System for fluidizing solid feedstock from a solid feed pump   

Abstract: According to various embodiments, a system includes a fluidization elbow. The fluidization elbow includes an elbow inlet, an elbow outlet downstream from the elbow inlet, and an elbow body disposed between the elbow inlet and the elbow outlet, wherein the elbow body turns and converges from the elbow inlet toward the elbow outlet. The fluidization elbow also includes multiple gas nozzles coupled to the elbow body, wherein the multiple gas nozzles include injection axes that generally converge toward the elbow outlet.

BACKGROUND OF THE INVENTION

The subject matter disclosed herein relates to a fluidization device for transitioning solid feedstock from a solid feed pump to a high pressure conveyance system.

Gasifiers convert carbonaceous materials into a mixture of carbon monoxide and hydrogen, referred to as synthesis gas or syngas. For example, a power plant may include one or more gasifiers that react a feedstock at a high temperature with oxygen and/or steam to produce syngas, which may be treated prior to use as a fuel. As will be appreciated, providing the gasifier with a substantially uniform and homogeneous distribution of gas and feedstock particles enhances efficiency and stability of the syngas conversion process. Unfortunately, transporting the feedstock particles from a region of low gas pressure into a region of high gas pressure using a solid feed pump induces the formation of agglomerations that may decrease gasifier efficiency and stability.

Certain embodiments commensurate in scope with the originally claimed invention are summarized below. These embodiments are not intended to limit the scope of the claimed invention, but rather these embodiments are intended only to provide a brief summary of possible forms of the invention. Indeed, the invention may encompass a variety of forms that may be similar to or different from the embodiments set forth below.

In accordance with a first embodiment, a system includes a solid feed pump having a pump inlet and a pump outlet, wherein the solid feed pump is configured to pump a solid feedstock, and a fluidization elbow disposed below the pump outlet. The fluidization elbow includes an elbow inlet coupled to the pump outlet, an elbow outlet downstream from the elbow inlet, an elbow body disposed between the elbow inlet and the elbow outlet, wherein the elbow body turns and converges from the elbow inlet toward the elbow outlet. The fluidization elbow also includes multiple gas nozzles coupled to the elbow body, wherein the multiple gas nozzles are configured to fluidize solid feedstock.

In accordance with a second embodiment, a system includes a fluidization elbow. The fluidization elbow includes an elbow inlet, an elbow outlet downstream from the elbow inlet, and an elbow body disposed between the elbow inlet and the elbow outlet, wherein the elbow body turns and converges from the elbow inlet toward the elbow outlet. The fluidization elbow also includes multiple gas nozzles coupled to the elbow body, wherein the multiple gas nozzles include injection axes that generally converge toward the elbow outlet.

In accordance with a third embodiment, a system includes a fluidization elbow. The fluidization elbow includes an elbow inlet, an elbow outlet downstream from the elbow inlet, and an elbow body disposed between the elbow inlet and the elbow outlet, wherein the elbow body turns and converges from the elbow inlet toward the elbow outlet. The fluidization elbow also includes multiple gas nozzles coupled to the elbow body and a controller configured to separately control gas flow through each gas nozzle of the multiple gas nozzles.

BRIEF DESCRIPTION OF THE 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 schematic block diagram of an embodiment of an integrated gasification combined cycle (IGCC) power plant utilizing a fluidization elbow between a solid feed pump and a gasifier;

FIG. 2 is a schematic diagram of an embodiment of the solid feed pump and the fluidization elbow, as shown in FIG. 1;

FIG. 3 is a cross-sectional side view of an embodiment of a nozzle assembly;

FIG. 4 is a cross-sectional side view of an embodiment of a nozzle assembly;

FIG. 5 is a cross-sectional side view of an embodiment of a nozzle assembly;

FIG. 6 is a perspective view of an embodiment of the fluidization elbow;

FIG. 7 is a rear view of an embodiment of the fluidization elbow, as shown in FIG. 6;

FIG. 8 is a cross-sectional side view of an embodiment of the fluidization elbow, as shown in FIG. 6;

FIG. 9 is a cross-sectional top view of an embodiment of the fluidization elbow, as shown in FIG. 6;

FIG. 10 is a perspective view of an embodiment of the fluidization elbow;

FIG. 11 is a rear view of an embodiment of the fluidization elbow, as shown in FIG. 10;

FIG. 12 is a cross-sectional side view of the fluidization elbow, as shown in FIG. 10;

FIG. 13 is a cross-sectional top view of the fluidization elbow, as shown in FIG. 10;

FIG. 14 is a perspective view of an embodiment of the fluidization elbow;

FIG. 15 is a rear view of an embodiment of the fluidization elbow, as shown in FIG. 14;

FIG. 16 is a cross-sectional side view of an embodiment of the fluidization elbow, as shown in FIG. 14;

FIG. 17 is a cross-sectional top view of an embodiment of the fluidization elbow, as shown in FIG. 14;

FIG. 18 is a perspective view of an embodiment of the fluidization elbow;

FIG. 19 is a rear view of an embodiment of the fluidization elbow, as shown in FIG. 18;

FIG. 20 is a cross-sectional side view of an embodiment of the fluidization elbow, as shown in FIG. 18;

FIG. 21 is a cross-sectional top view of an embodiment of the fluidization elbow, as shown in FIG. 18;

FIG. 22 is a perspective view of an embodiment of the fluidization elbow; and

FIG. 23 is a cross-sectional side view of an embodiment of the fluidization elbow, as shown in FIG. 22.

DETAILED DESCRIPTION

One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers\' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

Embodiments of the present disclosure include a fluidization device (e.g., a fluidization elbow) configured to establish a substantially uniform and homogenous flow of gas and solid particles coming out from a solid feed pump to a gasifier via a high pressure conveyance system, while substantially reducing or eliminating buildup of solids within the fluidization device. In certain embodiments, the fluidization elbow is disposed below a pump outlet of a solid feed pump (e.g., a posimetric pump) configured to pump a solid feedstock. The fluidization elbow includes an elbow inlet coupled to the pump outlet, an elbow outlet downstream from the elbow inlet, and an elbow body disposed between the elbow inlet and elbow outlet, wherein the elbow body turns and converges from the elbow inlet toward the elbow outlet. In addition, the fluidization elbow includes multiple gas nozzles coupled to the elbow body that are configured to fluidize the solid feedstock. In further embodiments of the fluidization elbow, the gas nozzles include injection axes that generally converge toward the elbow outlet. Yet further embodiments of the fluidization elbow include a controller configured to separately control gas flow through each gas nozzle of the multiple gas nozzles. In certain embodiments, the multiple gas nozzles are configured to inject multiple flow jets with different flow rates at different regions along the elbow body. For example, the multiple gas nozzles may include different nozzle diameters to affect the flow rates. In certain embodiments, the fluidization elbow includes at least one baffle disposed in the elbow body, where the baffle is configured to guide the solid feedstock around a turn of the elbow body. By utilizing these mechanical and fluid-dynamic features, the fluidization elbow may break up agglomerations within the flow of solid particles and near low velocity zones of the elbow, thereby providing the gasifier, via the higher conveyance system, with a substantially uniform and homogenous distribution of feedstock particles and gas which may enhance efficiency and stability of the syngas conversion process. Indeed, the fluidization elbow may allow a continuous flow to the gasifier with little or no residence time of the solid particles in the fluidization elbow.

