Control instrument and a control system for the gas generator

The invention disclosed herein relates to gas generators, and more particularly to a gas generator sensor and control device.

IGCC plants are able to generate energy from various coal feedstocks, such as coal or natural gas, relatively cleanly and efficiently. IGCC technology can transform coal raw material into a gas mixture of carbon monoxide (CO) and hydrogen (H2), i.e. synthesis gas, by reacting with oxygen and water vapor in a gas generator. The reactions in the gas generator can produce a by-product called slag. The slag usually goes down the inner wall of the gas generator and eventually leaves the gas generator. Sometimes the slag may not come out of the gas generator and may instead accumulate in the throat of the gas generator. In order to determine if the slag is blocking a throat on the gas generator, the operator may need to shut down the gas generator, remove the delivery injector, and manually inspect the inside of the gas generator. Unfortunately, the manual check results in a costly shutdown period for the gas generator and is somewhat subjective as it is based on the experience of the operator.

Some embodiments commensurate with the originally claimed invention are set out below. These embodiments are not intended to limit the scope of the invention as claimed, but only to provide a brief summary of the possible embodiments of the invention. Indeed, the invention may embrace various forms that may be similar to or different from the embodiments shown below.

In a first embodiment, the system comprises a gas generator including a chamber wall, an inlet, an outlet and a port, a combined delivery injector connected to the inlet, the combined delivery injector configured to inject first fuel and air into the chamber to heat the gas generator, and the combined delivery injector is configured to inject the second fuel and oxygen into the gas generator when heated, to gasify the second fuel, and an optical sensor coupled to the port, and a control system coupled to the optical sensor, the control system configured to acquire data from the optical sensor, process the data, and provide an output signal representative of the state of the gas generator based on the data.

In a second embodiment, the system includes a gas generator control device configured to acquire image data from an optical sensor directed to the gas generator chamber, process the image data, and provide an output signal representative of the state of the gas generator based on the image data, and a gas generator controller responsive to the output from the gas generator. control gas generator, wherein the gas generator controller is configured to adjust at least one of the flow of fuel or oxygen or the flow of air to the gas generator in response to the output.

In a third embodiment, the method includes acquiring an image of a gas generator chamber and spatially analyzing the image with respect to a baseline to identify wear or slag condition within the chamber.

These and other features, aspects, and advantages of the present invention will become better understood upon reading the following detailed description with reference to the accompanying drawings, in which like symbols represent like parts in the drawings.

The subject of the invention in its exemplary embodiments is shown in the drawing, in which:

Fig. 1 shows a block diagram of an embodiment of an IGCC power plant that may use an internal control and control system for a gas generator;

Fig. 2 shows a cross-sectional view of an embodiment of a gas generator with a system for internally controlling and controlling the gas generator;

Fig. 3 is a flowchart illustrating an embodiment of an internal process for controlling and controlling a gas generator during transition from reheat mode to gasification mode;

Fig. 4 is a flowchart illustrating an embodiment of a process for internally controlling and controlling a gas generator based on the image data analyzed to identify one or more conditions within the gas generator;

Fig. 5 shows an exemplary view of an embodiment of image data representative of the interior of a gas generator;

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Fig. 6 shows an exemplary view of processed image data representative of the interior of a gas generator;

Fig. 7 is a cross-sectional view of an embodiment of an optical device for internally monitoring the gas generator while the gas generator is operating; and

Fig. 8 shows a cross-sectional view of an embodiment of an optical device for internal control of the gas generator during the off period of the gas generator.

One or more specific embodiments of the present invention will be described below. In order to provide a concise description of these embodiments, all features of the actual implementation may not be found in the description. It should be noted that in the development of any such actual implementation, as in any technical or structural project, many implementation decisions must be made to achieve the contractors' specific objectives, such as compliance with system and business constraints, which may differ. between different realizations. Moreover, it should be noted that such a development effort may be complex and time consuming, but will nevertheless be a design, manufacturing and manufacturing procedure for those skilled in the art that will benefit from this disclosure.

When introducing elements of various embodiments of the present invention, the purpose of the terms "certain", "given", "said" is to indicate that there are one or more elements. The terms "comprising", "including" and "having" are intended to include and mean that there may be additional elements other than the listed elements.

