Patent Publication Number: US-2011067304-A1

Title: Gasification quench chamber baffle

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     This application is a Continuation in Part, claiming priority to U.S. patent application Ser. No. 12/494,385, {Attorney Docket No. 235585-1}, entitled “QUENCH CHAMBER ASSEMBLY FOR A GASIFIER”, filed on Jun. 30, 2009, which is hereby incorporated by reference. 
    
    
     BACKGROUND 
     The invention relates generally to gasifiers, and more particularly to a quench chamber assembly for a gasifier and a baffle used therein. 
     In a normal coal gasification process, wherein a particulated carbonaceous fuel such as coal or coke or a carbonaceous gas is burned, the process is carried out at relatively hot temperatures and high pressures in a combustion chamber. When injected fuel is burned or partially burned in the combustion chamber, an effluent is discharged through a port at a lower end of the combustion chamber to a quench chamber disposed downstream of the combustion chamber. The quench chamber contains a liquid coolant such as water. The effluent from the combustion chamber is contacted with the liquid coolant in the quench chamber; so as to reduce the temperature of the effluent. 
     When the fuel is a solid such as coal or coke, the gasifier arrangement permits a solid portion of the effluent, in the form of ash, to be retained in the liquid pool of the quench chamber, and subsequently to be discharged as slag slurry. A gaseous component of the effluent is discharged from the quench chamber for further processing. The gaseous component, however, in passing through the quench chamber, will carry with it a substantial amount of the liquid coolant. A minimal amount of liquid entrained in the exiting gas is not considered objectionable to the overall process. However, excessive liquid carried from the quench chamber and into downstream equipment, is found to pose operational problems. 
     In conventional systems, a baffle may be placed in the gas exiting path in the quench chamber. Consequently, as liquid-carrying gas contacts the baffle surfaces, a certain amount of the liquid will coalesce on the baffle surfaces. However, the rapidly flowing gas will re-entrain liquid droplets by sweeping droplets from the baffle&#39;s lower edge. While various configurations of complicated baffles have been contemplated to aid in removing the entrained liquid from the effluent gas, consideration of manufacturing and assembly simplification becomes more important. 
     There is a need for an improved quench chamber assembly configured to cool an effluent gas from a combustion chamber and also a simplified but effective baffle designed to remove entrained liquid content substantially from the effluent gas in a gasifier. 
     BRIEF DESCRIPTION 
     In accordance with one exemplary embodiment of the present invention, a gasification quench chamber device comprises a ring having a substantially vertical longitudinal axis; a plurality of pipes attached to the ring, each having an upper end and a lower end, wherein the plurality of lower ends extend downwards towards a sump in the gasification quench chamber; and a plurality of gussets configured to guide water towards the upper ends of the plurality of pipes. 
     In accordance with another exemplary embodiment of the present invention, a gasification quench chamber comprises a chamber having a liquid coolant disposed therein; a dip tube coupling a combustion chamber to the chamber and configured to direct syngas from the combustion chamber to the chamber to contact the liquid coolant and thereby product a cooled syngas; and a baffle disposed proximate to an exit path of the chamber, wherein the baffle comprises: a ring having a substantially vertical longitudinal axis; a plurality of pipes attached to the ring, each having an upper end and a lower end, wherein the plurality of lower ends extend downwards towards the liquid coolant; and a plurality of gussets configured to guide water towards the upper ends of the plurality of pipes. 
     In accordance with another exemplary embodiment of the present invention, a gasification quench chamber comprises a chamber having a liquid coolant disposed therein; a dip tube coupling a combustion chamber to the chamber and configured to direct syngas from the combustion chamber to the chamber to contact the liquid coolant and thereby product a cooled syngas; a draft surrounding the dip tube and defining an annular passage there between; and a baffle disposed proximate to an exit path of the chamber, wherein the baffle comprises: a ring having a substantially vertical longitudinal axis; a plurality of pipes attached to the ring, each having an upper end and a lower end, wherein the plurality of lower ends extend downwards towards the liquid coolant; and a plurality of gussets configured to guide water towards the upper ends of the plurality of pipes. 
     In accordance with another gasification quench chamber device comprises a ring having a substantially vertical longitudinal axis; a plurality of extension plates attached to the ring, each having an upper end and a lower end, wherein the plurality of lower ends extend downward towards a sump in a gasification quench chamber; and a plurality of gussets configured to guide water towards the upper ends of the plurality of extension plates. 