FIG. 1 is a diagram of an embodiment of an integrated gasification combined cycle (IGCC) system 100 utilizing a fluidization elbow 12 between a solid feed pump 10 and a gasifier 106 as mentioned above. In certain embodiments, the solid feed pump 10 may be a posimetric pump configured to output or pump a solid feedstock (e.g., dry coal particles) at a high pressure, for example more than approximately 700 PSIG. The term “posimetric” may be defined as capable of metering (e.g., measuring an amount of) and positively displacing (e.g., trapping and forcing displacement of) a substance being delivered by the pump 10. The pump 10 is able to meter and positively displace a defined volume of a substance, such as a solid fuel feedstock (e.g., dry coal particles). The pump path may have a circular shape or curved shape. The higher pressure solid particles then flow to the fluidization elbow 12 coupled to the pump 10. As discussed in detail below, the fluidization elbow 12 is configured to inject gas into the flow of solid particles to converge the flow from the solid feed pump 10 to a high pressure conveyance system coupled to the gasifier 106. The fluidization elbow 12 is also configured to prevent solids settling by reducing low velocity regions and to break up agglomerations within the flow of solid particles, thereby providing the gasifier 106 with a substantially uniform distribution of feedstock particles which may enhance the efficiency and stability of the syngas conversion process. Although the fluidization elbow 12 is discussed with reference to the IGCC system 100 in FIG. 1, the disclosed embodiments of the fluidization elbow 12 may be used in any suitable application (e.g., production of chemicals, fertilizers, substitute natural gas, transportation fuels, or hydrogen). In other words, the following discussion of the IGCC system 100 is not intended to limit the disclosed embodiments to IGCC.

The IGCC system 100 produces and burns a synthetic gas, i.e., syngas, to generate electricity. Elements of the IGCC system 100 may include a fuel source 102, such as a solid feed, that may be utilized as a source of energy for the IGCC. The fuel source 102 may include coal, petroleum coke, biomass, wood-based materials, agricultural wastes, tars, asphalt, or other carbon containing items. The solid fuel of the fuel source 102 may be passed to a feedstock preparation unit 104. The feedstock preparation unit 104 may, for example, resize or reshape the fuel source 102 by chopping, milling, shredding, pulverizing, briquetting, or pelletizing the fuel source 102 to generate a dry feedstock (e.g., particulate matter).

In the illustrated embodiment, the solid feed pump 10 (e.g., posimetric pump) delivers the feedstock from the feedstock preparation unit 104 to the gasifier 106. The solid feed pump 10 is configured to meter and pressurize (e.g., to a pressure of at least 700 PSIG) the fuel source 102 (e.g., solid feedstock) received from the feedstock preparation unit 104. The pressurized feedstock exits an outlet of the solid feed pump 10 and flows downward (e.g., via gravity) into a fluidization device (e.g., fluidization elbow 12) located below the outlet of the pump 10. Although in some embodiments, the fluidization device may be located at the same height of the elbow or above. The fluidization elbow 12 transitions the flow of the solid feedstock from the solid feed pump 10 to a high pressure conveyance system (e.g., a pipeline). The high pressure conveyance system may be a pneumatic system that conveys the solid feedstock to the gasifier 106 via high velocity gas flow. The fluidization elbow 12 may converge the flow of the solid feedstock from the solid feed pump 10 to the conveyance system to accelerate the solid particles. Also, the fluidization elbow 12 may include multiple gas nozzles to reduce low velocity regions and to prevent solids settling within the elbow 12 as well as to break up agglomerations of the solid feedstock (i.e., fluidize the solid feedstock) into solid particles to create a substantially uniform and homogenous flow of the gas and solid particles into the conveyance system and subsequently the gasifier 106. The substantially uniform and homogenous distribution of gas and feedstock particles may enhance the efficiency and stability of the syngas conversion process. The gasifier 106 converts the feedstock 102 into a syngas, e.g., a combination of carbon monoxide and hydrogen. This conversion may be accomplished by subjecting the feedstock to a controlled amount of steam and oxygen at elevated pressures, e.g., from approximately 20 bar to 85 bar, and temperatures, e.g., approximately 700 degrees Celsius to 1600 degrees Celsius, depending on the type of gasifier 106 utilized.

The gasification process includes the feedstock undergoing a pyrolysis process, whereby the feedstock is heated. Temperatures inside the gasifier 106 may vary during the pyrolysis process, depending on the fuel source 102 utilized to generate the feedstock. The heating of the feedstock during the pyrolysis process generates a solid, (e.g., char), and residue gases, (e.g., carbon monoxide, hydrogen, and nitrogen). The char remaining from the feedstock from the pyrolysis process may only weigh up to approximately 30% of the weight of the original feedstock.

A partial oxidation process also occurs in the gasifier 106. The oxidation process may include introducing oxygen to the char and residue gases. The char and residue gases react with the oxygen to form carbon dioxide and carbon monoxide, which provides heat for the gasification reactions. The temperatures during the partial oxidation process may range from approximately 700 degrees Celsius to 1600 degrees Celsius. Steam may be introduced into the gasifier 106 during gasification. The char may react with the carbon dioxide and steam to produce carbon monoxide and hydrogen at temperatures ranging from approximately 800 degrees Celsius to 1100 degrees Celsius. In essence, the gasifier utilizes steam and oxygen to allow some of the feedstock to be “burned” to produce carbon monoxide and release energy, which drives a second reaction that converts further feedstock to hydrogen and additional carbon dioxide.

In this way, a resultant gas is created by the gasifier 106. This resultant gas may include approximately 85% of carbon monoxide and hydrogen in equal proportions, as well as CH4, HCl, HF, COS, NH3, HCN, and H2S (based on the sulfur content of the feedstock). This resultant gas may be termed untreated, raw, or sour syngas, since it contains, for example, H2S. The gasifier 106 may also generate waste, such as slag 108, which may be a wet ash material. This slag 108 may be removed from the gasifier 106 and disposed of, for example, as road base or as another building material. Prior to cleaning the raw syngas, a syngas cooler 107 may be utilized to cool the hot syngas. The cooling of the syngas may generate high pressure steam which may be utilized to produce electrical power as described below. After cooling the raw syngas, a gas cleaning unit 110 may be utilized to clean the raw syngas. The gas cleaning unit 110 may scrub the raw syngas to remove the HCl, HF, COS, HCN, and H2S from the raw syngas, which may include separation of sulfur 111 in a sulfur processor 112 by, for example, an acid gas removal process in the sulfur processor 112. Furthermore, the gas cleaning unit 110 may separate salts 113 from the raw syngas via a water treatment unit 114 that may utilize water purification techniques to generate usable salts 113 from the raw syngas. Subsequently, the gas from the gas cleaning unit 110 may include treated, sweetened, and/or purified syngas, (e.g., the sulfur 111 has been removed from the syngas), with trace amounts of other chemicals, e.g., NH3 (ammonia) and CH4 (methane).

A gas processor 116 may be utilized to remove residual gas components 117 from the treated syngas such as, ammonia and methane, as well as methanol or any residual chemicals. However, removal of residual gas components 117 from the treated syngas is optional, since the treated syngas may be utilized as a fuel even when containing the residual gas components 117, e.g., tail gas. At this point, the treated syngas may include approximately 40% CO, approximately 40% H2, and approximately 20% CO2 and is substantially stripped of H2S. This treated syngas may be transmitted to a combustor 120, e.g., a combustion chamber, of a gas turbine engine 118 as combustible fuel. Alternatively, the CO2 may be removed from the treated syngas prior to transmission to the gas turbine engine.

The IGCC system 100 may further include an air separation unit (ASU) 122. The ASU 122 may operate to separate air into component gases by, for example, distillation techniques. The ASU 122 may separate oxygen from the air supplied to it from a supplemental air compressor 123, and the ASU 122 may transfer the separated oxygen to the gasifier 106. Additionally the ASU 122 may transmit separated nitrogen to a diluent nitrogen (DGAN) compressor 124.

