Page 39 - Industrial Plants

Figure 7 - Details of feedwater inlet and steam outlet headers: 7a) Tampa operated syngas cooler
downstream coal gasification process (courtesy of J. Wilhelm, TecfinTRE-Engineering Excellence Library;
7b) Fores Mega Syngas cooler design downstream gas-fuelled CPO process

quantities exceed by far the scale-up limit of the existing The right partner to design and
syngas coolers and waste-heat boilers, which are execute a variety of industrial-scale
based on a fired-tube design.
In order to win the challenge, Fores has developed an applications on CPO technology:
in-depth engineering analysis on the largest syngas Fores Engineering
cooler ever built: designed to cool down 400,000
m3/h ”dirty syngas” from a Texaco coal gasifier in an As illustrated in the above projects, Fores has given
IGCC power plant (one of the earlier application a significant contribution to the development and
featured with CO capture and Hydrogen ready gas scale-up of CPO technology to industrial maturity.
2
Turbine). This “water tube” syngas cooler was During these projects, Fores has gathered a
successfully in operation for 12 years at Tampa significant engineering know-how, for the design of
Electric ‘zero emission’ hydrogen power station and turnkey supply of CPO based syngas production
confirmed the industrial maturity of the design. plants of all sizes. Three operating references over
For the natural gas-based mega-methanol project, Fores the entire range of capacities from 50 to 10,000
has developed a simplified design version with a capacity Nm3/h indicate that CPO technology is a viable
of 600,000 Nm 3/h, maintaining the “water tube” principle solution for synthesis gas production, ready to be
and the proven mechanical design elements of the integrated with downstream synthesis processes for
Tampa syngas cooler, and issuing a relevant patent the production of e-fuels and SAF. For small and
application for this enabling feature to such large scale up medium production capacities under 10,000 Nm3/h,
design. The most challenging part in developing Mega modularised preassembled and pre-commissioned
Syngas coolers is the design of the headers for feedwater CPO units represent by far the most cost effective
inlet and steam outlet (see Figure 7). solution.
Considering the entire capacity spectrum, the
“On the basis of engineering and performed engineering studies confirm an interesting
operating experience in three upscale potential to mega size units for large
CPO plants, in recent years Fores industrial applications, which offer economies of
Engineering has also explored the scale that may effectively contribute in the future to
scale-up potential of the CPO process produce synthetic “low to zero emission” fuels at
and its adaption to various client’s affordable prices.
downstream applications in several Along with technological maturity, where Fores is
engineering studies ready to provide its engineering know how and

INDUSTRIAL PLANTS - May 2024
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