    
    
     
       DRAWINGS 
       These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein: 
         FIG. 1  is a diagrammatical representation of a gasifier having an exemplary quench chamber in accordance with an exemplary embodiment of the present invention; 
         FIG. 2  is a diagrammatical representation of a gasifier having an exemplary quench chamber with only dip tube in accordance with an exemplary embodiment of the present invention; 
         FIG. 3  is a diagrammatical representation of a portion of a quench chamber having an asymmetric or symmetric baffle and a deflector plate disposed therein in accordance with an exemplary embodiment of the present invention; 
         FIG. 4  is a diagrammatical representation of a portion of a quench chamber having an asymmetric or symmetric baffle with a curved end to form a gutter in accordance with an exemplary embodiment of the present invention; 
         FIG. 5  is a diagrammatical representation of a portion of a quench chamber having an asymmetric or symmetric baffle and a deflector plate disposed therein in accordance with an exemplary embodiment of the present invention; 
         FIG. 6  is a diagrammatical representation of a portion of a quench chamber having an asymmetric or symmetric baffle and a plurality of deflector plates disposed therein in accordance with an exemplary embodiment of the present invention; 
         FIG. 7  is a diagrammatical representation of a portion of a quench chamber having an asymmetric or symmetric baffle disposed therein in accordance with an exemplary embodiment of the present invention; 
         FIG. 8  is a diagrammatical representation of a portion of a quench chamber having an asymmetric or symmetric baffle and an annular passage having different cross-sectional areas disposed therein in accordance with an exemplary embodiment of the present invention; 
         FIG. 9  is a diagrammatical representation of a portion of a quench chamber having an asymmetric or symmetric baffle and an annular passage having different cross-sectional areas disposed therein in accordance with an exemplary embodiment of the present invention; and 
         FIG. 10  is a diagrammatical representation of a portion of a quench chamber having an asymmetric or symmetric baffle and a swirl generator disposed in an annular passage in accordance with an exemplary embodiment of the present invention; 
         FIG. 11  is a diagrammatical representation of a portion of a quench chamber having an asymmetric or symmetric baffle with a curved end, a swirl generator disposed in an annular passage, and a separator plate in accordance with an exemplary embodiment of the present invention; 
         FIG. 12  is a diagrammatical representation of a portion of a quench chamber having an asymmetric or symmetric baffle with a curved end to form a gutter and one or more openings coupled to a liquid guide pipe in accordance with an exemplary embodiment of the present invention; 
         FIG. 13  is a top view of a quench chamber in accordance with the embodiment illustrated in  FIG. 12 , 
         FIG. 14  is a cutaway perspective view of a baffle illustrated in  FIG. 13 ; 
         FIG. 15  is a diagrammatical representation of a portion of a quench chamber having an asymmetric or symmetric baffle having a closed bottom portion and an opening disposed opposite to a gas exit path in accordance with an exemplary embodiment of the present invention; 
         FIG. 16  is a top view of a portion of a quench chamber illustrated in  FIG. 15 ; 
         FIG. 17  is a diagrammatical representation of a portion of a quench chamber having an asymmetric faceted or round baffle having an opening disposed opposite to a gas exit path and having an extended edge to provide a torturous path in accordance with the exemplary embodiments of the present invention; 
         FIG. 18  is a diagrammatical representation of a portion of a quench chamber having a symmetric faceted or round baffle in accordance with the exemplary embodiments of the present invention; 
         FIG. 19  is a top view of a portion of a quench chamber illustrated in  FIG. 18 ; 
         FIG. 20  is a diagrammatical representation of a portion of a quench chamber having an asymmetric or symmetric faceted or round baffle having a mesh structure to capture entrained liquid in accordance with an exemplary embodiment of the present invention; 
         FIG. 21  is a diagrammatical representation of a portion of a quench chamber having an asymmetric or symmetric faceted or round baffle having a plurality of cut-out portions, metal pieces or plates disposed overlapping the cut-out portions with spacers disposed in-between to provide a torturous path for syngas flow in accordance with an exemplary embodiment of the present invention; 
         FIG. 22  is a diagrammatical representation of an asymmetric or symmetric faceted or round baffle spiral “gussets” disposed to guide the entrained liquid content in accordance with an exemplary embodiment of the present invention; 
         FIG. 23  is a diagrammatical representation of a quench chamber employing a helical baffle in the annular passage between a dip tube and a draft tube in accordance with an exemplary embodiment of the present invention; 
         FIG. 24  is a diagrammatical representation of a quench chamber employing an asymmetric or symmetric baffle having an extended portion near exit in accordance with an exemplary embodiment of the present invention; 
         FIG. 25  is a cutaway perspective view of a baffle illustrated in  FIG. 24 ; 
         FIG. 26  is cross sectional elevation view of a gasification quench chamber baffle, in accordance with an exemplary embodiment of the present invention; 
         FIG. 27  is sectional plan view of the gasification quench chamber baffle in  FIG. 26 , in accordance with an exemplary embodiment of the present invention; 
         FIG. 28  is cross sectional elevation view of a portion of a gasification quench chamber using the baffle in  FIG. 26 , in accordance with an exemplary embodiment of the present invention; 
         FIG. 29  is cross sectional elevation view of a gasification quench chamber baffle, in accordance with another exemplary embodiment of the present invention; 
         FIGS. 30A-30B  are close up elevation views of a portion of a gasification quench chamber baffle, in accordance with exemplary embodiments of the present invention; 
         FIG. 31  is sectional plan view of the gasification quench chamber baffle in  FIG. 29 , in accordance with an exemplary embodiment of the present invention; and 
         FIG. 32  is cross sectional elevation view of a portion of a gasification quench chamber using the baffle in  FIG. 29 , in accordance with an exemplary embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     In accordance with the exemplary embodiments disclosed herein, a gasifier having a quench chamber assembly configured to reduce temperature of syngas downstream of a combustion chamber is disclosed. The gasifier includes a quench chamber containing a liquid coolant disposed downstream of the combustion chamber. A syngas generated from the combustion chamber is directed via a dip tube to the quench chamber to contact the liquid coolant and produce a cooled syngas. A baffle is disposed proximate to an exit path of the quench chamber. The baffle may be a symmetric or asymmetric shaped baffle. A draft tube is disposed surrounding the dip tube such that an annular passage is formed between the draft tube and the dip tube. The cooled syngas is directed through the annular passage and impacted against the baffle so as to remove entrained liquid content from the cooled syngas before the cooled syngas is directed through the exit path. In some embodiments, a deflector plate is disposed between the liquid coolant and the exit path of the quench chamber and configured to remove entrained liquid content from the cooled syngas and prevent sloshing of liquid content to the exit path. In yet another embodiment, a swirl generator is disposed in the annular passage between the dip tube and the draft tube and configured to induce a swirling motion to the cooled syngas directed through the annular passage. In some embodiments, the baffle is asymmetric or symmetric, either open or angular, to remove entrained liquid content from the cooled syngas. In other embodiments, the baffle itself can have channels or cut-outs and overlays to remove entrained liquid and prevent sloshing of liquid content to the exit path. In other embodiments only dip tube is present and the annular section is formed between the dip tube and the quench chamber wall. The provision of asymmetric or symmetric shaped baffle, deflector plate, swirl generator, or combinations thereof substantially reduces entrainment of liquid content in the syngas directed through the exit path to the downstream components. Specific embodiments are discussed in greater detail below with reference to  FIGS. 1-32 . 