The DGAN compressor 124 may compress the nitrogen received from the ASU 122 at least to pressure levels equal to those in the combustor 120, so as not to interfere with the proper combustion of the syngas. Thus, once the DGAN compressor 124 has adequately compressed the nitrogen to a proper level, the DGAN compressor 124 may transmit the compressed nitrogen to the combustor 120 of the gas turbine engine 118. The nitrogen may be used as a diluent to facilitate control of emissions, for example.

As described previously, the compressed nitrogen may be transmitted from the DGAN compressor 124 to the combustor 120 of the gas turbine engine 118. The gas turbine engine 118 may include a turbine 130, a drive shaft 131 and a compressor 132, as well as the combustor 120. The combustor 120 may receive fuel, such as syngas, which may be injected under pressure from fuel nozzles. This fuel may be mixed with compressed air as well as compressed nitrogen from the DGAN compressor 124, and combusted within combustor 120. This combustion may create hot pressurized exhaust gases.

The combustor 120 may direct the exhaust gases towards an exhaust outlet of the turbine 130. As the exhaust gases from the combustor 120 pass through the turbine 130, the exhaust gases force turbine blades in the turbine 130 to rotate the drive shaft 131 along an axis of the gas turbine engine 118. As illustrated, the drive shaft 131 is connected to various components of the gas turbine engine 118, including the compressor 132.

The drive shaft 131 may connect the turbine 130 to the compressor 132 to form a rotor. The compressor 132 may include blades coupled to the drive shaft 131. Thus, rotation of turbine blades in the turbine 130 may cause the drive shaft 131 connecting the turbine 130 to the compressor 132 to rotate blades within the compressor 132. This rotation of blades in the compressor 132 causes the compressor 132 to compress air received via an air intake in the compressor 132. The compressed air may then be fed to the combustor 120 and mixed with fuel and compressed nitrogen to allow for higher efficiency combustion. Drive shaft 131 may also be connected to load 134, which may be a stationary load, such as an electrical generator for producing electrical power, for example, in a power plant. Indeed, load 134 may be any suitable device that is powered by the rotational output of the gas turbine engine 118.

The IGCC system 100 also may include a steam turbine engine 136 and a heat recovery steam generation (HRSG) system 138. The steam turbine engine 136 may drive a second load 140. The second load 140 may also be an electrical generator for generating electrical power. However, both the first and second loads 134, 140 may be other types of loads capable of being driven by the gas turbine engine 118 and steam turbine engine 136. In addition, although the gas turbine engine 118 and steam turbine engine 136 may drive separate loads 134 and 140, as shown in the illustrated embodiment, the gas turbine engine 118 and steam turbine engine 136 may also be utilized in tandem to drive a single load via a single shaft. The specific configuration of the steam turbine engine 136, as well as the gas turbine engine 118, may be implementation-specific and may include any combination of sections.

The IGCC system 100 may also include the HRSG 138. High pressure steam may be transported into the HSRG 138 from the syngas cooler 107. Also, heated exhaust gas from the gas turbine engine 118 may be transported into the HRSG 138 and used to heat water and produce steam used to power the steam turbine engine 136. Exhaust from, for example, a low-pressure section of the steam turbine engine 136 may be directed into a condenser 142. The condenser 142 may utilize a cooling tower 128 to exchange heated water for chilled water. The cooling tower 128 acts to provide cool water to the condenser 142 to aid in condensing the steam transmitted to the condenser 142 from the steam turbine engine 136. Condensate from the condenser 142 may, in turn, be directed into the HRSG 138. Again, exhaust from the gas turbine engine 118 may also be directed into the HRSG 138 to heat the water from the condenser 142 and produce steam.

In combined cycle systems such as IGCC system 100, hot exhaust may flow from the gas turbine engine 118 and pass to the HRSG 138, along with the steam generated by the syngas cooler 107, where it may be used to generate high-pressure, high-temperature steam. The steam produced by the HRSG 138 may then be passed through the steam turbine engine 136 for power generation. In addition, the produced steam may also be supplied to any other processes where steam may be used, such as to the gasifier 106. The gas turbine engine 118 generation cycle is often referred to as the “topping cycle,” whereas the steam turbine engine 136 generation cycle is often referred to as the “bottoming cycle.” By combining these two cycles as illustrated in FIG. 1, the IGCC system 100 may lead to greater efficiencies in both cycles. In particular, exhaust heat from the topping cycle may be captured and used to generate steam for use in the bottoming cycle.

FIG. 2 is a schematic diagram of an embodiment of the solid feed pump 10 and the fluidization elbow 12, as shown in FIG. 1. As shown in FIG. 2, the solid feed pump 10 includes a housing 214, inlet 200, outlet 202, and rotor 204. The solid feedstock upon entering the solid feed pump 10 via inlet 200 is transported from low to high pressure (e.g., at least approximately 700 PSIG) before being discharged from the outlet 202 of the pump 10. As illustrated, the rotor 204 includes two substantially opposed and parallel rotary discs, which include discrete cavities defined by protrusions to drive solids therebetween. The rotary discs are movable relative to the housing 214 in a rotational direction 216 from the inlet 200 towards the outlet 202. The inlet 200 and the outlet 202 are coupled to a curved passage 210 (e.g., circular or annular passage) disposed between the two rotary discs and within the housing 214. A solid feed guide 212 is disposed adjacent the outlet 202. The solid feed guide 212 extends across the curved passage 210 between rotary discs. The solid feed guide 212 includes a guide wall 222.

As particulate matter is fed through an opening 230 of the inlet 200, the solid feed pump 10 imparts a tangential force or thrust to the particulate matter in the rotational direction 216 of the rotor 204. The direction of flow 234 of the particulate matter is from the inlet 200 to the outlet 202. As the particulate matter rotates through the curved passage 210, the particulate matter encounters the guide wall 222 of the solid feed guide 212 disposed adjacent the outlet 202 extending across the curved passage 210. In this region, the particulate matter becomes highly compacted and exits the pump 10 at a generally constant rate. The solid feed guide 212 routes the particulate matter through an opening 236 of the outlet 202 into a discharge outlet 238. From the discharge outlet 238, the particulate matter or solid feedstock flows downward, as generally indicated by arrow 240, into a bottom discharge transition device (e.g., fluidization elbow 12). In certain embodiments, the fluidization elbow 12 may be located at the same height as the outlet 238 or above the outlet.

The fluidization elbow 12 is independent of the solid feed pump 10. The fluidization elbow 12 may be coupled to the discharge outlet 238 via, e.g., flanges 242, or some other fastening device. The fluidization elbow 12 is disposed below the pump outlet 202. As mentioned above, the fluidization elbow 12 transitions the flow of the solid feedstock from the solid feed pump 10 to a high pressure conveyance system 244 (e.g., a pipeline). As illustrated, the fluidization elbow 12 includes an elbow inlet 246, an elbow outlet 248 downstream from the elbow inlet 246, and an elbow body 250 disposed between the elbow inlet 246 and the elbow outlet 248. The elbow inlet 246 is coupled to the pump outlet 202 via the discharge outlet 238. The elbow outlet 248 is coupled to the gasifier 106 via the conveyance system 244, which is coupled to the elbow outlet 248. The elbow inlet 246 includes a diameter 252 generally the same as an outlet diameter 254 of the pump 10. The diameter 252 of the elbow inlet 246 is larger than a diameter 255 of the elbow outlet 248. The elbow inlet diameter 252 may be approximately 2, 3, 4, or 5 times larger than the elbow outlet diameter 255. Alternatively, the elbow outlet diameter 255 may range from approximately 20 to 50 percent of the length of the elbow inlet diameter 252. For example, the elbow outlet diameter 255 may be 20, 25, 30, 40, 45, or 50 percent, or any percent therebetween of the elbow inlet diameter 252. Due to the difference in diameters 252 and 255, the flow of conveyance gas and solid feedstock converges and accelerates from the elbow inlet 246 to the elbow outlet 248. The elbow body 250 turns, as generally indicated by arrow 253, and converges from the elbow inlet 246 toward the elbow outlet 248. The elbow body 250 includes an inner bend portion 256 and an outer bend portion 258. In certain embodiments, the outer bend portion 258 includes a wall portion 260 that curves in a downstream direction, as generally indicated by arrow 253, from the elbow inlet 246 toward the elbow outlet 248. Turning of the elbow body 250 may range from approximately 45 to 90 degrees, 50 to 80 degrees, or 60 to 70 degrees. For example, the elbow body 250 may turn at least approximately 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90 degrees, or any angle therebetween. Overall, the fluidization elbow 12 converges the flow of the solid feedstock from the elbow inlet 246 to the elbow outlet 248 in order to allow the conveyance gas to accelerate the flow of the solid particles into the conveyance system 244.

