Syngas Characteristics

Synthesis gas from gasification or reforming contains water vapor, tar compounds, and hydrocarbon condensate. Cooling before compression condenses these components. Suction separators remove liquids preventing compressor damage and maintaining gas purity for downstream catalytic processes.

Separator Configuration

Vertical vessel with syngas inlet after cooling, liquid knockout section, coalescing stage removing aerosols and tar mist, gas outlet to compressor, liquid drain to treatment, and high-level shutdown protecting compressor. Design handles challenging contaminants specific to syngas service.

Operating Pressure

Matches compressor suction typically 20-50 psig for atmospheric gasifiers, 300-600 psig for pressurized systems. Design accommodates pressure variations during load changes. Materials handle syngas composition including H2, CO, CO2, and trace contaminants.

Liquid Contaminants

Water condenses from cooling. Tar compounds from incomplete gasification. Heavy hydrocarbons from reforming. Ammonia and sulfur compounds depending on feedstock. Separator internals resist fouling from sticky tar deposits.

Material Selection

Stainless steel construction handles corrosive syngas components. Tar-resistant coatings prevent buildup on internals. Design accommodates thermal cycling. Materials selected for H2S and NH3 tolerance where present in syngas composition.

Tar Management

Heated vessel walls prevent tar solidification. Flush connections enable periodic cleaning. Drain system handles viscous tar liquids. Some designs include steam purging capability. Regular maintenance removes accumulated deposits maintaining separation efficiency.

Applications

Coal or biomass gasification syngas compression, steam methane reformer outlet protection, partial oxidation syngas systems, waste gasification facilities, and any syngas process requiring compression. Critical for Fischer-Tropsch, methanol, and ammonia synthesis facilities.

Compressor Protection

High and high-high level switches provide alarm and shutdown. Fast-acting valves stop flow before liquid reaches compressor. Redundant instruments ensure safety. Protection saves multi-million dollar compression equipment from catastrophic failures.

Performance Factors

Temperature affects tar viscosity and water condensation. Gas velocity must prevent liquid re-entrainment. Proper retention time allows complete separation. Design balances efficiency against vessel size and cost.

Liquid Disposal

Contaminated water and tar route to wastewater treatment. Some facilities recover tar for fuel value. Drain system sized for maximum liquid rates during upsets. Proper disposal prevents environmental issues.

Construction Standards

Design per ASME Section VIII for operating pressure. Materials for corrosive syngas service. Heating systems per applicable codes. Complete documentation with separation calculations and tar handling procedures.

ERGIL syngas compressor suction separators protect compression equipment while maintaining gas quality in synthesis gas facilities.