the preparation of hydrogen, carbon monoxide, and slag are currently being developed. Accordingly, details of the gasification process are related only insofar as is necessary for understanding of the present invention. In general, the gasification is carried out by partially combusting the coal with a limited volume of oxygen at a temperature normally between 800 °C and 2000 °C. If a temperature of between 1050 °C and 2000 °C is employed, the product gas will contain very small amounts of gaseous side products such as tars, phenols and condensable hydrocarbons. Suitable coals include lignite, bituminous coal, sub-bituminous coal, anthracite coal, and brown coal. Lignites and bituminous coals are preferred. In order to achieve a more rapid and complete gasification, initial pulverization of the coal is preferred. Particle size is preferably selected so that 70% of the solid coal feed can pass a 200 mesh sieve. The gasification is preferably carried out in the presence of oxygen and steam, the purity of the oxygen advantageously being at least 90% by volume, nitrogen, carbon dioxide and argon being permissible as impurities. If the water content of the coal is too high, the coal should be dried before use. The atmosphere will be maintained reducing by the regulation of the weight ratio of the oxygen to moisture and ash free coal in the range of 0.6 to 1.0, in particular 0.8 to 0.9. Although, in general, it is advantageous that the ratio between oxygen and steam be selected so that from 0 to 1.0 parts by volume of steam is present per part by volume of oxygen, the invention is applicable to processes having substantially different ratios of oxygen to steam. The oxygen used is advantageously heated before being contacted with the coal, e.g. to a temperature of from about 200° to 500°C. The high temperature at which the gasification is carried out is obtained by reacting the coal with oxygen and steam in a reactor at high velocity. An advantageous linear velocity of injection is from 10 to 100 meters per second, although higher or lower velocities may be employed. The pressure at which the gasification can be effected may vary between wide limits, e.g. from 1 to 200 bar. Residence times may vary widely; common residence times of from 0.2 to 20 seconds are described, with residence times of from 0.5 to 15 seconds being advantageous. After the starting materials have been converted, the reaction product, which comprises hydrogen, carbon monoxide, carbon dioxide, and water, as well as the aforementioned impurities, is removed from the reactor. This gas, which normally has a temperature between 1050°C and 1800°C, contains the impurities mentioned and flyslag, including carbon-containing solids. In order to permit removal of these materials and impurities from the gas, the reaction product stream should be first quenched and cooled. A variety of elaborate techniques have been developed for quenching and cooling the gaseous stream, the techniques in the quench zone and primary heat exchange zone in general being characterized by use of a quench gas and a boiler in which steam is generated with the aid of the waste heat. The quenched gas is then subjected to a variety of purification techniques to produce a product gas, commonly called synthesis gas, which has good fuel value as well as being suitable as a feed-stock for various processes. As mentioned, the inorganic incombustible material is separated from the fuel during the combustion of the mineral fuel. Depending on the operating conditions under which combustion takes place, in particular the temperature and the quality of the fuel, the material is obtained in solid or liquid condition or in a combination thereof. The slag flows along the reactor wall through the slag tap and is generally collected in a water bath located below the slag tap of the reactor, where it is collected, solidified, and subsequently discharged. The design of the chamber or vessel and slag tap employed is a matter of choice. Similarly, the sensing devices employed for obtaining the acoustical pressure values are known and within the ambit of those skilled in the art. Nevertheless, the slag tap should be rather narrow for various reasons. First, the escape of unconverted coal through the discharge opening should be avoided as much as possible. Second, the slag discharge opening should prevent water vapor formed during the cooling of the slag in the water bath from entering the reactor in excessive quantities. The penetration of the water vapor into the reactor in significant quantities could unfavorably affect the combustion process. Moreover, the water vapor will have a solidifying effect on the slag in the reactor, resulting in the slag flow to the slag discharge opening being reduced. Depending upon the conditions in the reactor, such as the type of carbon-containing fuel used, the slag will more or less easily flow to the slag tap and subsequently enter the cooling water bath. However, if the slag flow through the slag tap is reduced, it may cause blockage of the slag tap. If the slag tap becomes blocked, the slag will accumulate in the reaction zone and the combustion process must be interrupted to clean the slag tap. Apart from the loss of production involved in interruption of the process, there is also poor accessibility of the reactor owing to the high process temperature and pressure, which will result in the cleaning of the slag tap being a complicated and time consuming matter. In the present invention, monitoring of changes in the acoustical pressure in the reactor and outside the reactor at one or more loci near the slag tap at a pre-selected frequency allows the determination of blockage of the slag tap. The output voltages or signals of the transducers, after amplification in a suitable amplifying device, are processed