COAL GASIFICATION PLANT
COAL GASIFICATION
Coal Gasification is the conversion by partial oxidation at
elevated temperature of coal into a combustible gas termed as
synthesis gas or syngas.
The syngas contains CO, CO2, H2, CH4 and traces of higher
hydrocarbons etc.
Gasification of coal provides a means of generating a wide
range of products, power, chemicals, substitute natural gas
(SNG) and transport fuels.
In JSP – we are using syngas for reducing iron ore in DRI
SALIENT FEATURES
COAL GASIFICATION PLANT
Number of gasifiers : 7 Nos
Feed stock : non coking coal of 34-36% ash
Technology : Lurgi, SA.
Coal requirement : 2.4 MTpa
Syn gas Capacity : 225,000 Nm3/h
The composition of Syn gas
CO : 32.206 mol%
H2 : 52.023 mol%
CO2 : 3.039 mol%
CH4 : 12.008 mol %
Calorific value : 3500-3700 kcal/Nm3
Application : Reducing agent in DRI & as a Fuel
COAL PROPERTIES – design basis
Coal Properties Proximate Analysis Coal Properties Elemental Analysis
Moisture 6.4 - 7.5 % Carbon 76 %
Hydrogen 5.3 %
Ash 34.3 – 35.8 %
Nitrogen 1.9 %
Volatile Matter 26.2 %
Sulphur 0.7 %
Fixed Carbon 31.8 % Oxygen 16 %
Ash Fusion Temperature:
Initial Deformation Temperature – 1500 – 1530 C
Hemispherical Temperature – 1590 C
Flowing Temperature – 1600+ C
CGP - OVERALL BLOCK DIAGRAM
U - 03
U - 04
U – 08
U – 09
U – 05
U – 06 U – 07
Gasification Unit – 03
Main feed
Coal
Gasification agent (HP superheated steam & HP Oxygen)
Main Process
Gasification
Heat recovery
• 07 trains (Bunker, gasifier, coal lock, ash lock, wash cooler, primary waste heat boiler,
CLS each)
• Automatic Batch wise coal feeding and Ash removal by Coal lock and Ash lock resp..,
• Hydraulic system for operation of valves in coal lock and ash lock
• Dust collection system for dust collection during coal feeding
• Coal lock gas compressor for recycle of coal lock gas during coal lock de-pressurisation
Gasification Unit
Lurgi gasification is a moderate
temperature and pressure process.
Coal is Gasified typically at a
pressure of 27.0 Bar in presence of
high pressure steam & pure
oxygen to produce syngas for
further purification & use.
GASIFICATION ZONES:
1. Drying & Preheating Zone: The wet screened coal is dried and heated
2. Carbonisation Zone: The volatiles contained in the coal are driven out.
3. Gasification Zone: The gas streaming upwards from the combustion zone consists mainly
of CO2 and H2O and reacts in the gasification zone at 850°C .
C + H2O = CO+ H2 - 118.5 kJ/mol (dominating)
C + 2 H2O = CO2 + 2H2 -77.3 kJ/mol
CO+ H2O = CO2 +H2 -41.2 kJ/mol
C+CO2= 2CO -160.5 kJ/mol
C+ 2H2= CH4 -87.45 kJ/mol
CO+ 3H2= CH4+ H2O +19.3 kJ/mol
4. Combustion Zone:
C + O2= CO2 + 405.5 kJ/mol (dominating)
C + 1/2O2= CO + 122.9 kJ/mol
5. Ash Bed: The agent is heated by the ash leaving the combustion zone at 1500°C. Here the
agent temperature is heated up to approximately 450°C by heat exchanging with ash and
by reducing the ash temperature.
