Simulation of erosion wear and design optimization have been performed for a convective gas cooler with a helical coil. Based on the results of simulation of the standard gas cooler design with a flat baffle used in Shell gasification-based combined cycle unit, it is concluded that the particle impact angle is the main factor determining the erosion maximum. To reduce erosion, it is necessary to install a structural element instead of the flat baffle to align the flow path of ash particles at the inlet to the gas cooler. The results of simulation for various baffle shapes show that a hemispherical baffle is optimal. The use of a hemispherical baffle plate made it possible to align the ash particle flow path at the inlet to the gas cooler channels and reduce the maximum level of erosion by a factor of almost 4 compared to the standard geometry of the baffle plate.

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