The present invention relates to the internal monitoring and control of a gas generator using an optical device mounted to the gas generator separate from the location of the inlet or the delivery injector. For example, the optical device may receive image data of the interior of a gas generator, e.g., an inlet or outlet portion. The image data may include UV data, IR data, visible spectrum data, etc. The inspection device and controller may then analyze the image to evaluate the internal condition of the gas generator. For example, the system may determine, by interpreting the image data from the optical device, whether slag deposition or refractory wear is occurring in the gas generator. The system may also determine other internal states in the gas generator. In addition, the system can control the gasification process based on an analysis of the image data. For example, the system may use the image data to facilitate the transition from reheat mode to gasification mode. In some embodiments, an optical device may be mounted on the wall of the gas generator while the gas generator is in operation to allow for constant control and control of the gas generator. In other embodiments, an optical device may be removably positioned in a wall port of the gas generator such that the optical device is only used when image data is desired for gas generator analysis, e.g., during a shutdown period. In any configuration, the optical device allows the system to provide an objective and reproducible standard for analyzing the internal states of a gas generator without relying solely on operator experience and manual testing.

1 is a schematic diagram of an embodiment of an integrated gasification combined cycle (IGCC) fuel gasification system 100 that may include an internal control system and a control system for a gas generator. As shown in Figure 1, the IGCC system 100 is configured to gasify a feed or fuel source 102, drive steam and gas turbines, and generate electricity. The fuel source 102 can include various carbon fuels, such as coal or hydrocarbons, in solid or liquid form. The feed preparation unit 104 may be provided to prepare the fuel for gasification, e.g., by grinding, pulverizing, and pulverizing the solid form of the fuel source 102. However, the feed preparation unit 104 may be omitted if the fuel source 102 is in a liquid form.

The feed may be transferred to the gas generator 106 from the feed preparation unit 104. The gas generator 106 can convert the feed to syngas, e.g., a combination of carbon monoxide (CO) and hydrogen. This resulting gas can be called crude synthesis gas because it contains, for example, H 2 S. The gas generator 106 may also produce a by-product material, such as slag 108, which may be wet ash material. The gas purifier 110 may be used to purify crude syngas. The gas purifier 110 can purify crude synthesis gas to remove HCl, HF,

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COS, HCN and H.₂S from crude syngas, which may include sulfur separation 111 in a sulfur processor 112. In addition, the gas purifier 110 can separate the salts 113 from the crude synthesis gas via a water purification unit 114, which can use water purification techniques to produce useful salts 113 from the crude synthesis gas. Further, the gas from the gas purifier 110 may include purified syngas (e.g. sulfur 111 has been removed from the synthesis gas), with traces of other chemicals, e.g. NH3 (ammonia) and CH4 (methane).

In some embodiments, the carbon capture system 116 can remove and process carbon gas (e.g., carbon dioxide that is about 80-100 or 90-100 volume percent pure) contained in the synthesis gas. Carbon capture system 116 may also include a compressor, a purifier, a conduit that provides CO2 for sequestration or enhancement of crude oil production, a CO2 storage tank, or any combination of these components. The purified syngas, which has been subjected to the removal of its components containing sulfur and a large proportion of carbon dioxide, can then be transported as a combustible fuel to a combustion chamber 120, e.g., a gas turbine engine 118.

The IGCC 100 may further include an air separation unit (ASU) 122. The ASU 122 may be operated to separate air into its constituent gases, such as by distillation techniques. The ASU 122 can separate oxygen from the air supplied to it from the auxiliary air compressor and the ASU 122 can transfer the separated oxygen to the gas generator 106. In addition, the ASU 122 can transfer separated nitrogen to a nitrogen diluent compressor (DGAN) 124.

The DGAN compressor 124 can compress the nitrogen received from the ASU 122 to at least pressure levels equal to those in the combustion chamber 120, so as not to interfere with proper combustion of the synthesis gas. Thus, when the DGAN compressor 124 properly springs the nitrogen to the appropriate level, then the DGAN compressor can transfer pressurized nitrogen to the combustion chamber 120 of the gas turbine engine 118. Nitrogen can be used as a diluent, for example to help control emissions.