The fluidization elbow 12 also may include at least one baffle 263 disposed in the elbow body 250. One or more baffles 263 may be suspended from a bottom side portion 346 of the elbow body 250. Alternatively, the baffles 263 may be coupled to and supported by side walls of the elbow body 250 and span across the elbow body 250. As illustrated, the baffles 263 are oriented towards the elbow outlet 248. The baffles 263 are configured to guide the solid feedstock around the turn in the elbow body 250 as well as to prevent the build up of solid feedstock on the bottom of the fluidization elbow 12. The number of baffles 263 may range from 1 to 10 or more. For example, the fluidization device 12 may include at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 baffles.

Additionally, the fluidization elbow 12 includes multiple gas nozzles 264 configured to fluidize the solid feedstock. In other words, the multiple gas nozzles 264 break up agglomerations of the solid feedstock into particles to create a substantially uniform and homogenous flow of the gas and solid particles into the conveyance system 244. The gas nozzles 264 are coupled to the elbow body 250. In particular, the gas nozzles 264 are disposed along the outer bend portion 258. Indeed, the gas nozzles 264 may include sets of gas nozzles 264 disposed at different positions along a gas flow path, also indicated generally by arrow 253, through the elbow body 250 as described in more detail below. For example, as illustrated each gas nozzle 264 represents sets of gas nozzles 264 (e.g., sets 266, 268, 270, 272, 274, 276, and 278) disposed about a circumference of the fluidization elbow 12. The gas nozzles 264 are configured to inject multiple gas jets at different regions along the elbow body 250 to reduce low velocity zones within the fluidization elbow 12, such as at a bottom region or along walls of the elbow 12. In certain embodiments, the gas nozzles 264 are configured to inject multiple gas jets with different flow rates at different regions along the elbow body 250. For example, in some embodiments, the gas nozzles 264 may include different nozzle diameters to impart different flow rates to the nozzles 264. In some embodiments, some of the gas nozzles 264 may induce swirl to mix the gas and the solid particles. The gas nozzles 264 also include injection axes that generally converge toward the elbow outlet 248. Besides fluidizing the solid feedstock, the gas nozzles 264 help direct the flow of solid particles towards the elbow outlet 248 and the conveyance system 244. In certain embodiments, gas nozzles 264 may be included in the baffles 263 to help direct the flow of the solid particles towards the elbow outlet 248. High pressure, high velocity gas flow jets from the gas nozzles 264 also helps accelerate the particles into the conveyance system 244 reducing residence time of solid feedstock in the fluidization elbow 12. The gas velocity of the jets may range from approximately 100 to 900 feet/second. For example, the gas velocity may be approximately 100, 500, or 900 feet/second or any velocity therebetween. The residence time of solids inside the elbow 12 may range from approximately 0.02 to 0.5 seconds. For example, the residence time may be approximately 0.025, 0.035, or 0.5 seconds or any time therebetween. More specifically, the fluidization elbow 12 may be configured to flow the solid feedstock with a residence time of less than approximately 1 second. The high velocity gas also helps conveyance of the solid particles into the high pressure conveyance system 244, particularly if the conveyance system 244 operates as a pneumatic system that transfers the solid particles via high velocity gas flow into the gasifier 106. In certain embodiments, a permeable plate may be used, instead of gas nozzles 264, to fluidize the solid particles.

The fluidization elbow 12 also includes a controller 280 configured to separately control gas flow through each gas nozzle 264 of the multiple gas nozzles 264. The controller 280 is configured to control each nozzle 264 individually or multiple nozzles 264 as a group. The gas nozzles 264 are coupled to a compressed gas supply 282. A compressor 284 generates the compressed gas supply 282. The controller 280 controls the gas flow to each gas nozzle 264 via valves 286. As a result, the controller 280 may be configured to open or close the valves 286 and, thus, affect the amount of gas supplied to each gas nozzle 264 or each set of gas nozzles 264 to affect the flow rates. Also, the controller 280 is configured to adjust the tilt of the gas nozzles 264. The compressor 280 is also configured to control the compressor 284 to affect the pressure of the compressed gas supply 282 provided to the gas nozzles 264. As a result, the controller 280 via the valves 286 and the compressor 284 controls the fluidization of the solid feedstock throughout the fluidization elbow 12 to eliminate any low velocity regions. As a result, the overall design of the fluidization elbow allows for a uniform and homogenous distribution of gas and feedstock particles to flow along a smooth, converging flowpath from the solid feed pump 10 to the conveyance system 244, and subsequently to the gasifier 106 to enhance efficiency and stability of the syngas conversion process.

The gas nozzles 264 used in embodiments of the fluidization elbow 12 may include different embodiments. For example, the gas nozzles 264 may be individually coupled to fluidization elbow 12 via a variety of mounts, e.g., threaded connections, bolted flanges, or welds between the nozzles 264 and the elbow body 250. FIGS. 3 and 4 provide alternative embodiments for the gas nozzles 264. For example, FIG. 3 is a cross-sectional side view of an embodiment of a nozzle assembly 296. The nozzle assembly 296 includes a nozzle mount 298 supporting at least two gas nozzles 264 of the multiple gas nozzles 264. As illustrated, each gas nozzle 264 includes an opening 300 for the jets of gas to pass through. Also, as illustrated, the nozzle mount 298 includes four gas nozzles 264 (302, 304, 306, and 308). However, the number of gas nozzles 264 supported by each nozzle mount 298 may range from 2 to 100 nozzles 264. The nozzle mount 298 is configured to secure the at least two gas nozzles 264 to the elbow body 250. Indeed, in certain embodiments, multiple nozzle mounts 298 may be secured to the elbow body 250. The nozzle mounts 298 may be secured to the elbow body 250 via one or more fasteners 310 (e.g., a screw or bolt) through openings 312 of the mount 298. Alternatively, the mounts 298 may be secured via other types of fasteners. Each particular nozzle mount 298 may include gas nozzles 264 each having a same diameter 314. In other embodiments, as illustrated, each particular nozzle mount 298 may include gas nozzles 264 (e.g., 302, 304, 306, and 308) of different diameters 314. Each of the gas nozzles 264 supported by the nozzle mount 298 may include injection axes that generally converge toward the elbow outlet 248 when mounted on the elbow body 250. In certain embodiments, the gas nozzles 264 supported by the nozzle mount 298 may be angled approximately 1 to 90, 10 to 80, or 30 to 60 degrees relative to the mount 298. In further embodiments, the gas nozzles 264 on each nozzle mount 298 may be parallel, converging, or diverging relative to one another.