     Referring to  FIG. 1 , an exemplary gasifier  10  is disclosed. The gasifier  10  includes an outer shell  12  housing a combustion chamber  14  at an upper end and a quench chamber  16  at a lower end. Combustion chamber  14  is provided with a refractory wall  18  capable of withstanding the normal operating temperatures. A burner  20  is coupled via a path  22  to a fuel source  24 . A fuel stream including pulverized carbonaceous fuel such as coal, coke or the like, is fed into the combustion chamber  12  via the burner  20  removably disposed on an upper wall of the combustion chamber  14 . The burner  20  is further coupled via a path  26  to a combustion supporting gas source  28  configured to supply gas such as oxygen or air. 
     The combustible fuel is burned in the combustion chamber  14  to produce an effluent including syngas and a particulated solid residue. Hot effluent is fed from the combustion chamber  14  to the quench chamber  16  provided at the lower end of the shell  12 . The quench chamber  16  is coupled to a pressurized source  30  and configured to supply a pool of liquid coolant  32 , preferably water to the quench chamber  16 . The level of the liquid coolant in the quench chamber pool  16  is maintained at a desired height to assure an efficient operation depending on the conditions of the effluent fed from the combustion chamber  14  into the quench chamber  16 . The lower end of the gasifier shell  12  is provided with a discharge port  34  through which water and fine particulates are removed from quench chamber  16  in the form of a slurry. 
     In the illustrated embodiment, a constricted portion  36  of the combustion chamber  14  is coupled to the quench chamber  16  via a dip tube  38 . The hot effluent is fed from the combustion chamber  14  to the liquid coolant  32  in the quench chamber  16  via a passageway  40  of the dip tube  38 . A quench ring  42  is disposed proximate to the dip tube  38  and coupled to the pressurized source  30  so as to sustain a dip tube inner wall in a wetted condition to best accommodate the downward effluent flow. A lower end  44  of the dip tube  38  may be serrated, and positioned below the surface of the liquid coolant  32  to efficiently achieve cooling of the effluent. 
     A draft tube  46  is positioned in the quench chamber  16 . The draft tube  46  includes an elongated cylindrical body  48  fixedly supported in the gasifier shell  12 . A lower portion of the draft tube  46  is submerged in the liquid coolant  32 . The cylindrical body  48  terminates adjacent to, but spaced at its upper end, from the quench ring  42 . The cylindrical body  48  is also spaced from the dip tube  38  to define an annular passage  50 . The syngas is contacted with the liquid coolant  32  to produce a cooled syngas. The cooled syngas is then passed through the annular passage  50  towards an exit path  52  of the quench chamber  16 . 
     As discussed above, the gaseous component of the effluent is discharged for further processing via the exit path  52  from the quench chamber  16 . It is known conventionally that the gaseous component, however, in passing through a quench chamber, will carry with it a substantial amount of the liquid coolant. Excessive liquid carried from the quench chamber and into downstream equipment, is found to pose operational problems. In the illustrated exemplary embodiment, an asymmetric or symmetric shaped baffle  54  is disposed proximate to the exit path  52  in the quench chamber  16 . The baffle  54  extends a distance below an upper edge of the draft tube  46 , but above the surface of liquid coolant  32 . The cooled syngas directed through the annular passage  50  is impacted against an inner wall of the baffle  54 . In the normal course of quench cooling, the cooled gas stream would convey with it a certain amount of liquid coolant. However, as the cooled gas stream impinges against the inner surface of baffle  54 , the entrained liquid content in the gas stream will tend to coalesce on the inner surface of the baffle  54 . The gas stream after impacting the baffle  54  reverses direction and then moves along a path  56  into the exit path  52 . It should be noted herein that the illustrated gasifier is an exemplary embodiment and other configurations of gasifiers are also envisaged. For example, in some embodiments, the exemplary quench chamber  16  may be disposed beneath a radiant syngas cooler configured to partially reduce the syngas temperature before syngas enters the quench chamber. The details of the quench chamber  16  are discussed in greater detail below with reference to subsequent figures. 