As previously described, the pressurized nitrogen may be transferred from the DGAN compressor 124 to the combustion chamber 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, and a combustion chamber 120. The combustion chamber 120 may receive fuel, such as syngas, that may be injected under pressure from the fuel nozzles. This fuel may be mixed with compressed air as well as compressed nitrogen from a DGAN 124 compressor, and combusted in a combustion chamber 120. This combustion can produce hot exhaust gas at an increased pressure.

The combustion chamber 120 may direct the exhaust gas towards the exhaust gas outlet of the turbine 130. As exhaust gases from the combustion chamber 120 flow through the turbine 130, the exhaust gases force the turbine blades in the turbine 130 to rotate a drive shaft 131 along the axis of the engine 118 of the gas turbine. A drive shaft 131 can connect a turbine 130 to a compressor 132 to form a rotor. The compressor 132 may include blades coupled to the drive shaft 131. Thus, rotation of the turbine blades in the turbine 130 can cause the drive shaft 131 connecting the turbine 130 to the compressor 132 to rotate the blades in the compressor 132. This rotation of the blades in the compressor 132 causes the compressor 132 to compress the air received via the air inlet of the compressor 132 Compressed air may then be supplied to the combustion chamber 120 and mixed with fuel and compressed nitrogen to enable combustion with greater efficiency. The drive shaft 131 may also be connected to a load 134, which may be a stationary load, such as, for example, an electric generator for generating electricity in a power plant. In fact, load 134 may be any suitable device that is powered by the rotary output of the gas turbine engine 118.

The IGCC system 100 may also include a steam turbine engine 136 and a heat recovery steam generation (HRSG) system 138. The steam turbine engine 136 may drive the second load 140. The second load 140 may also be an electric generator to generate electrical power. However, both the first load 134 and the second load 140 may be different types of loads that can be driven by the gas turbine engine 118 and the steam turbine engine 136. Moreover, while the gas turbine engine 118 and the steam turbine engine 136 may drive separate loads 134 and 140 as shown in the illustrated embodiment, the gas turbine engine 118 and the steam turbine engine 136 may also be used in a tandem arrangement to drive a single load via single shaft. Specific configuration

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 system 100 may also include an HRSG system 138. The warm exhaust gas from the gas turbine engine 118 may be transported to the HRSG 138 system and used to heat water and generate steam used to power the steam turbine engine 136. For example, the outlet from the low pressure section of the steam turbine engine 136 may be directed to a condenser 142. The condenser 142 may use a cooling tower 128 to convert heated water to chilled water. The cooling tower 128 functions to supply cool water to the condenser 142 to assist in condensing the steam transferred to the condenser 142 from the steam turbine engine 136. Condensate from condenser 142 may, in turn, be directed to HRSG 138. Again, exhaust from gas turbine engine 118 may also be directed to HRSG 138 to heat water from condenser 142 and generate steam.

In combination cycle systems such as the IGCC 100 system, the hot exhaust gas may flow from the gas turbine engine 118 and flow to the HRSG 138 system where it can be used to generate high temperature and high pressure steam. The steam generated by the HRSG 138 may then be passed through the steam turbine engine 136 to generate power. In addition, the generated steam may also be supplied to any other process in which the steam may be utilized, such as a gas generator 106. The power generation cycle of the gas turbine engine 118 is often referred to as a "high cycle" while the power generation cycle of the steam turbine engine 136 is usually referred to as "lower cycle". By combining the two cycles as illustrated in Fig. 1, IGCC 100 can lead to higher efficiencies on both cycles. In particular, the exhaust heat from the upper cycle may be captured and used to generate steam for use in the lower cycle.

Figure 2 is a cross-sectional view of a system 150 for the internal monitoring and control of a gas generator 152 according to an exemplary embodiment. System 150 may include a combination injector 154, optics 156, sensor 158, gas generator control 160, and gas generator controller 162. The combination feed injector 154 includes a heating burner and a process feed injector. The combined feed injector 154 uses a heating burner during the heating mode to raise the temperature in the gasifier 152 to a horizontal suitable for gasification. When the temperature is high enough, the combined feed injector 154 changes from a heating burner to a process feed injector that is used during the gasification mode of the gas generator 152. Thus, the combined feed injector 154 remains connected to the gas generator 152 during both the heat-up mode and the gasification mode. Unfortunately, manual control within gas generator 152 would require the removal of the combined feed injector 154, which results in the loss of the advantage of combining the heater burner and the process feed injector into a single unit 154. In the illustrated embodiment, the optical device 156 and sensor 158 cooperate to obtain image data of the interior of the gas generator 152 without removing the combined delivery injector 154. The sensor 158 may be a UV sensor, an IR sensor, a visible light sensor, etc., or a combination thereof. Data from sensor 158 can then be interpreted by the tester 160 to determine the operating conditions, slag deposition, refractory consumption, and other parameters of the gas generator 152. Based on the detected state of the gas generator 152, the tester 160 can send signals to the controller 162. which then controls the combined delivery injector 154. For example, the controller 162 can adjust the combined feed injector 154 to improve the heating mode, improve the gasification mode, reduce or prevent slag deposition, and so on.

