In the IGCC system, HRB is one of the critical equipments which need further development. The design of HRB was not very successful in the early stages of IGCC development using entrained bed gasification process. The first IGCC Plant of 100MWe Cool Water Plant located in California adopted Texaco Gasification Process having radiant boiler followed by convection boiler. In view of the failure of radiant section this plant was operated in quench mode resulting in a lower overall efficiency. The syngas cooler is very prone to operation failure because of slagging due to the high temperature dirty gas service. Hence a need araised to develop the appropriate HRB taking into account dusty coal gas environment. Later designs of Texaco, Shell process and Noell have improved the HRB design by correcting the flow path geometry thus avoiding the ash deposits at the raw gas inlet. The paper highlights the intricacies in the design of HRB with a program developed to optimise the same for use in large utility IGCC plants. A novel approach for improving the gas side heat transfer coefficient while handling hot particulate laden raw gases in HRB of pressurised fluidised bed gasifier is presented and the results validated from available experimental plant.

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