     Referring to  FIG. 2 , an exemplary gasifier  10  is disclosed. The gasifier  10  is similar to the embodiment illustrated in  FIG. 1 . As discussed above, the hot effluent is fed from the combustion chamber  14  to the liquid coolant  32  in the quench chamber  16  via the passageway  40  of the dip tube  38 . The lower end  44  of the dip tube  38  may be serrated, and positioned below the surface of the liquid coolant  32  to efficiently achieve cooling of the effluent. It should be noted herein that in the illustrated embodiment, there is no draft tube. The syngas is contacted with the liquid coolant  32  to produce a cooled syngas. The cooled syngas is impacted against an inner wall of the baffle  54 . As the cooled gas stream impinges against the inner surface of baffle  54 , the entrained liquid content in the gas stream will tend to coalesce on the inner surface of the baffle  54 . The cooled syngas is then passed towards the exit path  52  of the quench chamber  16 . 
     Referring to  FIG. 3 , a portion of the quench chamber  16  is disclosed. As discussed above, the draft tube  46  is positioned surrounding the dip tube  38  in the quench chamber  16 . The syngas is contacted with the liquid coolant  32  to produce a cooled syngas. The cooled syngas is then passed through the annular passage  50  between the dip tube  38  and the draft tube  46  towards the exit path  52  of the quench chamber  16 . In addition to the asymmetric or symmetric shaped baffle  54 , a deflector plate  58  is also disposed between the liquid coolant  32  and the exit path  52 . It should be noted herein that the deflector plate  58  may be disposed at a predetermined angle with respect to the liquid coolant  32 . 
     Also as discussed previously, the cooled syngas directed through the annular passage  50  is impacted against an inner wall of the baffle  54 . As the cooled gas stream impinges against the inner surface of baffle  54 , the entrained liquid content in the gas stream will tend to coalesce on the inner surface of the baffle  54 . In the illustrated embodiment, in addition to the asymmetric or symmetric baffle  54 , the cooled syngas is also impacted against the deflector plate  58  so as to remove additional entrained liquid coolant content from the cooled syngas before being directed through the exit path. In other words, the deflector plate  58  provides an additional barrier for removing entrained liquid content from the cooled syngas fed from the quench chamber  16 . Also, the deflector plate  58  prevents sloshing of liquid coolant  32  to the exit path  52  of the quench chamber  16 . 
     Referring to  FIG. 4 , a portion of the quench chamber  16  is disclosed. In the illustrated embodiment, the baffle  54  is disposed proximate to the exit path  52  in the quench chamber  16 . The baffle  54  extends a distance below an upper edge of the draft tube  46 , but above the surface of liquid coolant  32 . As noted above, the cooled syngas directed through the annular passage  50  is impacted against an inner wall of the baffle  54 . It should be noted herein that in the illustrated embodiment, the baffle  54  is an asymmetric shaped baffle. In another embodiment, the baffle  54  may be a symmetric baffle. In the illustrated embodiment, the asymmetric baffle  54  includes a curved end portion  60  pointed towards the liquid coolant  32 . As the cooled gas stream impinges against the inner surface of the baffle  54 , the entrained liquid content in the gas stream will tend to coalesce on the inner surface of the baffle  54 . The gas stream after impacting the baffle  54  reverses direction and then moves along a path  56  into the exit path  52 . The asymmetric shape of the baffle  54  prevents the rapidly flowing gas from re-entrain liquid droplets by sweeping droplets from a baffle&#39;s lower edge. 
     Referring to  FIG. 5 , a portion of a quench chamber  62  is disclosed. In the illustrated embodiment, a baffle  63  is disposed proximate to an exit path  64  in the quench chamber  62 . In the illustrated embodiment, the baffle  63  is an asymmetric baffle. In another embodiment, the baffle  63  is a symmetric baffle. The baffle  63  extends a distance below an upper edge of a draft tube  66 , but above the surface of a liquid coolant  68 . As noted above, the cooled syngas directed through an annular passage  70  formed between a dip tube  72  and the draft tube  66  is impacted against an inner wall of the baffle  63 . In the illustrated embodiment, the baffle  63  includes a deflected end portion  74  pointed towards the liquid coolant  68 . As the cooled gas stream impinges against an inner surface of the baffle  63 , the entrained liquid content in the gas stream will tend to coalesce on the inner surface of the baffle  63 . 
     In addition to the baffle  63 , a deflector plate  76  is also disposed between the liquid coolant  68  and the exit path  64 . It should be noted herein that the deflector plate  76  is disposed at a predetermined angle pointed away from the liquid coolant  68 . In the illustrated embodiment, the deflector plate  76  is an asymmetric or symmetric shaped deflector plate having a deflected end portion  78 . In addition to the baffle  63 , the cooled syngas is also impacted against the deflector plate  76  so as to remove additional entrained liquid coolant content from the cooled syngas. Also, the deflector plate  76  prevents sloshing of liquid coolant  68  to the exit path  64  of the quench chamber  62 . The cooled syngas after impacting the baffle  63  and the deflector plate  76  is then directed through a gap  80  between the deflected end portions  74 ,  78  to the exit path  64  of the quench chamber  62 . 