Gas generator 152 defines first layer 164 and second layer 166. First layer 164 may be described as an outer layer or pressure-containing envelope of gas generator 152. Second layer 166 may be described as an inner layer or protective thermal liner. The second layer 166 is typically made of a fireproof material (e.g., ceramics). The second layer 166 defines an inner combustion chamber 168 to facilitate the gasification process. In addition, the first and second layers 164 and 166 together define an inlet 170, an outlet portion 172, a viewing or inspection through-hole 174, and a vaulted portion 176.

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Inlet 170 allows combination injector 154 to introduce fuel 178, fuel 180, air 181, and oxygen 182 into the combustion chamber 168. Inlet 170 may include a plurality of holes or a single hole depending on the exemplary embodiment. The fuel 178 may be the same as or different from fuel 180. In some embodiments, fuel 178 may be a clean combustion fuel (e.g., natural gas). This clean combustion fuel may be used by the preheating burner to raise the temperature in the chamber 168 prior to gasification operations or to maintain the temperature in the chamber 168 between gasification operations. During the gasification operation, inlet 170 may allow fuel 180 and oxygen 182 to enter chamber 168. For example, fuel 180 may be a carbonaceous feed, such as coal.

Outlet portion 172 allows synthesis gas and other byproducts, such as slag 108, to exit the gas generator reaction chamber 168. Outlet portion 172 may define a cone-shaped portion 184 and a throat 186. Gasification of fuel 180 can produce slag 108 within the combustion chamber 168. Normally, the slag 108 will either stick to the refractory wall 188 or slide down the wall 188 and exit the constriction 186. Slag exiting throat 186 may be cooled in a gas generator cooling chamber that is below exit 172 but not shown in Fig. 2, and then collected by a snap hopper, also not shown, for periodic discharge from the gas generator. Unfortunately, certain conditions in the gas generator 152 can cause slag to accumulate in the throat 186 due to insufficient slag flow. Ultimately, if the operating conditions of the gas generator 152 remain unchanged, the slag may significantly or completely obstruct the restriction 186. If the restriction 186 cannot be slagged while the gas generator is hot, then a mechanical tool may be required to open the restriction 186. The use of mechanical tools may require the gas generator 152 to be cooled to ambient temperature after which a mechanical drill or the like is then used to remove slag from the throat 186. Removing the slag with mechanical tools can be very costly in terms of wasted time and production.

To prevent such slag removal operations, the illustrated system 150 detects slag deposition and other gas generator conditions without removing the combined delivery injector 154. Through port 174 facilitates this by allowing visual inspection of gas generator chamber 168 without removing combined delivery injector 154. Through port 174. is of sufficient size to accommodate the optical device 156. Through-port 174 may be located on the arched portion 176 of gas generator 152 or elsewhere independent of inlet 170 and combined delivery injector 154. Placement of optics 156 on arched portion 176 can provide proper angle and view of gas generator outlet 172 . For example, optical device 156 may be capable of obtaining a field of view 175 of approximately 20-90 degrees. The optical device 156 transmits an optical view of the interior of the gas generator 152 to a sensor 158, which then converts the optical view into image data captured by the gas generator inspection device 160.

The optical device 156 may allow continuous observation of the combustion chamber 168 during both the heating mode and the gasification mode. This enables the sensor (s) 158 to detect conditions in the chamber 168 and throat 186, thereby allowing real-time control of the gas generator to improve operation and reduce undesirable conditions (e.g., slag deposition and refractory wear). In the illustrated embodiment, sensor 158 detects electromagnetic radiation. For example, sensor 158 may include devices that operate in the infrared, visible, and / or ultraviolet ranges of the electromagnetic spectrum. In addition, devices contained in sensor 158 may be cameras, pyrometers, or simple detectors.