FIG. 4 is a cross-sectional side view of another embodiment of the nozzle assembly 296. As illustrated, the nozzle assembly 296 includes nozzle mount 298 that includes a manifold 322. The manifold 322 includes a manifold inlet 324, a distribution chamber 326, and at least two gas nozzles 264 coupled to the distribution chamber 326. As illustrated, the gas nozzles 264 include openings 328 that serve as outlets from the distribution chamber 326. In certain embodiments, the openings 328 may be angled approximately 1 to 90, 10 to 80, or 30 to 60 degrees relative to the mount 298. High pressure gas enters the manifold inlet 324, as generally indicated by arrow 330, and then flows through the distribution chamber 326, as generally indicated by arrows 332, to exit via openings 328. The nozzle mount 298 may be secured to the elbow body 250 as described above. Indeed, also as above, multiple nozzle mounts 298 may be secured to the elbow body 258. As illustrated, each nozzle mount 298 may include gas nozzles 264 each having the same diameter 314. In certain embodiments, each nozzle mount 298 may include gas nozzles 264 with different diameters 314. Also, as above, each of the gas nozzles 264 supported by the nozzle mount 298 may include injection axes that generally converge toward the elbow outlet 248 when mounted on the elbow body 250.

FIG. 5 is a cross-sectional side view of another embodiment of the nozzle assembly 296. As illustrated, the nozzle assembly 296 includes nozzle mount 298 that includes a manifold 322. The manifold 322 includes a manifold inlet 324, a distribution chamber 326, and a permeable plate 334 coupled to the distribution chamber 326. The permeable plate 334 may include a sintered metal. Gas enters the manifold inlet 324, as generally indicated by arrow 330, and then flows through the distribution chamber 326, as generally indicated by arrows 332, and permeates through the plate 334 to fluidize the flow of solid particles. The nozzle mount 298 may be secured to the elbow body 250 as described above. Indeed, also as above, multiple nozzle mounts 298 may be secured to the elbow body 258.

FIGS. 6-23 illustrate various embodiments of the fluidization elbow 12 configured to fluidize the solid feedstock and to provide a uniform and homogenous flow of gas and feedstock particles to the conveyance system 244. For example, FIGS. 6-9 illustrate one embodiment of the fluidization elbow 12. FIG. 6 is a perspective view of an embodiment of the fluidization elbow 12. The fluidization elbow 12 includes the elbow inlet 246, the elbow outlet 248 downstream from the elbow inlet 246, and the elbow body 250 disposed between the elbow inlet 246 and the elbow outlet 248. The elbow inlet 246 includes an annular opening 342 for receiving the solid feedstock from the solid feed pump 10. As illustrated, the elbow body 250 turns, as generally indicated by arrow 253, and converges from the elbow inlet 246 toward the elbow outlet 248 (see FIG. 8). The elbow body 250 includes a topside portion 344 and a bottom side portion 346 (see FIG. 9) that converge or taper towards the elbow outlet 248. In addition, the elbow body 250 includes side portions 348 and 350 (see FIG. 9) that converge or taper towards the elbow outlet 248. The elbow outlet 248 extends from the elbow body 250 and is configured to couple with the conveyance system 244, e.g., a pipeline. A width 352 of the elbow body 250 increases from a top portion 354 to a bottom portion 356 of the elbow body 250. The increase in the width 352 provides sufficient space for the routing of the solid feedstock from the solid feed pump 10 to the conveyance system 244 to avoid pile up of solid feedstock within the fluidized elbow 12. A length 358 (see FIG. 8) of the elbow body 250 is configured to avoid low velocity zones while also providing a smooth transition for the solid feedstock. The length 358 of the elbow body 250 also increases from the top portion 354 to the bottom portion 356 of the elbow body. Thus, the elbow body 250 expands out from the elbow inlet 246 from the top portion 354 to the bottom portion 356 of the body 250. Also, a backside portion 360 of the elbow body 250 includes rounded corners 362 and 364 to smooth the transition of the solid feedstock flow as well as to avoid low velocity zones. Backside portions 366 and 360 of the elbow inlet 246 and the elbow body 250, respectively, include openings 368 for multiple gas nozzles 264.

FIG. 7 is a rear view of an embodiment of the fluidization elbow 12 shown in FIG. 6. The backside portion 366 of the elbow inlet 246 includes a set 378 of openings 368 for a set of gas nozzles 264 disposed in alignment along a width 380 of the backside portion 366 of the inlet 246. The backside portion 360 of the elbow body 250 also includes sets 382 and 384 of openings 368 for sets of gas nozzles 264 disposed in alignment along the width 352 of the elbow body 250. The openings 368 are also aligned in columns 388, 390, 392, 394, and 396 in a vertical direction along a total length 398 of the backside portions 360 and 366. As illustrated, the sets 378, 382, and 384 of openings 368 include 3, 3, and 5 openings, respectively, for a total of 11 openings 368 for 11 fuel nozzles 364. However, in other embodiments, the number of openings 368 in each set 378, 382, and 384, the number of sets, the total number openings 368, and the arrangement of the openings 368 may vary. For example, the number of openings 368 in each set may range from 1 to 10, the number of sets may range from 1 to 10, and the total number of openings 368 may range from 1 to 100. Also, the openings 368 may not be aligned in sets or rows or columns.

FIG. 8 is a cross-sectional side view of an embodiment of the fluidization elbow 12 shown in FIG. 6. As described above, the elbow body 250 turns, as generally indicated by arrow 253, and converges from the elbow inlet 246 toward the elbow outlet 248. The elbow body 250 includes inner bend portion 256 and outer bend portion 258. Turning of the elbow body 250 may range from approximately 45 to 90 degrees, 50 to 80 degrees, or 60 to 70 degrees. For example, the elbow body 250 may turn at least approximately 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90 degrees, or any angles therebetween. As illustrated, multiple gas nozzles 264 are disposed along the outer bend portion 258. The multiple gas nozzles 264 are coupled to the openings 368. Each illustrated gas nozzle 264 may represent a set of gas nozzles 264. Both the openings 368 and their respective gas nozzles 264 are oriented towards the elbow outlet 248. As a result, the gas nozzles 264 include injection axes 408 that generally converge toward the elbow outlet 248, e.g., outlet axis 249. For example, opening 410 and gas nozzle 412 are oriented at a greater angle than opening 414 and gas nozzle 416. Also, opening 414 and gas nozzle 416 are oriented at a greater angle than opening 418 and gas nozzle 420. Accordingly, the gas nozzles 264 are arranged to avoid low velocity zones in the flow of the solid feedstock.

As mentioned above, the gas nozzles 264 are configured to fluidize the solid feedstock to provide a uniform and homogenous flow as well as to converge and accelerate the flow towards the elbow outlet 248. As previously mentioned, the fluidized elbow 12 also includes at least one baffle 263 disposed in the elbow body 250 configured to guide the flow of solid feedstock around the turn in the elbow body 250. In certain embodiments, one or more baffles 263 may include gas nozzles 264 to assist in converging the flow towards the elbow outlet 248.

FIG. 9 is a cross-sectional top view of an embodiment of the fluidization elbow 12 shown in FIG. 6. FIG. 9 illustrates the convergence of side portions 348 and 350 and bottom side portion 346 towards the elbow outlet 248. Also, as previously mentioned, the corners 362 and 364 of the backside portion 360 of the elbow body 250 are rounded to avoid low velocity regions as well as to smoothly transition the flow of the solid feedstock towards the elbow outlet 248. Additionally, the openings 368, as illustrated by set 384, are oriented to allow their respective fuel nozzles 364 to converge the flow of the solid feedstock towards the elbow outlet 248, as generally indicated by arrows 430 directed toward outlet axis 249.

