The multi-nozzle opposed gasification technology is moving from stability to improvement”

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The Multi-Nozzle Opposed Gasification Technology: Moving from Stability to Improvement Author/Source: China Chemical Industry News Date: 2017-12-08 Clicks: 14 From November 16th to 17th, 2017, a conference on the application experience of multi-nozzle opposed gasification technology was held in Ningbo. More than 200 enterprise representatives and industry experts from across the country attended the conference. The attendees spoke highly of the technical advantages of the multi-nozzle opposed gasification technology, such as its high carbon conversion rate, scalability, and the long-term reliable operation of burners and refractory bricks. They praised the technology’s effectiveness in industrial applications. They also believed that Yankuang Group and East China University of Science and Technology’s extensive technical expertise and innovative service platforms will help enterprises further improve the economic efficiency, operational longevity, and environmental performance of their gasification facilities. 　 　　During the conference, Yankuang Group and East China University of Science and Technology presented the latest technological improvements and applications, while the various operating plants shared their experiences in the construction, operation, and management of such facilities, thereby promoting common progress and improvement in the operation and management of gasification units. This conference was hosted by Yankuang Group Co., Ltd. and East China University of Science and Technology, and organized by Shandong Yankuang Guotuo Technology Engineering Co., Ltd. and the Clean Coal Research Institute of East China University of Science and Technology. 　 　　Since the successful industrial implementation of the multi-nozzle opposed gasification technology in 2005, its owners, Yankuang Group and East China University of Science and Technology, have been holding meetings to share practical experience since 2007 in order to create a platform for technical exchange. A total of five main conferences and five smaller meetings were held, and 2017 marked the tenth edition of this technical exchange event. 　 　　 　 It has significant advantages and a large market share in China. According to statistics, among more than 20 coal gasification technologies available both domestically and internationally, the multi-nozzle opposed coal gasification technology holds a substantial market share. It is widely used in modern new coal chemical projects as well as in the upgrading of traditional coal chemical plants, representing the international leading level of current large-scale coal gasification technologies. The multi-nozzle gasification technology has successfully developed a series of gasifiers with daily coal processing capacities of 1,000 tons, 1,500 tons, 2,000 tons, 2,500 tons, and 3,000 tons. The pressure in these gasifiers ranges from 1.5 to 8.7 megapascals, allowing for optimized selection suitable for coal chemical plants of different scales. 　 　　Guo Baogui, Chairman and General Manager of Yankuang Water-Coal Slurry Gasification and Coal Chemicals **Engineering Research Center Co., Ltd. and Executive Chairman of Yankuang Guotuo, said: “To date, the multi-nozzle opposed water-coal slurry gasification technology has been licensed to 52 enterprises both domestically and internationally. A total of 144 gasifiers have been installed, with the largest of them capable of processing 3,000 tons of coal per day – making it the gasifier with the highest coal processing capacity in the world. The designed capacity for a single gasifier is 4,000 tons per day.” ”　 　　It is reported that among these 52 enterprises, 50 are located in China (with 137 gasification units), and 2 are located abroad (with 7 gasification units). The total capacity of these gasification facilities is approximately 200,000 tons of coal per day, with each unit being capable of processing between 750 and 4,000 tons of coal per day. Among them, the multi-nozzle opposed coal slurry gasification technology with a daily coal processing capacity of 2,000 tons or more holds a 100% market share in the gasification technology sector. In the multi-nozzle opposed water-coal slurry gasification technology, gasifiers with a daily processing capacity of 2,000 tons or more account for over 60% of all types of gasifiers. Guo Baogui explained that these achievements are mainly attributed to the significant technical advantages of the multi-nozzle opposed gasification technology in terms of safety, stability, environmental friendliness, and energy efficiency, as well as to technical training. The owner of the project technology possesses excellent technical services and support capabilities in areas such as technology selection, equipment installation and commissioning, startup, and production operation services. 　 　　Wang Yifei, a professor at East China University of Science and Technology, said: “Multi-nozzle gasifiers use multiple burners for feeding, which is clearly an advantage over single-nozzle gasification technology when it comes to scaling up the size of gasifiers.” ； The multi-nozzle gasification technology enhances the mass transfer process through impinging flow, improving the efficiency of the gasification reaction and the carbon conversion rate, while reducing the consumption of coal and oxygen ； The premembrane nozzles used in the multi-nozzle water-coal slurry gasification technology exhibit excellent atomization performance; nozzle wear is significantly reduced compared to single-nozzle gasifiers, resulting in a longer service life for the nozzles ； The excellent furnace flow field structure of the multi-nozzle water-coal slurry gasification technology significantly extends the service life of refractory bricks, offering a clear advantage over single-nozzle gasification furnaces ； The washing and purification efficiency of the syngas staged purification system in the multi-nozzle water-coal slurry gasification technology is significantly better than that of the single-nozzle water-coal slurry gasification process, as well as that of other existing gasification technologies. ”　 　　Guo Baogui explained that currently, 63 gasification units from 23 companies are in operation, and the average service life of the burners used in these gasification units at various manufacturers is over 90 days, with the longest service life reaching 194 days ； The service life of the refractory bricks in the domes of all operating plants exceeds 8,000 hours; in most plants, the lifespan of these bricks is over 12,000 hours, with the highest values reaching 18,000 hours. The bricks used in the cylinders have a service life of over 40,000 hours. 　 　　