Gas generator controller 160 receives image data from sensor 158 using data acquisition circuit or logic 190. Data acquisition circuit / logic 190 forwards this information to data processing circuit / logic 192 for data processing. After the data has been processed, it may then be sent to the graphic display circuit / logic 194 to be viewed on the display 196 and interpreted by a technician. The technician, after interpreting the data, can then determine whether to change the conditions in the gas generator using the user input 198. If the technician determines that a change is necessary due to the conditions in the gas generator 152, then to

User input may be provided to the gas generator controller 162. In some embodiments, gas generator controller 160 may provide the acquired, processed image data to controller 162, which may automatically control the operation of gas generator 152 with or without user input. The change may include adjusting heating control 200, air control 201, oxygen control 202, first fuel control 204, and / or second fuel control 206. For example, if the image data indicates slag deposition or refractory wear, then controller 162 may use heat control 200 to adjust the heat mode in gas generator 152, air control 201 to control air flow 181, oxygen control 202 to control oxygen flow 182. , a first fuel control 204 for controlling the fuel flow 178 and / or a second fuel control 206 for controlling the fuel flow 180. Various adjustments may change the fuel-oxygen or fuel-air ratio, combustion temperature (in the case of a preheat mode), gasification temperature, gasification by-products, and other parameters that may increase or decrease slag deposition and refractory wear. Thus, in response to inspected image data representative of the internal conditions in gas generator 152, controller 162 can quickly respond to undesirable conditions and provide corrective actions without any shutdown period of gas generator 152.

Figure 3 is a flowchart illustrating an embodiment of a process 210 for internally monitoring and controlling a gas generator 152 during transition from heat-up mode to gasification mode using the system 150 of Figure 2. Process 210 may begin with a combined feed injector 154 operating step to heat the generator. gas 152 (block 212). As noted above, a natural gas flame may be used to heat the gas generator 152 so that normal gasification fuel may be burned immediately upon entering the combustion chamber 168. Then, the sensor (s) 158 (e.g., the IR sensor) may then begin acquiring infrared image data within the gas generator 152 during the heating mode (block 214). The infrared image data can then be analyzed to identify one or more conditions within the gas generator during the heat-up mode (block 216). For example, an infrared image may indicate the temperature distribution, refractory wall condition, constriction condition, and average temperature in the gas generator 152. The next step includes controlling operation of the gas generator 152 in response to the identified conditions (block 218). For example, if the infrared image data indicates that the refractory has not reached the appropriate temperature, then the holding burner will remain on until a sufficient temperature is reached. Alternatively, the UV sensor data may indicate that there is no flame from the preheating burner. In this case, the controller 218 may restart the holding burner or sound an alarm to alert the technician. During the heating operation, steps 214, 216, and 218 may be repeated to continuously monitor and control the heating operation.

When the temperature is high enough for the normal operation of the gas generator, process 210 transfers to combined feed injector 154 operation to transition from heat-up mode to gasification mode (block 220). For example, transition 220 may switch from air 181 and heating fuel 178 (e.g., natural gas) to oxygen 182 and normal gasification fuel 180 (e.g., coal) or other carbonaceous feedstocks. As noted, the fuel 178 used in the preheat mode is not gasified, while the fuel 180 used in the gasification mode undergoes gasification reactions to produce syngas. After transit, process 210 acquires sensor / image data within gas generator 152 while in gasification mode (block 222). The sensor / image data can then be analyzed to identify conditions within the gas generator 152 during the gasification mode (block 224). For example, the intensity or color of light in different areas of an image may indicate higher or lower temperatures in those areas. This in turn may indicate refractory wear, slag deposition, or normal conditions. In some embodiments, image data may be compared with baseline image data to aid in detecting undesirable conditions. In a further example, the sensor / image data can be analyzed to determine if the gasification response is optimal or if the conditions are less than optimal. The sensor / image data may represent the temperature distribution which may indicate fuel / oxygen mixing, reaction completeness, and so on. Based on this sensor / image data, gas generator 152 may be controlled in response to the identified state (block 226). For example, the amount of fuel / air or fuel / oxygen may be

Increased or decreased to correct or adjust the condition. These adjustments can reduce or prevent slag deposition, refractory wear, or other undesirable conditions. These adjustments can also improve the efficiency of the gasification reaction to increase synthesis gas production or optimize the synthesis gas composition. It should be understood that steps 222, 224, and 226 of the gasification mode may be repeated to continuously monitor and steer the gasification operations.

