Utilization of Coal Fines : Fluidized bed Gasification 7th Coal Summit & Expo 5th & 6th September 2018, Hotel The Ashok, New Delhi Utilization of Coal Fines : Fluidized bed Gasification Dr. Dev Gupta 6th September 2018

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Existing solutions to Gasification based solutions 5oC VAM Chiller Thermic fluid-350 oC Large Boilers : 570 oC (Solid fuel) Indirect heating/cooling: Process/Power Next Solution for Industries: Based on Coal firing >800 oC Steel, Ceramic, Chemical Industries : Direct firing Existing fuels : FO/ NG/LDO

Coal Gasification based Energy Solutions Fuel shift for heating Application Coal Gasification and gas conditioning compression Methanol Generation (Automobile Fuel) Coal Synthesis gas (CO+H2) Input for Chemical/Fertilizer plants as feed By Gasification process coal can be converted to syngas, syngas is a starting molecule for fuel energy, SNG, Methanol & other liquid fuels

Fluidized Bed Combustion to Gasification Thermax CFBC Thermax's CFBC boiler is based on Babcock & Wilcox's unique internal re-circulation CFB boiler design and employs a patented two-stage particle separation system. Thermax AFBC With over 265 installations across the world, the boiler offers benefits like fuel flexibility, high efficiency, low emissions, and reduced capital and operating expenses. New Development MAIN FRAME : Fluidized bed Fluidized bed gasifier

Thermax’s Fluidized Bed Gasification System Sensible heat recovery Coal Feeding System Dust Separation Clean gas to burners Fluidized Bed Gasifier Syngas Cooler Filter for heating applications Handles Wide Variety of Coal (Type and Size) Flyash Fineash coal size 0.5 -6 mm Completely DRY System All equipments are similar to FBC

Indo-EU collaboration:- Optimash 1.2 TPD coal firing <0.2 barg 5.0 TPD coal firing <5 barg Gasification Pilot Plant in TL’s Pune R&D Facility https://cordis.europa.eu/result/rcn/192397_en.html

Coal Tested at Facility:- PSD of coal fine Sieve Size (mm) Average size Cumulative % (-) 4.76 5 11.4 4 4.38 15.4 2.8 3.4 18.9 2 2.4 39.3 1 1.5 54.7 0.841 0.9205 59.2 0.595 0.718 64.5 0.21 0.4025 91.4 0.105 0.1575 95.9 0.074 0.0895 97.4 <0.074 0.037 100.0 Sieve Size (mm) Average size Cumulative % (-) 2 1.04 1 1.5 76.6 0.841 0.9205 82.9 0.595 0.718 88.3 0.5 0.5475 93.5 0.3 0.4 97.0 0.21 0.255 97.5 0.105 0.1575 98.4 0.074 0.0895 100 Sieve Size (mm) Average size Cumulative % (-) 2.8 8 2 2.4 43 1 1.5 80 0.841 0.921 85 0.595 0.718 89 0.5 0.548 94 0.3 0.4 100 RAW sample -South African (RB1) coal sieve analysis of < 5 mm coal Crushed Indonesian coal Crushed Indian coal 30% Ash

Gasifier output Commercial offering: (Single Train of gasifier) Parameter Unit Air based Enrich ed O2 CO Vol.% 18.74 16.0 H2 16.78 28.1 CH4 1.0 3.2 CO2 8.038 24.5 N2 48.49 26.6 Temp # * oC 900-950 850 CV (wet basis) Kcal/Nm3 1173 1650 Commercial offering: (Single Train of gasifier) upto 72 TPD coal firing unit equiv. ~30000 sm3/day of NG Facility to check Performance of desired coal at TL’s pilot plant (Pune)

Case study: Fines issue in DRI Kiln (Reduction Process) Size : 3 to 20 mm Fraction of Input Coal from material feed : 60 % Design Scenario Size : 0 to 3 mm Fraction of Input : 30 % Size : 3 to 20 mm Fraction : 10 % Current Scenario Size : 0 to 3 mm Fraction : 40 % Air per ton of iron ore : 1900 to 2000 Nm3/hr Air per ton of coal : 3000 to 3500 Nm3/ton of coal Primary Air : 33 % of total air Secondary Air : 66 % of total air 14to16 % of char generated, 65 % of char is of -3 mm Daily coal consumption : 0.9 TPD per TPD of sponge Coal with higher Fixed Carbon Coal Available : SA RB1 and Indian coal ( as per availability)

DRI Kiln: Mechanism

Ideal/ Theoretical Case C/Fe =0.32 Iron Ore = 155 TPD Coal = 64 TPD Fe = 100 TPD O GJ/ tDRI Energy : 16 GJ/ t DRI FC 50% VM 30% 6000 kcal/kg Rs 8 / kg Char = 0 TPD C = 32 TPD MORE DETAILS Actual Case C/Fe = 0.48 Iron Ore = 155 TPD Fe = 100 TPD Heat loss : 2.3 GJ/ t DRI Energy : 23.6 GJ/ t DRI FC 50% VM 30% 6000 kcal/kg Char = 15 TPD 5.5 GJ/ t 25 % loss of input Coal = 95 TPD C = 45 TPD For 100 TPD case, The unburnt char present in DRI output is ~15%. Hence 15 TPD char equivalent to 5.5 GJ/t DRI Steel energy is lost in the kiln. This is a major cause of inefficiency This amounts to 25% energy input

Better Scenario with syngas firing CO2 + H2O Coal + Syngas (50%) (50%) 1-3mm 0-1 mm Rich in CO and H2 Hot gas injection C Reduced Air firing Rotary kiln also acts as a gasifier as it produces CO to promote reducing reactions. As observed earlier, fines present in coal leads to equipment inefficiency as a gasifier system. If syngas rich in CO and H2 is produced outside the kiln, the fines can be effectively utilized in gasifier and better control on the process as reactants are gaseous phase The syngas will provide reducing environment in the kiln (higher partial pressure of CO and H2), hence enhances the reduction rate of iron ore. Target:- The payback period (scale + large scale multiplications) will be certainly Less than TWO YEARS!

Thank you for attention For further queries: devkumar.gupta@thermaxglobal.com