Abstract: A method of assembling a synthesis gas (syngas) cooler for a gasification system includes positioning a dip tube within a shell of the syngas cooler. The dip tube is configured to quench the syngas flowing through the shell and/or at least partially channel the syngas through the dip tube. The method also includes coupling an isolation tube to the dip tube such that the isolation tube is substantially concentrically aligned with, and radially outward of, the dip tube. The isolation tube is coupled in flow communication with a purge gas source and is configured to at least partially form a dynamic pressure seal. The method further includes coupling at least one of the isolation tube and the dip tube in fluid communication with a fluid retention chamber. The method also include at least partially filling the fluid retention chamber with fluid, thereby further forming the dynamic pressure seal.

Abstract: An annular injector is described. The injector includes a first bayonet assembly and a second bayonet assembly each including a terminal end and a tip end. The second bayonet assembly is configured to be concentrically coupled at least partially about the first bayonet assembly. An outer diameter of the first bayonet assembly and an inner diameter of the second bayonet assembly vary at the tip end to define a first substantially annular nozzle. The first bayonet assembly includes a maximum outer diameter that is greater than a minimum inner diameter of the second bayonet assembly and at least a portion of at least one of the first bayonet assembly and the second bayonet assembly extends from the tip end to the terminal end. The injector includes a third bayonet assembly configured to be concentrically coupled at least partially about the second bayonet assembly to define a second substantially annular nozzle.

Abstract: A method for monitoring functionality of a seal assembly within an injector feed assembly is described. The method includes providing a buffer fluid to the seal assembly, measuring at least one of a pressure and a flow rate of the buffer fluid, and determining a functionality of the seal assembly based at least partially on the at least one of a pressure and a flow rate of the buffer fluid.

Abstract: A method of assembling a gasification reactor includes extending an injection device at least partially into the gasification reactor. The injection device includes a plurality of substantially concentric conduits coupled to a modular tip and at least one outer surface. The modular tip includes a plurality of cooling channels and a plurality of substantially annular nozzles defined therein. The method further includes forming at least one layer of insulation about at least a portion of the at least one outer surface to facilitate insulating at least a portion of the injection device from heat within the gasification reactor.

Abstract: A method is provided that includes removing carbon dioxide from untreated syngas received from a gasifier to produce a gas stream comprising carbon dioxide, modifying the gas stream by adding carbon monoxide, hydrogen, hydrogen sulfide, or any combination thereof, and providing the gas stream from an acid gas remover to a feed system for use as a conveyance gas to convey a feedstock into the gasifier. Systems implementing these and other methods are also provided.

Abstract: A method of assembling a spray quench apparatus is provided. The method includes coupling a first end of an exit tube to a quench chamber such that the exit tube end is in flow communication with the quench chamber, coupling at least one spray nozzle to an opposite second end of the exit tube such that water emitted from the spray nozzle fills the exit tube and forms a film of water across an inner surface of the exit tube, coupling a water source to the quench chamber for providing a substantially continuous water film along an inner surface of the quench chamber, and coupling at least one discharge apparatus to the quench chamber for providing water spray into the quench chamber, wherein the water of the water film and water sprays drains into a water sump.

Abstract: A feed injector system comprises substantially concentric channels with one being configured for pneumatically conveying pulverized solid fuel feed from a respective source to a reaction zone and another configured to impart convey a fluid oxidizer stream with and without swirl.

Abstract: Methods and systems for a feed injector are provided. The feed injector system includes a plurality of annular channels that are substantially concentric about a longitudinal axis. The plurality of annular channels direct a flow of fluid substantially axially therethrough from a respective source to a reaction zone. The feed injector system also includes a swirl member extending into the fluid flow path defined in at least one of the plurality of annular channels wherein the swirl member is configured to impart a circumferential flow direction to fluid flowing through the at least one annular channel.

Abstract: A method of assembling a spray quench apparatus is provided. The method includes coupling a first end of an exit tube to a quench chamber such that the exit tube end is in flow communication with the quench chamber, coupling at least one spray nozzle to an opposite second end of the exit tube such that water emitted from the spray nozzle fills the exit tube and forms a film of water across an inner surface of the exit tube, coupling a water source to the quench chamber for providing a substantially continuous water film along an inner surface of the quench chamber, and coupling at least one discharge apparatus to the quench chamber for providing water spray into the quench chamber, wherein the water of the water film and water sprays drains into a water sump.

Abstract: A method of assembling a synthesis gas (syngas) cooler for a gasification system includes positioning a dip tube within a shell of the syngas cooler. The dip tube is configured to quench the syngas flowing through the shell and/or at least partially channel the syngas through the dip tube. The method also includes coupling an isolation tube to the dip tube such that the isolation tube is substantially concentrically aligned with, and radially outward of, the dip tube. The isolation tube is coupled in flow communication with a purge gas source and is configured to at least partially form a dynamic pressure seal. The method further includes coupling at least one of the isolation tube and the dip tube in fluid communication with a fluid retention chamber. The method also include at least partially filling the fluid retention chamber with fluid, thereby further forming the dynamic pressure seal.