Figure 4 is a flowchart illustrating an embodiment of a process 240 for internally monitoring and controlling a gas generator 152 based on image data analyzed to identify one or more conditions within gas generator 152. The process 240 includes obtaining image data of chamber 168 (e.g. throat) of the gas generator 152 (block 242). For example, the process 240 can obtain image data of the chamber 168 of the gas generator 152 to obtain a baseline. The reference image data may represent a new or refurbished state of gas generator 152. Process 240 may also obtain cavity image data 168 after or while gas generator 152 is operating. For example, process 240 may continuously inspect the interior cavity 168 of gas generator 152 during the heat-up mode and gasification mode. . Process 240 then spatially analyzes the image data relative to a baseline to determine changes to gas generator 152, e.g., throat 186 (block 244). For example, a comparison 244 of the spatial analysis between the baseline and the current image data may indicate refractory wear, slag deposition, or other geometry changes within the chamber 168 of the gas generator 152. Specifically, spatial analysis comparison 244 may indicate refractory wear or slag deposition in the throat 186. Process 240 then controls the operation of the gas generator 152 in response to the wear or slag condition identified by the spatial analysis comparison (block 246). For example, control 246 of the gas generator can adjust air flow, oxygen flow, fuel flow, fuel / air ratio, fuel / oxygen ratio, steam flow, or other operating parameters to reduce or eliminate the identified condition. In particular, gas generator control 246 can reduce or limit slag deposition by lowering the temperature of the gas generator by reducing the heat input from the heater burner or reducing the oxygen concentration by lowering the air / fuel or oxygen / fuel ratio for the heater burner. As discussed above, steps 242, 244, and 246 may be repeated to continuously monitor and steer gasification operations.

Figure 5 shows an exemplary view of a visual image (e.g., image 250) that corresponds to the interior cavity 168 of the gas generator 152, as viewed from the optical device 156 and sensor 158, i.e., image 250 represents the field of view of the optical device 156 and sensor 158. In the illustrated embodiment, image 250 represents the four areas 252, 254, 256, and 258 of inner chamber 168. Area 252 corresponds to part of the wall 188 of the gas generator, area 254 corresponds to the cone-shaped bottom 184, area 256 corresponds to the area of ​​the cone-shaped bottom 184 closest to the throat 186 of the gas generator, and area 258 corresponds to the throat 186 of the gas generator and the portions of the outlet 172 of the gas generator that are visible by the constriction 186 of the gas generator from the viewpoint of the optical device 156. The different shading of the regions illustrates the temperature difference. For example, area 252 and most of area 254 will have lighter shading due to the higher temperatures at wall 188 and the bottom 184 of the cone-shaped gas generator 152. Area 258 will have a much lower temperature than areas 252 and 254 because area 258 corresponds to the materials. below the throat 186 which are not directly heated by the gasification reactions and as a result have much darker shading. Area 256 has correspondingly intermediate shading as it is a combination of two different thermal regions (i.e., the high temperatures of the gas generator chamber 168 and the lower temperatures of the cooling chamber below gas generator 152). The boundary between regions 256 and 258 generally defines the constriction 186.

Figure 6 is an exemplary view of processed image data (e.g., processed image 260) after image 250 of Figure 5 has been processed by the data processing circuit / logic 192 in the gas generator controller 160 of Figure 2. As seen in Figure 6, the image 260 includes the same areas 252, 254, 256, and 258 of Figure 5, but image 260 is in digital form such that each individual pixel of digital image 260 is a small, corresponding portion of image 250. The wavelength (or color) and intensity of the incident radiation associated with each pixel can be transformed by the data processing circuit / logic 192 into