FIGS. 10-13 illustrate another embodiment of the fluidization elbow 12. FIG. 10 is a perspective view of an embodiment of the fluidization elbow 12. The fluidization elbow 12 includes the elbow inlet 246, the elbow outlet 248 downstream from the elbow inlet 246, and the elbow body 250 disposed between the elbow inlet 246 and the elbow outlet 248. The elbow inlet 246 includes the annular opening 342 for receiving the solid feedstock from the solid feed pump 10. As illustrated, the elbow body 250 turns, as generally indicated by arrow 253, and converges from the elbow inlet 246 toward the elbow outlet 248 (see FIG. 12). The elbow body 250 includes the topside portion 344 and the bottom side portion 346 (see FIG. 13) that converge or taper towards the elbow outlet 248. In addition, the elbow body 250 includes the side portions 348 and 350 (see FIG. 14) that converge or taper towards the elbow outlet 248. The elbow outlet 248 extends from the elbow body 250 and is configured to couple with the conveyance system 244, e.g., a pipeline. The width 352 of the elbow body 250 increases from the top portion 354 to the bottom portion 356 of the elbow body 250. The increase in the width 352 provides sufficient space for the routing of the solid feedstock from the solid feed pump 10 to the conveyance system 244 to avoid pile up of solid feedstock within the fluidized elbow 12. The length 358 (see FIG. 12) of the elbow body 250 is configured to avoid low velocity zones while also providing a smooth transition for the solid feedstock. The length 358 of the elbow body 250 also increases from the top portion 354 to the bottom portion 356 of the elbow body 250. Thus, the elbow body 250 expands out from the elbow inlet 246 from the top portion 354 to the bottom portion 356 of the body 250. Also, the backside portion 360 of the elbow body 250 includes rounded corners 362 and 364 to smooth the transition of the solid feedstock flow as well as to avoid low velocity zones. In addition, the backside portion 360 of the elbow body 250 bows or curves away from backside portion 366 of the inlet 246, as generally indicated by arrow 440. The bowing or curving 440 increases the space for the routing of the solid feedstock by the fluidization elbow 12. Backside portions 366 and 360 of the elbow inlet 246 and the elbow body 250, respectively, include openings 368 for multiple gas nozzles 264.

FIG. 11 is a rear view of an embodiment of the fluidization elbow 12 shown in FIG. 10. The backside portion 366 of the elbow inlet 246 includes the set 378 of openings 368 for the set of gas nozzles 264 generally disposed in alignment along the width 380 of the backside portion 366 of the inlet 246. The backside portion 360 of the elbow body 250 also includes sets 382 and 384 of openings 368 for sets of gas nozzles 264 disposed in alignment along the width 352 of the elbow body 250. The openings 368 are also aligned in columns 388, 390, 392, 394, and 396 in a vertical direction along the total length 398 of the backside portions 360 and 366. As illustrated, the sets 378, 382, and 384 of openings 368 include 3, 3, and 5 openings, respectively, for a total of 11 openings 368 for 11 fuel nozzles 364. However, in other embodiments, the number of openings 368 in each set 378, 382, and 384, the number of sets, the total number openings 368, and the arrangement of the openings 368 may vary. For example, the number of openings 368 in each set may range from 1 to 10, the number of sets may range from 1 to 5, and the total number of openings 368 may range from 1 to 30. Also, the openings 368 may not be aligned in sets or rows or columns. In certain embodiments, instead of openings 368, the permeable plate 334 is attached to the elbow 12.

FIG. 12 is a cross-sectional side view of an embodiment of the fluidization elbow 12 shown in FIG. 10. As described above, the elbow body 250 turns, as generally indicated by arrow 253, and converges from the elbow inlet 246 toward the elbow outlet 248. The elbow body 250 includes the inner bend portion 256 and the outer bend portion 258. Turning of the elbow body 250 may range from approximately 45 to 90 degrees, 50 to 80 degrees, or 60 to 70 degrees. For example, the elbow body 250 may turn at least approximately 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90 degrees, or any degrees therebetween. As illustrated, multiple gas nozzles 264 are disposed along the outer bend portion 258. The multiple gas nozzles 264 are coupled to the openings 368. Each illustrated gas nozzle 264 may represent a set of gas nozzles 264. Both the openings 368 and their respective gas nozzles 264 are oriented towards the elbow outlet 248. As a result, the gas nozzles 264 include injection axes 408 that generally converge toward the elbow outlet 248. For example, opening 410 and gas nozzle 412 are oriented at a greater angle than opening 414 and gas nozzle 416. Also, opening 414 and gas nozzle 416 are oriented at a greater angle than opening 418 and gas nozzle 420. As mentioned above, the backside portion 360 of the elbow body 250 is bowed or curved, as indicated by arrow 440. The bowed or curved backside portion 360 may allow the injection axes 408 of the multiple gas nozzles 264 to generally converge toward the elbow outlet 248 without having to angle the nozzles 264. In other words, the multiple gas nozzles 264 may be perpendicularly installed with respect to the backside portion 360 of the elbow body 250. Accordingly, the gas nozzles 264 are arranged to avoid low velocity zones in the flow of the solid feedstock.

As mentioned above, the gas nozzles 264 are configured to fluidize the solid feedstock to provide a uniform and homogenous flow as well as to converge and accelerate the flow towards the elbow outlet 248. As previously mentioned, the fluidized elbow 12 also includes at least one baffle 263 disposed in the elbow body 250 configured to guide the flow of solid feedstock around the turn in the elbow body 250. In certain embodiments, one or more baffles 263 may include gas nozzles 264 to assist in converging the flow towards the elbow outlet 248.

FIG. 13 is a cross-sectional top view of an embodiment of the fluidization elbow 12 shown in FIG. 10. FIG. 13 illustrates the convergence of side portions 348 and 350 and bottom side portion 346 towards the elbow outlet 248. Also, as previously mentioned, the corners 362 and 364 of the backside portion 360 of the elbow body 250 are rounded to avoid low velocity regions as well as to smoothly transition the flow of the solid feedstock towards the elbow outlet 248. Additionally, the openings 368, as illustrated by set 384, are oriented to allow their respective fuel nozzles 364 to converge the flow of the solid feedstock towards the elbow outlet 248, as generally indicated by arrows 430 directed toward outlet axis 249.

FIGS. 14-17 illustrate a further embodiment of the fluidization elbow 12. FIG. 14 is a perspective view of an embodiment of the fluidization elbow 12. The fluidization elbow 12 includes the elbow inlet 246, the elbow outlet 248 downstream from the elbow inlet 246, and the elbow body 250 disposed between the elbow inlet 246 and the elbow outlet 248. Generally, the elbow inlet 246, the elbow outlet 248, and the elbow body 250 include an annular shape. The elbow inlet 246 includes the annular opening 342 for receiving the solid feedstock from the solid feed pump 10. As illustrated, the elbow body 250 turns, as generally indicated by arrow 253, and converges from the elbow inlet 246 toward the elbow outlet 248 (see FIG. 16). The elbow inlet 246 includes a top portion 450 and a bottom portion 452 that includes width 380 that gradually decreases from the top portion 450 to the bottom portion 452 (see FIG. 15). The elbow body 250 includes the topside portion 344 and the bottom side portion 346 (see FIG. 17) that converge or taper towards the elbow outlet 248. In addition, the elbow body 250 includes the side portions 348 and 350 (see FIG. 17) that converge or taper towards the elbow outlet 248. Also, the elbow body 250 includes a conical portion 448 that extends towards the elbow outlet 248. The elbow outlet 248 extends from the elbow body 250 and is configured to couple with the conveyance system 244, e.g., a pipeline. The width 352 of the elbow body 250 gradually decreases from the top portion 354 to the bottom portion 356 of the elbow body 250. The length 358 (see FIG. 16) of the elbow body 250 is configured to avoid low velocity zones while also providing a smooth transition for the solid feedstock. The backside portion 360 of the elbow body 250 curves towards the elbow outlet 248 and eliminates the possibility for settling of solid feedstock towards the backside portion 360 of the body 250. Backside portions 366 and 360 of the elbow inlet 246 and the elbow body 250, respectively, include openings 368 for multiple gas nozzles 264.