     Referring to  FIG. 6 , a portion of a quench chamber  82  is disclosed. In the illustrated embodiment, a baffle  84  is disposed proximate to an exit path  86  in the quench chamber  82 . In the illustrated embodiment, the baffle  84  is an asymmetric baffle. In another embodiment, the baffle  84  may be a symmetric baffle. The cooled syngas is directed through an annular passage  88  formed between a dip tube  90  and a draft tube  92  and impacted against an inner wall of the baffle  84 . In the illustrated embodiment, the baffle  84  includes a deflected end portion  94  pointed towards a liquid coolant  96  contained in the quench chamber  82 . The baffle  84  may also include at least one gusset  98 . As the cooled gas stream impinges against an inner surface of the baffle  84 , the entrained liquid content in the gas stream will tend to coalesce on the inner surface of the baffle  84 . The gusset  98  facilitates to drain the liquid coolant collected on the surface of the baffle  84 . 
     In the illustrated embodiment, a plurality of deflector plates  100 ,  102  are disposed between the liquid coolant  96  and the exit path  86 . It should be noted herein that the deflector plates  100 ,  102  are disposed at a predetermined angle pointing towards the liquid coolant  96 . The cooled syngas is impacted against the baffle  84  and the deflector plates  100 ,  102  so as to remove additional entrained liquid coolant content from the cooled syngas. The deflector plates  100 ,  102  prevent sloshing of liquid coolant  96  to the exit path  86  of the quench chamber  82 . The cooled syngas is impacted against the baffle  84  and the deflector plates  100 ,  102  and then directed through a gap  104  between the baffle  84  and the deflector plates  100 ,  102  to the exit path  86  of the quench chamber  82 . 
     Referring to  FIG. 7 , a portion of a quench chamber  106  is disclosed. In the illustrated embodiment, a baffle  108  is disposed proximate to an exit path  110  in the quench chamber  106 . In the illustrated embodiment, the baffle  108  is an asymmetric baffle. In another embodiment, the baffle  108  is a symmetric baffle. The cooled syngas is directed through an annular passage  112  formed between a dip tube  114  and a draft tube  116  and impacted against an inner wall of the baffle  108 . In the illustrated embodiment, the baffle  108  includes a stepped portion  118  pointed towards a liquid coolant  120  contained in the quench chamber  106 . As the cooled gas stream impinges against an inner surface of the baffle  108 , the entrained liquid content in the gas stream will tend to coalesce on the inner surface of the baffle  108 . The cooled syngas after impacting the baffle  108  is then redirected through a path  122  to the exit path  110  of the quench chamber  106 . 
     In accordance with the embodiments discussed herein, the provision of the baffle, deflector plate, or combinations there of facilitates to reduce cooled syngas flow velocity, and also to increase gas flow path distance between the liquid coolant and the exit path of the quench chamber. This results in increased residence time of the gas and liquid coolant mixture in the quench chamber leading to enhanced removal of entrained liquid content from the cooled syngas. 
     Referring to  FIG. 8 , a portion of a quench chamber  124  is disclosed. In the illustrated embodiment, baffle  126  is disposed proximate to an exit path  127  in the quench chamber  124 . The baffle  126  may be a symmetric or an asymmetric baffle. As noted in the previous embodiments, hot effluent is directed from a combustion chamber to the quench chamber  124  via a dip tube  128 . A draft tube  130  is disposed surrounding the dip tube  128  such that an annular passage  132  is formed between the dip tube  128  and the draft tube  130 . The cooled syngas is directed through an annular passage  132  formed between the dip tube  128  and the draft tube  130  and impacted against an inner wall of the baffle  126  so as to remove additional entrained liquid coolant content from the cooled syngas. 
     In the illustrated embodiment the draft tube  130  includes a stepped portion  134 . In other words, the annular passage  132  formed between the dip tube  128  and the draft tube  130  has different cross-sectional areas. The cross-sectional area of the annular passage  132  increases from one end  136  to another end  138 . This reduces any plugging at the end  136 . 
     Referring to  FIG. 9 , a portion of a quench chamber  140  is disclosed. In the illustrated embodiment, a baffle  142  is disposed proximate to an exit path  144  in the quench chamber  140 . The baffle  142  may be a symmetric or an asymmetric baffle. As noted in the previous embodiments, hot effluent is directed from a combustion chamber to the quench chamber  140  via a dip tube  146 . A draft tube  148  is disposed surrounding the dip tube  146  such that an annular passage  150  is formed between the dip tube  146  and the draft tube  148 . The cooled syngas is directed through an annular passage  150  formed between the dip tube  146  and the draft tube  148  and impacted against an inner wall of the baffle  142  so as to remove additional entrained liquid coolant content from the cooled syngas. 
     In the illustrated embodiment the draft tube  148  has varying cross-sectional area. In other words, the annular passage  150  formed between the dip tube  146  and the draft tube  148  has different cross-sectional areas. The cross-sectional area of the annular passage  150  increases from one end  152  to another end  154 . 
     In accordance with the embodiments discussed with reference to  FIGS. 8-9 , an annular passage having different cross-sectional areas facilitate to reduce syngas speed fed through the annular passage. In addition, this also increases the cross-sectional area between the draft tube  148  and the quench vessel inner wall. This results in enhanced removal of entrained liquid content from the cooled syngas. 