A map of the spatial temperature distribution of the chamber 168 corresponding to image 250. As mentioned above, the inspection device 160 may acquire a baseline image 260 of a new or renewed state of the gas generator 152, and then obtain real-time operating images 260 of the gas generator 152 to evaluating any changes to chamber 168 during operation. For example, the inspection apparatus 160 is able to spatially analyze the baseline and operating images 260 and determine whether the diameter of the throat 186 has increased in size or decreased. For example, when the refractories are consumed, the diameter of the throat 186 will increase in size. This increase in the size of the throat 186 will lead to an increase in the size of the temperature region 258 and a decrease in the size of the temperature region 254. Conversely, in the event that slag begins to clog the constriction 186, the size of the temperature region 258 will decrease and the size of the temperature region 256 will increase. As the inspection device 160 compares the baseline and operating images 260 and identifies spatial differences that indicate wear or slag deposition, the controller 162 can automatically adjust the operating parameters of the gas generator 152 to reduce, remove, or prevent the identified condition. The controller 162 also may generate alarms (e.g., audio, visual, or both) to alert the technician of the identified condition, and may allow the technician to select appropriate countermeasures. While only four regions are illustrated in the present embodiment, it will be understood that additional embodiments may include more or less than four temperature regions that may be used in determining the status of gas generator 152.

Figure 7 is a cross-sectional view of an embodiment of an optical device 156 for internally monitoring a gas generator 152 while a gas generator 152 is operating. An optical device 156 may be mounted on a gas generator 152 through a port 174. This allows a sensor 158 (e.g., a visual camera, a UV camera, an IR camera, etc.) examine the chamber 168 of the gas generator 152 through the optical device 156. The optical device 156 may include a portion 270 in the form of an optical tube, a cooling / mounting system 272, a pressurized housing / security system 274, and a beam splitter portion 276.

The optical tube portion 270 defines a hollow body 277, an aperture tip 278, and transfer lenses 280. The transfer lenses 280 fit within the hollow body 277 of the optical tube portion 270 and convey images of the gas generator 152 through the optical tube portion 270 to the portion. 276 in the form of a beam splitter. Although nine transfer lenses are shown in this embodiment, other embodiments may include more or fewer than the nine transfer lenses shown in Figure 7. Likewise, the shapes and orientations of the transfer lenses shown are illustrative, and other embodiments may include lenses of different nature. shapes and orientations as well as optical fiber elements.

The beam splitter portion 276 includes a housing 282 and beam splitters 284. Beam splitters 284 are held in place in housing 276 at an angle with respect to axis 283. Beam splitters 284 form multiple images of gas generator chamber 186 152, allowing multiple sensors 158 to receive images of gas generator 152. For example, beam splitters 284 may send images to a sensor. IR, UV sensor and / or visible light sensor. While two beam splitters are depicted in the present embodiment, other embodiments may include more or less than two beam splitters (e.g., 1 to 10).

A cooling / mounting system 272 is provided to protect the optical device from the internal temperatures and pressures of gas generator 152. The cooling / mounting system 272 includes a cooling jacket 286 that surrounds an optical tube portion 270 and a mounting portion 288. The cooling jacket defines a cooling path 290. and an exit path 292. A cooling path 290 directs a coolant 291 (e.g. water, coolant, etc.) around the optical tube portion 270 to the end portion 294 of the cooling jacket 286. The end portion 294 of the cooling jacket 286 changes the cooling path 290 into the output path 292. The attachment portion 288 defines a coolant inlet 296 and a coolant outlet 298 This allows the coolant to enter and exit cooling jacket 286. Coolant inlet 296 and outlet 298 may be connected to tanks that supply coolant and which collect coolant upon exiting cooling jacket 286. The coolant may also be cooled by a cooling system such as a cooling tower, cooling loop, or heat exchanger.

The attachment portion 288 may also define a gas input 300 that allows the shielding gas 301 to enter the optical tube portion 270. This gas input 300 may allow gas

With protective (e.g., nitrogen) entry into the optical tube portion 270 and flow in the hollow body 277 toward opening 278. Upon reaching opening 278, gas 301 exits optical tube portion 270 and enters gas generator 152. In this way, the shielding gas 301 ensures that the opening 278 remains free of ash, debris, slag etc. By keeping the opening 278 free from obstructions during and after gasification, the optical images can be transferred to the sensor (s) 158 without having to remove the optical device 156 for cleaning.