FIG. 15 is a rear view of an embodiment of the fluidization elbow 12 shown in FIG. 14. The backside portion 366 of the elbow inlet 246 includes a single opening 368 (i.e., 454) centrally located at the bottom portion 452 of the inlet 246 for the gas nozzle 264. The opening 454 forms a part of the set 378 of openings 368. In some embodiments, the opening 454 may be centrally located at the top portion 354 on the backside portion 360 of the elbow body 250 as part of the set 378 of openings 368. The backside portion 360 of the elbow body 250 also includes sets 378, 382, and 384 of openings 368 for sets of gas nozzles 264 generally disposed in alignment along the width 352 of the elbow body 250. The openings 368 are also aligned in columns 388, 390, and 392 in a vertical direction along the total length 398 of the backside portions 360 and 366. As illustrated, the sets 378, 382, and 384 of openings 368 include 3, 3, and 3 openings, respectively, for a total of 9 openings 368 for 9 fuel nozzles 364. However, in other embodiments, the number of openings 368 in each set 378, 382, and 384, the number of sets, the total number openings 368, and the arrangement of the openings 368 may vary. For example, the number of openings 368 in each set may range from 1 to 10, the number of sets may range from 1 to 10, and the total number of openings 368 may range from 1 to 100. Also, the openings 368 may not be aligned in sets or rows or columns. In certain embodiments, instead of openings 368, the permeable plate 334 is attached to the elbow 12.

FIG. 16 is a cross-sectional side view of an embodiment of the fluidization elbow 12 shown in FIG. 14. As described above, the elbow body 250 turns, as generally indicated by arrow 253, and converges from the elbow inlet 246 toward the elbow outlet 248. The elbow body 250 includes inner bend portion 256 and outer bend portion 258. The outer bend portion 258 includes the wall portion 260 that curves in a downstream direction, as generally indicated by arrow 253, from the elbow inlet 246 toward the elbow outlet 248 to help accelerate the flow of the solid feedstock as well as to eliminate any cavity for settling of the feedstock as described above. Turning of the elbow body 250 may range from approximately 45 to 90 degrees, 50 to 80 degrees, or 60 to 70 degrees. For example, the elbow body 250 may turn at least approximately 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90 degrees, or any angle therebetween. As illustrated, multiple gas nozzles 264 are disposed along the outer bend portion 258. The multiple gas nozzles 264 are coupled to the openings 368. Each illustrated gas nozzle 264 may represent a set of gas nozzles 264. Both the openings 368 and their respective gas nozzles 264 are oriented towards the elbow outlet 248. As a result, the gas nozzles 264 include injection axes 408 that generally converge toward the elbow outlet 248, e.g., outlet axis 249. For example, opening 410 and gas nozzle 412 are oriented at a greater angle than opening 414 and gas nozzle 416. Also, opening 414 and gas nozzle 416 are oriented at a greater angle than opening 418 and gas nozzle 420. Accordingly, the gas nozzles 264 are arranged to avoid low velocity zones in the flow of the solid feedstock.

As mentioned above, the gas nozzles 264 are configured to fluidize the solid feedstock to provide a uniform and homogenous flow as well as to converge the flow towards the elbow outlet 248. As previously mentioned, the fluidized elbow 12 also includes at least one baffle 263 disposed in the elbow body 250 configured to guide the flow of solid feedstock around the turn in the elbow body 250. In certain embodiments, one or more baffles 263 may include gas nozzles 264 to assist in converging the flow towards the elbow outlet 248.

FIG. 17 is a cross-sectional top view of an embodiment of the fluidization elbow 12 shown in FIG. 14. FIG. 17 illustrates the convergence of side portions 348 and 350 and bottom side portion 346 towards the elbow outlet 248. Additionally, the openings 368, as illustrated by set 384, are oriented to allow their respective fuel nozzles 364 to converge the flow of the solid feedstock towards the elbow outlet 248, as generally indicated by arrows 430 directed toward outlet axis 249.

FIGS. 18-21 illustrate a still further embodiment of the fluidization elbow 12. FIG. 18 is a perspective view of an embodiment of the fluidization elbow 12. The fluidization elbow 12 includes the elbow inlet 246, the elbow outlet 248 downstream from the elbow inlet 246, and the elbow body 250 disposed between the elbow inlet 246 and the elbow outlet 248. Generally, the elbow inlet 246, the elbow outlet 248, and the elbow body 250 include an annular shape. The elbow inlet 246 includes the annular opening 342 for receiving the solid feedstock from the solid feed pump 10. As illustrated, the elbow body 250 turns, as generally indicated by arrow 253, and converges from the elbow inlet 246 toward the elbow outlet 248 (see FIG. 20). The elbow body 250 includes the topside portion 344 and the bottom side portion 346 (see FIG. 21) that converge or taper towards the elbow outlet 248. In addition, the elbow body 250 includes the side portions 348 and 350 (see FIG. 21) that converge or taper towards the elbow outlet 248. The elbow body 250 also includes side portions 464 and 466 that bow or curve out from near the top portion 354 to a mid-portion 468 of the body 250. Then, the side portions 464 and 466 curve back in from the mid-portion 468 to the bottom portion 356 of the elbow body 250. The bowing of the side portions 348 and 350 provides sufficient space for the routing of the solid feedstock from the solid feed pump 10 to the conveyance system 244 to avoid pile up of solid feedstock within the fluidized elbow 12. Also, the elbow body 250 includes a conical portion 448 that extends towards the elbow outlet 248. The elbow outlet 248 extends from the elbow body 250 and is configured to couple with the conveyance system 244, e.g., a pipeline. The width 352 of the elbow body 250 increases from the top portion 354 to the mid-portion 468 and decreases from the mid-portion 468 to the bottom portion 356 of the elbow body 250. The length 358 (see FIG. 20) of the elbow body 250 is configured to avoid low velocity zones while also providing a smooth transition for the solid feedstock. The backside portion 360 of the elbow body 250 also bows out (see FIG. 20) to provide more space for the flow of the solid feedstock through the fluidization elbow 12. Backside portions 366 and 360 of the elbow inlet 246 and the elbow body 250, respectively, include openings 368 for multiple gas nozzles 264.

FIG. 19 is a rear view of an embodiment of the fluidization elbow 12 shown in FIG. 18. As mentioned above, FIG. 19 illustrates the bowing of the elbow body 250. Also, the backside portion 360 of the elbow body 250 also includes sets 378, 382, and 384 of openings 368 for sets of gas nozzles 264 generally disposed in alignment along the width 352 of the elbow body 250. The openings 368 are also aligned in columns 388, 390, and 392 in a vertical direction along a length 398 of the backside portions 360. As illustrated, the sets 378, 382, and 384 of openings 368 include 3, 3, and 3 openings, respectively, for a total of 9 openings 368 for 9 fuel nozzles 364. However, in other embodiments, the number of openings 368 in each set 378, 382, and 384, the number of sets, the total number openings 368, and the arrangement of the openings 368 may vary. For example, the number of openings 368 in each set may range from 1 to 10, the number of sets may range from 1 to 10, and the total number of openings 368 may range from 1 to 100. Also, the openings 368 may not be aligned in sets or rows or columns. In certain embodiments, instead of openings 368, the permeable plate 334 is attached to the elbow 12.