     Referring to  FIG. 10 , a portion of a quench chamber  156  is disclosed. In the illustrated embodiment, a draft tube  158  is positioned surrounding a dip tube  160  in the quench chamber  156 . The cooled syngas is passed through the annular passage  162  formed between the dip tube  160  and the draft tube  158  towards an exit path  164  of the quench chamber  156 . A baffle  166  is disposed proximate to the exit path  164  in the quench chamber  156 . In the illustrated embodiment, the baffle  166  is an asymmetric baffle. In another embodiment, the baffle  166  is a symmetric baffle. The baffle  166  extends a distance below an upper edge of the draft tube  158 , but above the surface of liquid coolant  168  filled in the quench chamber  156 . The baffle  166  includes a curved end portion  170 , and a plurality of gussets  172 . An inner surface of the baffle may be made sticky. 
     The cooled syngas is directed through the annular passage  162  and impacted against an inner wall of the baffle  166 . In the illustrated embodiment, a rotary device, for example a swirl generator  174  is disposed in the annular passage  162  and configured to induce swirling motion to the cooled syngas passed through the annular passage  162 . As the cooled gas stream impinges against the inner surface of baffle  166 , the imparted swirling motion facilitates the entrained liquid content in the gas stream to coalesce on the inner surface of the baffle  166 . In other words, the swirling motion imparts higher centrifugal force and thus generates higher droplet diameter of the entrained liquid. The gussets  172  of the baffle  166  facilitate to drain the liquid content removed by the baffle  166 . 
     Referring to  FIG. 11 , a portion of the quench chamber  156  is disclosed. This embodiment is similar to the embodiment illustrated in  FIG. 10 . Additionally, a separator plate  176  is disposed between the draft tube  158  and the baffle  166 . The swirl generator  174  is disposed in the annular passage  162  and configured to induce swirling motion to the cooled syngas passed through the annular passage  162 . This results in forming a entrained liquid film on an inner wall of the draft tube  158  and the resulting liquid film is directed downward using the separator plate  176 . 
     Referring to  FIG. 12 , a portion of the quench chamber  156  is disclosed. This embodiment is similar to the embodiment illustrated in  FIG. 10 . The baffle  166  includes the curved end portion  170  having a slope portion  178  and a plurality of holes  180  to provide an exit path for entrained liquid content collected on the curved end portion  170 . The collected liquid content drained through the holes  180  is guided downwards through a guide pipe  182  coupled the curved end portion  170 . An end of the water guide pipe  182  may be partially dipped in the liquid coolant in the quench chamber  156 . 
     Referring to  FIG. 13 , a portion of the quench chamber  156  is disclosed. This embodiment is similar to the embodiment illustrated in  FIG. 12 . The baffle  166  includes the plurality of gussets  172  disposed proximate to the exit path  164 . One or more gussets  172  may be disposed on an inner circumference of the baffle  166 . The gussets  172  may be circumferentially aligned with the exit path  166  and may have a curvature extending along a portion of the inner circumference of the baffle  166 . According to certain embodiments, the gussets  172  may extend approximately along one third of the inner circumference of the baffle  166 . Specifically, the gussets  172  may be designed to contact the increased velocity syngas and direct flow of entrained liquid content collected on the baffle  166  away from the exit path  164 . For example, the gussets  172  may impede droplets of the liquid content from becoming entrained in the higher velocity syngas directed towards the exit path  164 . The gussets  172  may also promote coalescence of the entrained liquid content. 
     Referring to  FIG. 14 , a portion of the baffle  166  is disclosed. As discussed previously, one or more gussets  172  may be disposed on the inner circumference of the baffle  166 . According to certain embodiments, the gussets  172  may extend approximately along one third of the inner circumference of the baffle  166 . In the illustrated embodiment, the gussets  172  may be angled downward in the quench chamber to direct the entrained liquid content away from the exit path of the quench chamber. 
     Referring to  FIG. 15 , a quench chamber  184  is disclosed. In the illustrated embodiment, a draft tube  186  is positioned surrounding a dip tube  188  in the quench chamber  184 . The cooled syngas is passed through the annular passage  190  formed between the dip tube  188  and the draft tube  186  towards an exit path  192  of the quench chamber  184 . A faceted or round baffle  194  is disposed proximate to the exit path  192  in the quench chamber  184 . In one embodiment, the baffle  194  is an asymmetric baffle. In another embodiment, the baffle  194  is a symmetric baffle. A bottom  196  of the baffle  194  is closed such that an area between the baffle bottom  196  and draft tube  186  is blocked using an annular plate. The baffle  194  has an opening  198  disposed opposite to the exit path  192  such that the syngas flows along a torturous path. 
     Referring to  FIG. 16 , a top view of the quench chamber  184  is illustrated. As discussed previously, the baffle  194  is disposed proximate to the exit path  192  in the quench chamber  184 . The baffle  194  has an opening  198  disposed opposite to the exit path  192  such that the syngas flows along a torturous path. 
     Referring to  FIG. 17 , a quench chamber  200  is disclosed. In the illustrated embodiment, a draft tube  202  is positioned surrounding a dip tube  204  in the quench chamber  200 . The cooled syngas is passed through the annular passage  206  formed between the dip tube  204  and the draft tube  202  towards an exit path  208  of the quench chamber  200 . A faceted or round baffle  210  is disposed proximate to the exit path  208  and surrounding the dip tube  204  and the draft tube  202  in the quench chamber  200 . The syngas is cooled by contacting a liquid coolant  212  in the quench chamber  200 . 