To attach the optical device 156 to the gas generator 152, the mounting portion 288 may include a mounting ring 302 that is perpendicular to the optical tube portion 270. The ring 302 may be annular in shape and wrap completely around the optical tube portion 270. The ring 302 is designed to fit between the gas generator nozzle flange 304 and the device blind flange 306. When flange 304 and flange 306, which may be conventional bolted flanges, are bolted together, optical device 156 may be attached to gas generator 152. In certain example embodiments, optical device 156 may be welded, bolted, or attached to a gas generator. 152 through through hole 174 in a sealed manner. In some embodiments, the fixation ring 302 may include protrusions 308 (e.g. annular) extending from the upper side 310 and lower side 312. These protrusions 308 can block lateral movement and seal the optical device 156 when attached to gas generator 152 using a flange 304 and a flange 306.

The pressurized containment / containment system 274 is configured to provide an optically transparent means for containing pressure within the gas generator 152 during the gasification operation and blocking the reactants from escaping from the gas generator 152 in the event of a failure of the pressurized enclosure. In the present embodiment, the safety system 274 includes a first sight glass 314, a second sight glass 316, a safety valve 318, and a pressurized gas chamber 320. The sight glasses 314 and 316 provide a dual sealing mechanism that allows the passage of optical images from the lenses 280 to the beam splitters 284. If one of the sight glasses 314 or 316 fails, then the safety system 274 is designed to close the safety valve 318. The system operates by detecting a loss of pressure gas under pressure in the chamber 320. If one or both of the sight glasses 314 or 316 fails, then pressurized gas in the chamber 320 may escape, resulting in a loss of pressure. Pressure losses can then be detected by the controller 162, which then closes the safety valve 318, preventing heat and gas generator reagents from escaping through the optical device 156. As noted, the optical device 156 in Figure 7 is configured to be mounted in the port 174 of the gas generator 152 during any stage of gas generator 152 operation. Likewise, it should be noted that not all the details needed to practice the optical device 156 are shown in Figure 7.

In still other embodiments, it may be advantageous to have a removable optical device. Figure 8 is a cross-sectional view of an embodiment of an optical device 156 that can be removably mounted to a gas generator 152. The removable optical device 156 of Figure 8 has many of the same features as the permanently mounted optical device 156 of Figure 7. For example, the illustrated optical device 156 may include an optical tube portion 270, a cooling / fastening system 272 surrounding the optical tube portion 270, and a beam splitter portion 276. Unlike the optical device 156 of Figure 7, the illustrated optical device 156 may not include the pressurized housing / containment system 274 or the use of a shielding gas to clear opening 278 of obstructions. For example, the illustrated optical device 156 may only be inserted while the preheating burner is in use and then removed when gasification is initiated. As described above, the holding burner may use a clean flame, such as a natural gas flame. When the optical device 156 is exposed to a pure flame, it may not be necessary to keep the opening 278 free from obstructions. In addition, no pressure containment / containment system may be needed as the optics 156 is removed before the higher pressure characteristics of the gasification operation become dominant.

The technical implications of the presented embodiments include the possibility of controlling the inside of the gasification chamber when using combined feed injectors, i.e. feed injectors that combine the functions of a preheating burner and a process feed injector in one unit. Combined injector as described above

The delivery device, or the like, prevents direct observation of the gas generator chamber, since the injector remains installed in the upper part of the gas generator. The illustrated embodiments allow the interior of the gas generator chamber to be visually inspected without the need to remove the combined delivery injector. As a result, the inner chamber can be inspected during gas generator operation to identify slag deposition, refractory material wear, and operating conditions inside the gas generator. In particular, the illustrated embodiments compare the baseline image with the working images of the interior of the gas generator chamber to identify spatial changes that indicate wear or slag deposition. The disclosed embodiments, in turn, can provide control functions responsive to the identified conditions based on the comparisons of the images. Thus, the illustrated embodiments increase the life of the gas generator, increase the efficiency of the gas generator, and reduce the shutdown time of the gas generator.

The present written description uses examples to illustrate the invention, including its best practice, and to enable any skilled person to make the invention, including making and using any devices or systems, and carrying out any associated methods. The patentable scope of the invention is defined by the claims and may include other examples that will be apparent to those skilled in the art. Other such examples are intended to fall within the scope of the claims as long as they have structural features that do not differ from the literal claim language, or if they contain equivalent features with negligible differences from the literal claim language.