Wang Yifei, a professor at East China University of Science and Technology, said, “The actual operational experience of units such as Jiangsu Linggu throughout 2016 has fully demonstrated the reliability of the multi-nozzle opposed water-coal slurry gasification technology. The gasification unit of Yankuang Lunan Chemical Co., Ltd. operated for 8,293 hours per year without any backup unit, achieving a world-leading level of operation for water-coal slurry gasifiers. The gasification unit of Jiangsu Supor operated at high load for over 510 days continuously.” ”　 　　Wanhua Chemical (Ningbo) Co., Ltd. built three multi-nozzle opposed coal-water slurry gasification units with a daily processing capacity of 1,000 tons of coal each; two of these units were in operation while one served as a backup. The gasification pressure was 6.5 megapascals. The facility came online in January 2010, and it was able to operate at full capacity stably for long periods of time shortly after its commissioning. 　 　　Sun Dehao, manager of Wanhua Chemical (Ningbo)’s coal-to-gas facility, explained that from the outset of its operation, the facility has focused on ways to shed the label of traditional coal chemical industries, which are associated with high pollution levels, high energy consumption, and high risks. It has also strived to move away from the image of large-scale chemical production characterized by rough management practices, and to adopt lean production methods and refined management approaches. By focusing on four key management areas – enhancing the awareness of maintaining stable production while reducing consumption, improving risk management capabilities, perfecting the technical management system, and laying a solid foundation for employee development – the facility has achieved satisfactory results. 　 　　Sun Dehao said that since the gasification unit was put into operation in 2010, its load has been increasing year by year. Through gradual upgrades, at a cost equivalent to only 10% of the initial investment, the unit’s capacity has now reached 130% of its designed capacity, generating an economic benefit of 230 million yuan for the enterprise each year. After the capacity-increasing renovation, inspections of the equipment and pipe wall thicknesses showed that everything was in normal condition. 　　　The first-phase methanol plant of New Energy Phoenix (Tengzhou) Energy Co., Ltd. was put into operation in December 2009, with an annual production capacity of 300,000 tons of methanol ； Phase II was put into operation in November 2011, with an annual production capacity of 300,000 tons of methanol. The gasification unit employs a multi-nozzle opposed water-coal slurry pressurized gasification process, with a daily coal feeding capacity of 1,500 tons per furnace ； The gasification system operates in a two-in-one-backup configuration. The plant was originally designed to produce 600,000 tons of alcohol-ammonia per year, but after expansion its annual production capacity has reached 800,000 tons of methanol. 　 　　Zeng Fanheng, manager of the New Energy Phoenix gasification unit, said, “At present, the gasification unit is capable of operating for extended periods; the process burners have an average service life of over 80 days, with the longest recorded service life being 110 days.” ； The refractory bricks for the dome have been in use for over 15,000 hours, while those for the cylinder have been in use for over 26,000 hours ； The quench ring downcomer was used continuously for 5 years without any failures or the need for replacement ； The average operating cycle for a single system is 134 days; the longest recorded cycle is 207 days. ”It is understood that in order to further increase the production capacity of its gasification units, Xinneng Phoenix has collaborated with East China University of Science and Technology and Yankuang Guotuo to modify the furnace brick structure, oxygen pipelines, mixers, cyclone separators, water scrubbing towers, and other components of these gasification units. Two gasification furnaces have been successfully modified, while the third one is currently under modification; it is expected that once the modifications are completed, the annual production capacity will reach 900,000 tons of methanol. 　　　Carbon conversion rate is one of the key indicators for measuring the advancement of gasification technology. As verified through performance tests, the carbon conversion rate of most multi-nozzle water-coal slurry gasification technologies exceeds 99%. Inner Mongolia Rongxin (3000 TPD, 6.5 MPa): 72-hour continuous industrial operation test from September 23 to 26, 2015; carbon conversion rate of 99.6% ； During the 72-hour full-load performance test conducted from October 13 to 16, 2010, New Energy Phoenix achieved a carbon conversion rate of 99.16% ； Jiangsu Linggu (2000TPD, 4.0MPa) achieved a carbon conversion rate of 99.2% during the 72-hour continuous industrial operation test from November 25 to 28, 2011 ； During the 72-hour continuous industrial operation test conducted from December 20 to 23, 2016, Zhongyan Kunshan (1200TPD, 6.5MPa) achieved a carbon conversion rate of 99.64%. 　 　　