and the frequency response function is derived and is compared with a predetermined value at the preselected frequency. In this procedure, the autopower spectral density of the amplified signal from the gasifier is computed [S gg (f)], as is the crosspower spectral density between the amplified signals [S gs (f)] from the gasifier location and the location outside the slag tap of the gasifier. The crosspower spectral density between the gasifier location and the outside (slag tap) location is then divided by the autopower spectral density of the gasifier location to produce a mathematically complex frequency response function which has both magnitude and phase functions and real and imaginary functions or components. Thus, Here, the bar denotes a mathematically complex quantity, while the absence of the bar denotes a real quantity. Nevertheless, as will be appreciated by those skilled in the art, the term "frequency response function" is understood to encompass real and imaginary functions. It should be noted that the complex frequency response function may also be computed directly by dividing the Fourier transform of the amplified slag tap signal by that of the amplified gasifier signal. Also, the frequency response function magnitude may be computed by taking the square root of the ratio of the slag tap autospectral density to that of the gasifier. However, these latter two approaches are not ordinarily used in practice since they produce some inaccuracies. According to the invention, either or both the magnitude or phase functions derived may be used to compare with a predetermined value or previously determined analogous function(s). As used herein, a "pre-determined" value, at a pre-selected frequency, refers to an acceptable sound pressure frequency response function value. Such a value may be arrived at in more than one way, an example being the establishment of the value on start-up of the gasifier by the recording of the sound pressures at resonant frequencies before any substantial blockage can occur. Another manner of determining the pre-determined ratio is by the use of a white noise source, at non-operating conditions, such as before start-up, with suitable correlation of the value of the ratio obtained to the standard conditions of operation. The term "pre-selected", with reference to the frequency, refers to one of the normal resonant frequencies of the gasifier or harmonics thereof. Normally, the pre-selected frequency will be a narrow range rather than a point value, and is so understood herein. Since, as those skilled in the art will understand, these frequencies will vary from reactor to reactor, and are dependent on such factors as, for example, the configuration of the vessel, precise ranges of the frequency cannot be given. However, a suitable frequency may be ascertained by the white noise technique mentioned, supra. Based on the observed acoustical pressure frequency response function upon beginning the operation of the gasifier with a clean slag tap, an observed change or deviation in the frequency response function value generally indicates some percentage blockage of the slag tap. An estimate of percentage blockage may be obtained by the white noise tests mentioned, supra, by insertion of calibrated blockages into the slag tap and noting the changes in magnitude and/or phase in the frequency response function. The method of the invention allows determination of the beginning of blockage before any noticeable significant frequency shift. One advantage of the present invention is the capability of controlling the blockage of the slag tap, thus extending the time periods between shutdown of the gasifier. Additionally, the flexibility of operating the process under various conditions, such as a range of pressures, temperatures, and types of coal which characteristically produce different amounts of slag is achieved. The invention will now be described by way of example in more detail with reference to the accompanying drawings, in which: Fig. 1 illustrates schematically the use of the invention in one type of gasifier for the gasification of coal; Fig. 2 illustrates the results of a "white noise" calibration procedure; and Fig. 3 ilustrates a comparator derived from such a procedure. Referring now to fig. 1, pulverulent coal is passed via a line 1 into burners 2 of a gasifier 3, the burners 2 being operated under partial oxidation conditions in an enclosed reaction chamber 4 to produce synthesis gas, flyslag or flyash, and slag. Synthesis gas and flyslag leave the reaction space 4 and pass from the upper portion of the gasifier to a conduit 5 where the gas and flyslag are quenched, the flyslag becoming solidified. The gas and flyslag particles are then passed for further treatment and separation (not shown). Concomitantly, slag produced falls to the lower portion of the chamber 4 and is allowed to flow by gravity through a slag discharge opening or tap 6. Molten slag drops into a waterbath 7 where it is solidified, and where it may be discharged by suitable techniques. As noted, the slag tap 6 must not be allowed to plug or become blocked. According to the invention, a dynamic pressure transducer is mounted in the gasifier 3 at a suitable location, such as at 10. A second transducer is mounted below the slag tap at 11. Each transducer produces an oscillating voltage which is amplified in a suitable amplifying device, shown as 12, and the voltages are sent to a fast Fourier transform (FFT) analyzer 13 where they are Fourier transformed into mathematically complex signals in the frequency domain. The signals are then used to compute the mathematically complex frequency response function as described, supra. This value is compared with a predetermined value. Although a spectrum of frequencies may be scanned, one of the resonant