     Referring to  FIG. 18 , a quench chamber  201  is disclosed. In the illustrated embodiment, a symmetric baffle  203  is disposed proximate to an exit path  205  and surrounding a dip tube  207  and a draft tube  209  in the quench chamber  201 . 
     Referring to  FIG. 19 , a quench chamber  200  is disclosed. This embodiment is same as the embodiment illustrated in  FIG. 17 . In the illustrated embodiment, the draft tube  202  is positioned surrounding the dip tube  204  in the quench chamber  200 . The cooled syngas is passed through the annular passage  206  formed between the dip tube  204  and the draft tube  202  towards the exit path  208  of the quench chamber  200 . A baffle  210  is disposed proximate to the exit path  208  and surrounding the dip tube  204  and the draft tube  202  in the quench chamber  200 . In the illustrated embodiment, the baffle  210  is a faceted baffle. The illustrated baffle  210  includes a plurality of splash plates  214 ,  216 ,  218 ,  220 ,  222 ,  224 ,  226 . The baffle  210  has an opening  227  opposite to the exit path  208 . In another embodiment, the plates  224  and  226  may also be removed so that the baffle  210  has a larger opening that will further decrease the syngas flow velocity and facilitate removal of entrained liquid content from the syngas. The baffle  210  has a shorter edge opposite to the exit path  208 . A side of the baffle proximate to the exit path  208  extends down towards a liquid coolant  212  to provide a tortuous path for the flow of syngas. This forces the syngas to flow towards the opening of the baffle  210  at the opposite end where a very large area exists that will decrease the syngas flow velocity and facilitate removal of entrained liquid content from the syngas. It should be noted herein that the baffle  210  is angled up toward the opposite end of the exit path  208  to facilitate for pressure relief. 
     Referring to  FIG. 20 , a faceted baffle  228  is disclosed. In the illustrated embodiment, the faceted baffle  228  includes a chevron type mesh  230  instead of the splash plates illustrated in  FIG. 19 . The chevron mesh  230  includes a plurality of drainage traps  232  supported by bolts  234 . The chevron mesh  230  allows passage of syngas and removes the entrained liquid content from the syngas. In an alternate embodiment, a portion of the plates  214 ,  216 ,  218 ,  220 ,  222 ,  224 ,  226  of the baffle  210  illustrated in  FIG. 19  may be partially replaced by the chevron mesh  230 . 
     Referring to  FIG. 21 , one of the splash plate  214  of the baffle  210  is illustrated. In the illustrated embodiment, a plurality of vertical strips portions are removed from the splash plate  214  to form corresponding cut-out portions  236 . A metal piece  238  that is slightly larger in height and width of the cut-out portion  236  is then placed overlapping of each cut-out portion  236 . The metal pieces  238  are attached to the splash plate  214  with spacers  240  disposed in-between to allow torturous path for gas flow through the cut-out portions  236  of the plate  214 . 
     Referring to  FIG. 22 , one of the splash plate  224  is illustrated. In the illustrated embodiment, a plurality of channels or gussets  242  are provided on an inner face of the splash plate  224 . The gussets  242  are angled to allow entrained liquid content to flow down the splash plate  224  to the gutters of the baffle. 
     Referring to  FIG. 23 , a quench chamber  244  is disclosed. In the illustrated embodiment, a draft tube  246  is positioned surrounding a dip tube  248  in the quench chamber  244 . The cooled syngas is passed through an annular passage  250  formed between the dip tube  248  and the draft tube  246  towards an exit path  252  of the quench chamber  244 . A baffle  254  is disposed proximate to the exit path  252  in the quench chamber  244 . The baffle  254  may be a symmetric baffle or an asymmetric baffle. Additionally, a helical baffle  256  is disposed in the annular passage  250  and may be designed to induce a spiraled or rotational flow pattern of the syngas through the annular passage  250 . The rotational flow may increase flow path of the syngas in the quench chamber  244 , which in turn may increase the pressure drop to reduce fluid flow fluctuations. Furthermore, the baffle  256  may promote a spiraled flow that may reduce entrainment of water and ash within the syngas. Moreover, the extended flow path of the syngas in the quench chamber  244  may enhance the heat transfer rate. In general, the helical baffle  256  may create a tortuous path for the flow of syngas within the quench chamber  244 . 
     Referring to  FIG. 24 , a quench chamber  258  is disclosed. In the illustrated embodiment, a draft tube  260  is positioned surrounding a dip tube  262  in the quench chamber  258 . The cooled syngas is passed through an annular passage  264  formed between the dip tube  262  and the draft tube  260  towards an exit path  266  of the quench chamber  258 . A baffle  268  is disposed proximate to the exit path  266  in the quench chamber  258 . The baffle  268  may be a symmetric baffle or an asymmetric baffle. In the illustrated embodiment, the baffle  268  includes an extended portion  270  which may be angled to divert the entrained liquid content away from a lip of the baffles  268  thereby reducing entrainment of liquid content in the exiting syngas. 
     Referring to  FIG. 25 , the baffle  268  is illustrated. As discussed previously, the baffle  268  is disposed proximate to the exit path in the quench chamber. In the illustrated embodiment, the baffle  268  includes an extended portion  270  that may extend along approximately one third of an inner circumference  272  of the baffle  268 . Moreover, in certain embodiments, the extended portion  146  may include a gutter portion to divert entrained liquid content away from a lower lip of the extended portion  146 . 
