Low-Effluent Syngas Handling System

Abstract

A system for processing a syngas stream including particulate matter, a combustible gas, and acid components is disclosed. The system includes a gasifier vessel configured to produce a raw syngas stream; a gas cooling apparatus configured to cool the raw syngas stream to produce a cooled syngas stream; an HCl and particulate removal apparatus configured to produce a reduced-HCl syngas stream; a first reheat apparatus configured to produce a first reheated syngas stream; a COS and HCN hydrolysis apparatus configured to produce a hydrolyzed syngas stream; an H 2 S removal apparatus configured to produce a reduced-H 2 S syngas stream; a second reheat apparatus configured to produce a second reheated syngas stream; an activated carbon bed apparatus configured to produce a polished syngas stream; and a compression and intercooling apparatus configured to compress and cool the polished syngas stream to produce a clean syngas stream.

What is claimed is: 
     
         1 . A system for processing a syngas stream including particulate matter, a combustible gas, and acid components, the system comprising:
 a gasifier vessel configured to produce a raw syngas stream;   a gas cooling apparatus configured to cool the raw syngas stream to produce a cooled syngas stream;   an HCl and particulate removal apparatus configured to remove at least a portion of HCl contained in the cooled syngas stream and at least a portion of remaining particulate matter in the cooled syngas stream to produce a reduced-HCl syngas stream;   a first reheat apparatus configured to increase the temperature of the reduced-HCl syngas stream to produce a first reheated syngas stream;   a COS and HCN hydrolysis apparatus configured to remove at least a portion of COS and HCN contained in the first reheated syngas stream to produce a hydrolyzed syngas stream;   an H 2 S removal apparatus configured to remove at least a portion of H 2 S in the hydrolyzed syngas stream to produce a reduced-H 2 S syngas stream;   a second reheat apparatus configured to increase the temperature of the reduced- H 2 S syngas stream to produce a second reheated syngas stream;   an activated carbon bed apparatus configured to polish the second reheated syngas stream to produce a polished syngas stream; and   a compression and intercooling apparatus configured to compress and cool the polished syngas stream to produce a clean syngas stream.   
     
     
         2 . The system of  claim 1 , further comprising:
 a first particulate removal apparatus configured to remove particulates from the cooled syngas stream prior entry of the cooled gas stream to the HCl and particulate removal apparatus.   
     
     
         3 . The system of  claim 2 , further comprising a path configured to return at least a portion of the particulate matter removed in the first particulate removal apparatus to the gasifier vessel. 
     
     
         4 . The system of  claim 2 , further comprising:
 a gas pressurization apparatus configured to pressurize the cooled syngas gas stream prior to the first particulate removal apparatus.   
     
     
         5 . The system of  claim 2 , further comprising:
 a gas pressurization apparatus configured to pressurize the cooled syngas stream after the first particulate removal apparatus.   
     
     
         6 . The system of  claim 1 , wherein the compression and intercooling apparatus is configured to extract water from the polished syngas stream to produce a clean water return stream and to increase the pressure of the clean syngas stream. 
     
     
         7 . The system of  claim 6 , further comprising:
 a clean water return from the compression and intercooling apparatus to at least one of the gas cooling apparatus, the HCl and particulate removal apparatus, and the H 2 S removal apparatus.   
     
     
         8 . The system of  claim 1 , wherein the syngas cooling apparatus is configured to remove at least a portion of the particulate matter within the raw syngas stream. 
     
     
         9 . The system of  claim 8 , further comprising a path configured to return at least a portion of the particulate matter removed in the syngas cooling apparatus to the gasifier vessel. 
     
     
         10 . The system of  claim 1 , wherein the HCl and particulate removal apparatus is configured to discharge a dry waste stream. 
     
     
         11 . The system of  claim 1 , wherein the H 2 S removal apparatus is configured to generate a first effluent return stream, and the first effluent return stream is returned to the HCl and particulate removal apparatus. 
     
     
         12 . The system of  claim 11 , wherein all water within the first effluent return stream is evaporated in the HCl and particulate removal apparatus, and at least a portion of the contaminants within the first effluent return stream is removed by the HCl and particulate removal apparatus. 
     
     
         13 . The system of  claim 1 , wherein the H 2 S removal apparatus is configured to generate a first effluent discharge stream. 
     
     
         14 . The system of  claim 13 , wherein a flow rate of the first effluent discharge stream is zero. 
     
     
         15 . The system of  claim 1 , wherein the second reheat apparatus is configured to increase the temperature of the syngas to above a dew point temperature. 
     
     
         16 . The system of  claim 1 , wherein the activated carbon bed apparatus is configured to remove at least a portion of the mercury contained within the syngas. 
     
     
         17 . The system of  claim 1 , wherein the first reheat apparatus and the second reheat apparatus are connected to a common heat source. 
     
     
         18 . The system of  claim 1 , further comprising:
 an NH 3  removal apparatus configured to remove at least a portion of the NH 3  within the reduced-H 2 S syngas stream.   
     
     
         19 . The system of  claim 18 , further comprising:
 a clean water return from the compression and intercooling apparatus to at least one of the gas cooling apparatus, the HCl and particulate removal apparatus, the H 2 S removal apparatus, and the NH 3  removal apparatus.   
     
     
         20 . The system of  claim 18 , wherein the NH 3  removal apparatus is configured to generate a second effluent return stream and the second effluent return stream is returned to the HCl and particulate removal apparatus. 
     
     
         21 . The system of  claim 20 , wherein all water within the second effluent return stream is evaporated in the HCl and particulate removal apparatus, and at least a portion of contaminants within the second effluent return stream is removed by the HCl and particulate removal apparatus. 
     
     
         22 . The system of  claim 21 , wherein a flow rate of second effluent discharge stream is zero. 
     
     
         23 . The system of  claim 18 , wherein the NH 3  removal apparatus is configured to generate a second effluent discharge stream.