frequencies of the gasifier or the gasifier slag-chamber system in the 87 to 96 Hz range may be used. This frequency may be determined on startup of the reactor, when there is assurance that the tap is not plugged. As experience is obtained with operation of the tap while slag is flowing, a baseline can be obtained for future comparison. Any significant deviation from the baseline of frequency response function at the resonance frequency may be interpreted as possible blockage of the slag tap. In order to establish the relationship between sound generated in a gasifier and received in suitably located transducers (in this case microphones) in and outside the gasifier with varying percentages of plugging of the slag tap, experiments were conducted on shutdown of the gasifier and at ambient conditions. A loudspeaker (white noise) was placed at one of the burner locations in the gasifier to act as a substitute for the burners which will normally provide the noise source during operation (as mentioned, other sound sources may be relied on). The loudspeaker provided random noise of constant amplitude over a wide frequency range (5 - 5,000 Hz). The microphones were used to measure sound pressure, and an additional microphone was placed in front of the loudspeaker to monitor sound source characteristics. In these tests, the product outlet or quench zone outlet of the gasifier was fully open, but the slag tap was gradually "plugged" from a fully open condition, in increments of 20% closure, to a fully closed condition. The microphone signals were analyzed on the basis of frequency response function magnitude spectra. Fig. 2 shows the effect of slag tap plugging on the gasifier-to-slag bath frequency response function. 0% quench inlet plugging, white noise, no water in the slag bath; 40 °K, 1 bar and illustrates the variation in the gasifier to slag tap frequency response function for slag tap percent closures of 0 to 100 percent. The horizontal axis represents the frequency in Hz, whereas the vertical axis represents the frequency response. The curves A, B, C, D, E and F represent a percent area closed of slag tap of 0, 20, 40, 60, 80 and 100 respectively. Several narrowband frequency ranges, corresponding to resonance frequencies through the slag tap, show orderly decreases in sound pressure amplification as the slag tap is plugged. If a narrowband resonance range, e.g., 87 to 96 Hz, is chosen and integrated to obtain the areas under the peaks for the different values of slag tap area percent plugged, the values denoted by the square symbols in fig. 3 are obtained. In fig. 3 the effect of slag tap plugging on gasifier-to-slag tap frequency response integral in the 87-96 Hz range is shown. The vertical axis of fig. 3 represents the frequency response integral, whereas the horizontal axis represents the percentage plugged of the slag tap area. From fig. 3, then, a frequency response integral reading of about 57, for example, indicates that the slag tap is at worst 20 percent plugged, assuming no plugging of the quench outlet. These results may be used as a comparator for operating runs, and have been shown to be well correlated with actual high temperature gasifier runs. An equally effective comparator may be obtained by simply plotting the decreases in peak value in the 87 to 96 Hz range as a function of percent of slag tap plugging. Various modifications of the invention will become apparent to those skilled in the art from the foregoing description and accompanying drawings. Such modifications are intended to fall within the scope of the appended claims.

Claims: A process for monitoring the open cross sectional area of the slag tap of a gasifier for the gasification of coal to detect changes therein, while carrying out a process for the partial oxidation of coal in the gasifier, applying first and second pressure transducers, characterized by the steps of: a) providing at least one first acoustical pressure transducer in said gasifier; b) providing at least one second acoustical pressure transducer at a locus proximate the slag tap outside the gasifier; c) utilizing characteristics of sound emanating from the gasifier, whether endemic or supplied by an inserted source, concomitantly receiving sound pressure generated in said gasifier in both the at least one first pressure transducer and the at least one second pressure transducer, and transmitting from each of said transducers a time domain electrical signal proportionate to the amplitude of the sound pressure received by each of said respective transducers; d) converting said time domain signals respectively to mathematically complex signals in the frequency domain proportional to their pressure magnitude and/or pressure phase; e) comparing the frequency domain signal from the at least one transducer below the slag tap to the frequency domain signal from the at least one transducer in the gasifier at a preselected frequency, and deriving a frequency response function from the comparison; and f) comparing the magnitude and/or the phase of said function with a predetermined value. The process as claimed in claim 1 characterized in that, in response to a deviation of the frequency response function produced in step e) from the predetermined value, the process for the partial oxidation of coal in the gasifier is discontinued. The process as claimed in claim 1 characterized in that, in response to a deviation of the frequency response function produced in step e) from the predetermined value, a flux is added to coal fed to the gasifier.

Inventors: CLOMBURG LLOYD ANTHONY JR, CRENWELGE OTTO EMIL JR, CLOMBURG, LLOYD ANTHONY, JR., CRENWELGE, OTTO EMIL, JR.
Applicants: SHELL INT RESEARCH, SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V.
Application year: 1990
Main classification: C10J3
IPC codes: C10J3