1. 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

2. Thermax :Expertise in Energy & Environment Solutions
Hazardous Waste Treatment
Waste Water Treatment
Air Pollution Control
Waste Products
Raw Material
Desired Products
Utilities
Power
Heating
Cooling
Water
Chemicals

3. 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

4. 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

5. 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

6. 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 mm
Completely DRY System
All equipments are similar to FBC

7. 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

8. 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

9. 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
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)

10. 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)

11. DRI Kiln: Mechanism

12. 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

13. Better Scenario with syngas firing
CO2 + H2O
Coal Syngas
(50%) (50%)
1-3mm 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!

14. Thank you for attention
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