     Referring to  FIGS. 26 and 27 , a sectional side view and top view respectively of a gasification quench chamber baffle in accordance with aspects of the present invention is disclosed. The gasification quench chamber baffle, or baffle  310  includes a ring  318  that has a substantially vertical longitudinal axis. The ring  318  has a plurality of extensions  316  extending downward from the ring  318 . Extending to the plurality of extensions  316  is a plurality of gussets or gussets plates  314 . As shown in  FIG. 26 , the plurality of gussets  314  have a sloped configuration to aid in guiding water towards the plurality of extensions  316  and to the liquid coolant in the quench chamber  300  ( FIG. 28 ). At or near an upper end of the baffle  310  may be a structural or attachment element  302  configured to aid in the attachment of the baffle  310  to the quench chamber  300 . 
     Referring to  FIG. 28 , a portion of a quench chamber  300  is disclosed. This embodiment is similar in some aspects to the embodiment illustrated in  FIG. 12 . The baffle  310  includes at least one of the plurality of gussets  314  and the plurality of extensions  315  configured to provide an exit path for entrained liquid content collected on the side surface  312  of the baffle  310 . The collected liquid content is guided downwards along the gussets  314  towards the extensions  316 . An end of the extensions  316  and/or gussets  314  may be partially dipped in the liquid coolant  168  in the quench chamber  300 . Note that although the outside periphery (e.g., ring  318  and gussets  314 ) of the baffle  310  is depicted as vertical, other configurations are possible under aspects of the present invention. For example, the outside of the baffle  310  may be canted slightly inward towards its lower end, so that the axis of the ring  318  and gussets may be, for example, 5 degrees from vertical. Other angles are possible without departing from aspects of the invention. This angulation may further aid in effectively gathering moisture with the baffle  310  so to direct it to the quench chamber sump. 
     Referring to  FIGS. 29 and 31 , a sectional side view and top view respectively of a gasification quench chamber baffle in accordance with aspects of another embodiment of the present invention is disclosed. The gasification quench chamber baffle, or baffle  350  includes a ring  360  that has a substantially vertical longitudinal axis. The ring  360  has a plurality of gussets  356  leading to a plurality of pipes  354 . As shown in  FIG. 29 , the plurality of gussets  356  have a sloped configuration to aid in guiding water towards the plurality of pipes  354  and to the liquid coolant  168  in the quench chamber  300  ( FIG. 32 ). At or near an upper end of the baffle  350  may be a structural or attachment element  352  configured to aid in the attachment of the baffle  350  to the quench chamber  300 . As shown specifically in  FIG. 31 , an additional plate or guide  357  may be located adjacent to the upper end  358  of the pipes  354 . The plate or guide  357  is located inboard of the pipe  354 . In this manner, gathered moisture is more efficiently guided towards the pipes  354 . By effectively guiding the moisture with the gussets  354  and/or guides  357  to the pipes  354  and the sump (below), moisture re-entrainment with the syngas is mitigated and/or avoided altogether. 
     Referring to  FIGS. 30A and 30B , close-up views of two configurations of the interface between a pipe  354  and the guiding gussets  356  of a baffle  350  (see e.g.,  FIG. 29 ) are shown. The gussets  356  may be configured so that they directly slope towards an upper end  358  of the pipe  354  (see e.g.,  FIG. 30A ). In another embodiment, the gussets  356  may be configured wherein they slope towards the upper ends  358  of the pipes  354 , but the upper end  358  extends higher than the bottom end of the sloping gussets  356  (see e.g.,  FIG. 30B ). In any event, the gussets  356  are configured and sloped such that gathered liquid is guided towards the pipes  354  and to the liquid coolant  168  within the quench chamber  300 . 
     Referring to  FIG. 32 , a portion of a quench chamber  300  is disclosed. This embodiment is similar in some aspects to the embodiment illustrated in  FIG. 12 . The baffle  350  includes at least one of the plurality of gussets  356  and the plurality of pipes  354  configured to provide an exit path for entrained liquid content collected on the side surface  312  of the baffle  350 . The collected liquid content is guided downwards along the gussets  356  towards the pipes  354 . A lower end of the pipes  354  may be partially immersed in the liquid coolant  168  in the quench chamber  300 . Note that although the outside periphery construct (e.g., ring  360 , gussets  356 , pipe  354 ) of the baffle  350  is depicted as vertical, other configurations are possible under aspects of the present invention. For example, the outside of the baffle  350  may be canted slightly inward towards its lower end, so that the axis of the ring  360  and gussets  356  may be, for example, 5 degrees from vertical. Other angles are possible without departing from aspects of the invention. This angulation may further aid in effectively gathering moisture with the baffle  350  so to direct it to the quench chamber sump. 
     The entrainment mitigation mechanisms depicted in  FIGS. 1-32  may be employed separately or in combination with one another. Moreover, as may be appreciated, the relative sizes, shapes, and geometries of the entrainment mitigation mechanisms may vary. The entrainment mitigation mechanisms may be employed in a quench chamber during the initial manufacturing, or the entrainment mitigation mechanisms may be retrofit into existing quench units. Further, the entrainment mitigation mechanisms may be adjusted based on operational parameters, such as the type of carbonaceous fuel, the system efficiency, the system load, or environmental conditions, among others to achieve the desired amount of flow damping. 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 
     While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.