Abstract: A method of startup for a gasification system includes assembling a fuel mixture for use by a gasifier at a fuel mixture assembly point, wherein the fuel mixture includes a quantity of particulate solid fuel and a quantity of non-ventable carrier gas. The method includes channeling the fuel mixture through a first conduit to a fuel mixture disassembly system including a non-ventable carrier gas removal apparatus, establishing a substantially steady flow of the fuel mixture within the first conduit, and redirecting the fuel mixture through a second conduit to the gasifier to facilitate gasifier startup.

Abstract: A method for transporting a solid particulate within a gasifier system is provided. The method includes discharging solid particulate through an inlet into an opening defined within a rotor, wherein the inlet and the solid particulate are at a first pressure. The method further includes rotating the rotor such that at least one end of the opening is aligned in flow communication with a duct at a second pressure that is different from the first pressure. The solid particulate is discharged from the rotor opening through an outlet such that the solid particulate is at the second pressure, and the rotor is rotated such that at least one end of the rotor opening is aligned in flow communication with a pressure source that is at approximately the first pressure, and such that the opening is at the first pressure.

Abstract: A fuel feed system for use in a gasification system includes a feed preparation section, a pressurization and conveyance section, and a slag additive section. The feed preparation section is configured to grind the fuel to a predetermined size and to adjust the moisture content within the particulate fuel. The pressurization and conveyance section is coupled in flow communication with the feed preparation section, and includes at least one solids pump configured to receive a flow of the particulate fuel at a first pressure and discharge the particulate fuel at a second pressure. The slag additive section is configured to feed a slag additive mixture into the gasifier and to substantially control the total water content within the gasification system.

Abstract: A system for controlling gas leakage in a solids delivery system is provided. The system includes a bulk solids pump comprising an inlet for a particulate material and an outlet for discharge of said particulate material. The system also includes a buffer gas channel configured to impede backflow of process gas into the bulk solids pump, such as from a downstream system or process. The system further includes a pressure differential system configured to control a flow rate of the buffer gas and maintain a positive differential in pressure between the buffer gas and the process gas.

Abstract: A process for minimizing evaporator scaling during the recovery of liquids and solids from the aqueous effluent discharged during a partial oxidation gasification, wherein the aqueous effluent contains ammonium chloride (NH.sub.4 Cl). The aqueous effluent is evaporated to produce a distillate water and a brine having an NH.sub.4 Cl concentration of about 10 to 60 weight percent. The brine can be further concentrated and ammonium chloride crystals are recovered. The distillate water is recycled to the gasification reaction. No effluent discharges to the environment.

Abstract: The present invention relates to a method for minimizing hydrogen halide corrosion in quench gasifier during the non-catalytic partial oxidation reaction of a halogen-containing hydrocarbonaceous feed, to produce a hydrogen halide-containing synthesis gas, finely divided particulate solids, and a nontoxic slag. The hydrogen halide-containing synthesis gas is contacted with water in the quench zone of the gasifier. The quench water contains a neutralizing agent, in excess of the amount necessary to neutralize hydrogen halide acids present therein, to thereby form halide salts. The quench water containing the halide salts is purified to recover the halide salts. The salt-free water is essentially environmentally non-toxic and can either be recycled to the process or discarded in conformity with environmental regulations.

Abstract: A pumpable slurry of shredded scrap solid carbonaceous plastic-containing material that contains associated inorganic matter in admixture with a comminuted aluminosilicate-containing material having noncombustible constituents is reacted by partial oxidation to produce synthesis gas, reducing gas, or fuel gas. The noncombustible constituents in the aluminosilicate-containing material captures the inorganic matter in the scrap solid carbonaceous plastic-containing material while in the reducing atmosphere of the gasifier to produce nontoxic, nonleachable slag. The slurrying medium is water, liquid hydrocarbonaceous fuel, or mixtures thereof. Scrap plastics may be disposed of by the subject process without polluting the nation's environment.

Abstract: A method is disclosed for recovering condensed solidified volatile metals from the slag that exits the reactor section of a partial oxidation reactor. In a partial oxidation reactor, condensed solidified volatile metals become adsorbed to the surface of the slag particles and other particulate matter associated with the gasification reaction, such as ash and soot. These particulate materials can be removed and recovered. Finely divided slag particles can be separated and contacted with a mineral acid to dissolve the adsorbed condensed volatile metals. An acid liquor results which contains dissolved volatile metal salts of the acid. The acid liquor containing the dissolved volatile metal acid salts is then electrolyzed to reduce the dissolved volatile metal acid salts to the corresponding elemental metal for recovery.