FIG. 20 is a cross-sectional side view of an embodiment of the fluidization elbow 12 shown in FIG. 18. As described above, the elbow body 250 turns, as generally indicated by arrow 253, and converges from the elbow inlet 246 toward the elbow outlet 248. The elbow body 250 includes inner bend portion 256 and outer bend portion 258. The outer bend portion 258 includes the wall portion 260 that curves in a downstream direction, as generally indicated by arrow 253, from the elbow inlet 246 toward the elbow outlet 248 to help accelerate the flow of the solid feedstock. Turning of the elbow body 250 may range from approximately 45 to 90 degrees, 50 to 80 degrees, or 60 to 70 degrees. For example, the elbow body 250 may turn at least approximately 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90 degrees, or any angle therebetween. As illustrated, multiple gas nozzles 264 are disposed along the outer bend portion 258. The multiple gas nozzles 264 are coupled to the openings 368. Each illustrated gas nozzle 264 may represent a set of gas nozzles 264. Both the openings 368 and their respective gas nozzles 264 are oriented towards the elbow outlet 248. As a result, the gas nozzles 264 include injection axes 408 that generally converge toward the elbow outlet 248, e.g., outlet axis 249. For example, opening 410 and gas nozzle 412 are oriented at a greater angle than opening 414 and gas nozzle 416. Also, opening 414 and gas nozzle 416 are oriented at a greater angle than opening 418 and gas nozzle 420. Accordingly, the gas nozzles 264 are arranged to avoid low velocity zones in the flow of the solid feedstock.

As mentioned above, the gas nozzles 264 are configured to fluidize the solid feedstock to provide a uniform and homogenous flow as well as to converge and accelerate the flow towards the elbow outlet 248. As previously mentioned, the fluidized elbow 12 also includes at least one baffle 263 disposed in the elbow body 250 configured to guide the flow of solid feedstock around the turn in the elbow body 250. In certain embodiments, one or more baffles 263 may include gas nozzles 264 to assist in converging the flow towards the elbow outlet 248.

FIG. 21 is a cross-sectional top view of an embodiment of the fluidization elbow 12 shown in FIG. 18. FIG. 21 illustrates the convergence of side portions 348 and 350 and bottom side portion 346 towards the elbow outlet 248. Additionally, the openings 368, as illustrated by set 384, are oriented to allow their respective fuel nozzles 364 to converge the flow of the solid feedstock towards the elbow outlet 248, as generally indicated by arrows 430 directed toward outlet axis 249.

FIGS. 22 and 21 illustrate yet a further embodiment of the fluidization elbow 12. FIG. 22 is a perspective view of an embodiment of the fluidization elbow 12. The fluidization elbow 12 includes the elbow inlet 246, the elbow outlet 248 downstream from the elbow inlet 246, and the elbow body 250 disposed between the elbow inlet 246 and the elbow outlet 248. Generally, the elbow inlet 246 includes a cylindrical shape and the elbow body 250 includes a conical shape. In certain embodiments, the position of the elbow inlet 246 may vary along the length 358 of the elbow body 250. As illustrated, the elbow inlet 246 is disposed near the backside portion 360 of the elbow body 250. In other embodiments, the elbow inlet 246 may be more centrally disposed between the backside portion 360 of the elbow body 250 and the elbow outlet 248. The length 358 of the elbow body 250 is configured to avoid low velocity zones while also providing a smooth transition for the solid feedstock. The elbow inlet 246 includes the annular opening 342 for receiving the solid feedstock from the solid feed pump 10. As illustrated, the elbow body 250 converges from the elbow inlet 246 toward the elbow outlet 248 in a downstream direction, generally indicated by arrow 486 to accelerate the flow of the solid feedstock from the elbow inlet 246 towards the elbow outlet 248. In particular, the elbow body 250 includes an annular wall 480 (e.g., conical wall) that converges from the backside portion 360 towards the elbow outlet 248. The elbow outlet 248 extends from the elbow body 250 and is configured to couple with the conveyance system 244, e.g., a pipeline.

A diameter 482 of the elbow body 250 decreases from the backside portion 360 towards the elbow outlet 248. The backside portion 360 of the elbow body 250 has an elliptical shape (e.g., circular shape). The backside portion 360 of the elbow body 250 includes openings 368 for multiple gas nozzles 264 disposed proximate to a circumference 484 of the backside portion 360. As illustrated, the openings 368 are equally spaced in an annular arrangement. As illustrated, the backside portion includes 8 total openings 368 for 8 fuel nozzles 264. However, in other embodiments, the number of openings 368 and the arrangement of the openings 368 may vary. For example, the number of openings 368 may range from 1 to 100, 5 to 50, or 10 to 20. Also, the openings 368 may not be disposed proximate to the circumference 484 of the backside portion 360, but nearer to the center of the backside portion 360. Further, the openings 368 may not be equally spaced or arranged in an annular arrangement. In certain embodiments, instead of openings 368, the permeable plate 334 is attached to the elbow 12.

FIG. 23 is a cross-sectional side view of an embodiment of the fluidization elbow 12 shown in FIG. 22. As illustrated, multiple gas nozzles 264 are disposed on the backside portion 360. The multiple gas nozzles 264 are coupled to the openings 368. In certain embodiments, a portion of or the entire backside portion 360 of the elbow body may include nozzle assembly 296 as described above. Both the openings 368 and their respective gas nozzles 264 are oriented towards the elbow outlet 248. As a result, the gas nozzles 264 include injection axes 408 that generally converge toward the elbow outlet 248, e.g., outlet axis 249. For example, opening 488 and gas nozzle 490 are oriented at a greater angle than opening 492 and gas nozzle 494. The gas nozzles 264 are arranged to avoid low velocity zones in the flow of the solid feedstock.

As mentioned above, the gas nozzles 264 are configured to fluidize the solid feedstock to provide a uniform and homogenous flow as well as to converge the flow towards the elbow outlet 248. As illustrated, a cross-sectional area 496 of the elbow body 250 decreases from the backside portion 360 towards the elbow outlet 248. As previously mentioned, the fluidized elbow 12 also includes at least one baffle 263 disposed in the elbow body 250 configured to guide the flow of solid feedstock within the elbow body 250. In certain embodiments, one or more baffles 263 may include gas nozzles 264 to assist in converging the flow towards the elbow outlet 248. As illustrated, the elbow outlet 248 is disposed at an angle 498 relative to an axis 500 extending from the bottom side portion 346 of the elbow body 250. In certain embodiments, the angle 498 may range from approximately 0 to 45, 10 to 30, or 15 to 25 degrees. For example, the angle 498 may be approximately 0, 5, 10, 15, 20, 25, 30, 35, 40, or 45 degrees, or any angle therebetween.

Technical effects of the disclosed embodiments include providing systems with fluidization elbows 12 configured to establish a substantially uniform and homogenous flow of gas and solid particles that is coming out from the solid feed pump 10 to the gasifier 106 via a high pressure conveyance system, while avoiding pile ups of the solid particles in the fluidization elbow 12. The location of the fluidization elbow 12 below the outlet 202 of the solid feed pump 10 allows the solid particles to flow into the elbow 12 downward and to be promptly discharged. However, the location of the fluidization elbow 12 does not need to be located below the outlet of the solid feed pump 10. The convergence of the elbow body 250 from the elbow inlet 246 to the elbow outlet 248 accelerates the flow of the solid particles and reduces the residence time in the elbow 12 to less than approximately 1 second. In addition, the location of the fluidization elbow 12 allows the elbow 12 to include sufficient space for routing the solid particles from the solid feed pump 10 to the conveyance system 244. The design of the fluidization elbow 12 also allows for easy installation and maintenance as well as simple operability since the elbow 12 is independent of the solid feed pump 10.

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 language of the claims.