Devices, systems, facilities and processes for multistage direct contact cooler design

Abstract

A multistage direct contact cooler is configured to cool process gases for downstream process requirements. The multistage direct contact cooler includes a high temperature stage and a low temperature stage. Cooling duties for the high temperature stage of the direct contact cooler are achieved by air cooling. Cooling duties for the low temperature stage of the direct contact cooler are achieved by evaporative cooling with an option to include additional air cooling to reduce evaporative losses.

The invention is claimed as follows: 
     
         1 . A process for cooling hot process gases, the process comprising:
 providing a multi-stage direct contact cooler configured to cool the hot process gases, the multi-stage direct contact cooler comprising a high temperature stage and a low temperature stage;   air cooling a first cooling water configured to be circulated in the high temperature stage; and   evaporative cooling a second cooling water configured to be circulated in the low temperature stage.   
     
     
         2 . The process of  claim 1 , wherein the air cooling is provided by one of an air-cooled heat exchanger, a chiller package, and a gas-to-air heat exchanger. 
     
     
         3 . The process of  claim 1 , further comprising the step of air cooling the second cooling water configured to be circulated in the low temperature stage upstream. 
     
     
         4 . The process of  claim 1 , wherein a difference between a cooling water supply temperature of the first cooling water entering the high temperature stage and a temperature of partially cooled saturated process gases exiting the high temperature stage is less than about 10° F. 
     
     
         5 . A process for cooling hot process gases, the process comprising:
 providing a multi-stage direct contact cooler configured to cool the hot process gases, the multi-stage direct contact cooler comprising a high temperature stage and a low temperature stage;   cooling, via at least one air-cooled heat exchanger, a first water media configured to be circulated in the high temperature stage, the at least one heat exchanger configured to supply cooling duty to the high temperature stage; and   cooling, via at least one evaporative type cooler, a second cooling water configured to be circulated in the low temperature stage, the at least one evaporative type cooler configured to supply cooling duty to the low temperature stage.   
     
     
         6 . The process of  claim 5 , further comprising the step of cooling, via at least one further air-cooled heat exchanger, the second cooling media upstream of the at least one evaporative type cooler. 
     
     
         7 . The process of  claim 5 , wherein the at least one evaporative type cooler comprises a cooling tower. 
     
     
         8 . The process of  claim 5 , wherein a difference between a cooling water supply temperature of the first cooling water entering the high temperature stage and a temperature of partially cooled saturated process gases exiting the high temperature stage is less than about 10° F. 
     
     
         9 . A process for cooling hot process gases, the process comprising:
 providing a multi-stage direct contact cooler configured to cool the hot process gases, the multi-stage direct contact cooler comprising a high temperature stage and a low temperature stage;   cooling, via a first air cooling device, a first cooling water configured to be circulated in the high temperature stage, the at least one heat exchanger configured to supply cooling duty to the high temperature stage;   cooling, via a second air cooling device, a second cooling water configured to be circulated in the low temperature stage, the at least one evaporative type cooler configured to supply at least a first portion of the cooling duty to the low temperature stage; and   cooling, via at least one evaporative type cooler, the second cooling water downstream of the at least one air-cooled heat exchanger, wherein the at least one evaporative type cooler is configured to provide a second portion of the cooling duty to the lower temperature stage.   
     
     
         10 . The process of  claim 9 , wherein each of the first and second air cooling devices comprises one of an air-cooled heat exchanger, a chiller package, and a gas-to-air heat exchanger. 
     
     
         11 . The process of  claim 9 , wherein the at least one evaporative type cooler comprises a cooling tower. 
     
     
         12 . A system for cooling hot process gases, the system comprising:
 a multi-stage direct contact cooler comprising a high temperature stage and a low temperature stage;   a first cooling device configured to cool a first cooling water circulated in the high temperature stage, and   a second cooling device configured to cool a second cooling water circulated in the low temperature stage.   
     
     
         13 . The system of  claim 12 , wherein each of the first and second cooling devices is selected from the group consisting of an air-cooled heat exchanger and an evaporative type cooler. 
     
     
         14 . The system of  claim 12 , further comprising a third cooling device configured to cool the second cooling media upstream of the second cooling device. 
     
     
         15 . The system of  claim 12 , wherein a difference between a cooling water supply temperature of the first cooling water entering the high temperature stage and a temperature of partially cooled saturated process gases exiting the high temperature stage is less than about 10° F.