Gasifier Parameters
TR1 Agent (HP steam + Oxygen mixture) temperature
TR2 Gasifier top flange temperature
TR3 Jacket temperature
TR4 Ash lock temperature
TR5 Gasifier outlet temperature
TR6 Wash cooler outlet temperature
SIC-1X01 Grate Speed
CO2, % CO2 in gas outlet
CO, % CO in gas outlet
Gasification Unit – 03
Operating Parameters
Temperature Control – by grate speed
Load control – by Oxygen flow
CO2 control – by Steam-Oxygen Ratio, to some extent
Raw gas Composition:
H2 – 39.155 %
CO – 24.478 %
CO2 – 25.876 %
CH4 – 9.494 %
H2S – 0.172 %
OHC – 0.4 %
Coal Bunker
Flare
Vent
Coal Feeder RG header to
unit-04
Coal lock gas to Injection GL
compressor
Coal
Raw gas from U-04 lock
RG
Jacket
steam WHB
KOD
HP BFW
WC LP
Downcomer
Gasifier
BFW
GL
HP Steam
Blow down
Agent
PV1 to ash lock
Gas liquor to Dusty
Ash PC-x01
Start-up air coolers
lock
Oxygen
Gas Cooling Unit – 04
Main feed
Raw gas from Unit-03
Main Process
Cooling & condensation
• 02 parallel trains of Sec waste heat Exchanger, Air fin cooler, Trim and Final cooler
• Raw gas coming from unit-03 cooled in three steps
• Cooled gas without tar & oil sent to Rectisol (unit-08)
• Condensed liquid sent to gas liquor separation (unit-05) for recovery of tar and Oil
• Heat recovered from raw gas by LP steam generation
Rectisol – 08
Main feed
Cooled Raw gas from unit-04
Main Process
Cooling
Absorption by methanol
Regeneration of methanol
• Methanol is used to absorb all impurities (CO2, H2S, COS, CS2, Naptha) from raw gas
• Refrigeration system (propylene compressor) for cooling Methanol & raw gas
• Removal of CO2, H2S from Methanol by regeneration
• H2S rich gas supply to Sulphur recovery unit-09
• Recovery of rectisol Naptha
Sulphur Recovery Unit-09
Main feed
H2S rich gas acid gas from Rectisol-08
Main Process
Oxy claus process & LTGT process
Incineration system
• Acid gas from Rectisol & enriched sour gas from LTGT section is thermally combusted in
oxy claus thermal reactor followed by catalytic conversion in reactors
• Acid gas from Rectisol is enriched by MDEA absorption
Gas Liquor Separation Unit – 05
Main feed
Dusty Gas liquor from Unit-03
Tarry Gas liquor from Unit-04
Oil Gas Liquor from Unit-04
Main Process
Expansion
Cooling
Gravity Separation
• By products Tar and Oil is separated by gravity, collected & stored in tanks
• Gas liquor (tar and oil removed) containing phenol & Ammonia sent to phenosolvan
(06)
Phenosolvan Unit – 06
Main feed
Gas liquor from Gas Liquor separation unit-05
Main Process
Extraction by DIPE
DIPE regeneration by Distillation
• Gas liquor from Unit-05 is filtered
• Phenol is extracted by DIPE in 05 series extractors
• Distillation of the extract (crude phenol + DIPE) for Regeneration of DIPE
• Vacuum Distillation of crude phenol to separate Phenol & Pitch
• De-phenolised gas liquor (Raffinate) is sent to ammonia recovery
Ammonia Recovery Unit – 07
Main feed
De-phenolised gas liquor from Phenosolvan-06
Main Process
Stripping
Ammonia absorption
• Acid gases are removed from the Dephenolised gas liquor.
• Ammonia is removed from gas liquor and the water is sent to ETP
• Residual Organics is separated from Gas Liquor and sent to Incinerator (unit-09)
• Ammonia recovered is sent to Ammonia Bullets in Tank Farm
By Products - Coal Gasification plant
Ammonia : 2.1 T/h
Elemental Sulphur : 0.8 T/h
Phenol : 0.83 T/h
Phenolic Pitch : 0.17 T/h
Gasification Oil : 5.9 T/h
Naptha : 3.3 T/h
Tar : 2.6 T/h
THANK YOU