Continuous improvement 　　Developing new technologies for the next generation 　　Since the industrial application of multi-nozzle gasification technology, Yankuang Group and East China University of Science and Technology have regarded the enhancement and refinement of this technology as an important aspect of ensuring its sustainable development. By drawing on practical engineering examples, they have carried out numerous technical improvements: the modifications to the structure and support systems of the refractory bricks not only did not affect the safe operation of the gasification furnace, but also helped to increase the volume of its combustion chamber, providing viable technical solutions for boosting the furnace’s production capacity ； The improvement in the tray design of the water wash tower effectively prevented water carryover, ensuring long-term stable operation of the gasification unit ； The heat exchange mechanism inside the evaporative hot water tower has been changed from packing to a tray structure, which not only does not affect the efficiency of heat exchange but also reduces the maintenance workload. These improvements have been implemented in multiple projects, yielding good results. 　 　　While improving existing technologies, Yankuang Group and East China University of Science and Technology are also actively developing new technologies for the next generation that are more efficient. 　 　　The large-scale water-coal slurry gasification technology development and demonstration project, proposed by Yankuang Group in collaboration with various domestic research institutions and enterprises including East China University of Science and Technology, has been included in the **key research and development plan for the 13th Five-Year Plan**, and comprehensive research and development work has already begun. The main research tasks include developing a complete set of technologies for large-scale water-coal slurry gasification, constructing a demonstration unit with multiple nozzles and an opposing configuration capable of processing 4,000 tons of coal per day per furnace, and achieving continuous and stable operation. The successful development and application of ultra-large-scale gasification furnaces will provide more efficient and advanced technologies for large-scale coal chemical projects such as coal-to-oil and coal-to-olefins, thereby significantly reducing the investment required for such facilities. 　　Currently, Yankuang Group is conducting research on multi-nozzle opposed water-coal slurry gasification waste boiler process gasifiers, as well as building industrial demonstration projects for them. Pan Rong, deputy general manager of Yankuang Guotuo, explained that this technology enables full and efficient utilization of the sensible heat in high-temperature syngas, which is of great significance for reducing energy consumption in the water-coal slurry gasification process. It also represents an improvement and enhancement of the multi-nozzle opposed water-coal slurry gasification process, and it is a coal chemical technology project that is being promoted and advocated. Yankuang Guotuo is working in partnership with East China University of Science and Technology, Yanzhou Coal Industry Yulin Methanol Plant, and China Tianchen Engineering Co., Ltd. to advance the project as a whole. 　 　　　Innovative services to ensure the entire lifecycle of equipment. Clean coal gasification units are the core technology for modern coal chemical enterprises; their successful commissioning and stable operation are crucial for the normal production of these enterprises. The parent company and Yankuang Guotuo provide end-to-end lifecycle services for the plants, including coal type analysis, gasification technology selection, technology transfer, personnel training, commissioning guidance, and ongoing technical support, thereby ensuring the successful construction and operation of the customers’ plants. 　 　　It is reported that Yankuang Guotuo, leveraging the strong talent pool in Yankuang’s coal chemical industry, as well as its extensive experience in operation and management and its professional team, can provide owners with services such as the construction, commissioning, startup, maintenance, operation support, and transportation of production facilities. 　 　　Since September 2011, the Yankuang Guotuo Training Center has trained over 400 qualified professionals in operations, maintenance, instrumentation and control, and analysis for companies such as Anyang Yingde Gas Co., Ltd., Henan Xinlianxin Fertilizer Co., Ltd., Sinochem Kunshan Co., Ltd., Rongxin Chemical, Beijing Energy Group Co., Ltd., Jiangsu Huachang (Group) Co., Ltd., Qinghai Salt Lake Industry Co., Ltd., Ningbo Zhongjin Petrochemical Co., Ltd., and Zhejiang Petrochemical Co., Ltd. Among them, the gasification units of Anyang Yingde Gas Co., Ltd., Xinlianxin Company, Rongxin Chemical, Zhongyan Kunshan Co., Ltd., and Huachang Group successfully completed the commissioning of their new facilities following training, and have reached a stable operating state. 　 　　Due to geographical differences, various companies use different types of coal, and fluctuations in coal quality significantly affect the stable operation of coal gasification units. The stability of the coal mix becomes one of the key factors limiting the stable operation of such units. To this end, the central company provides users with raw coal analysis and evaluation services to guide the operation of the facilities. Wang Zhenhua said, “Relying on the Coal Quality Evaluation Laboratory, the Central Company provides users with services such as industrial analysis and elemental analysis of raw coal, slurryability testing, analysis of viscosity-temperature characteristics, and optimized adjustment plans. These services help ensure the stable operation of users’ gasifiers.” ”　 　　In addition, Yankuang Guotuo also provides water-coal slurry additive services for its clients. Pan Rong explained that this service works in partnership with the center’s coal quality evaluation laboratory to provide customized formulations of water-coal slurry additives based on the user’s coal specifications, thereby increasing the concentration of the coal slurry and improving the operational efficiency of gasification units. 　 　　The process burner is an important component of multi-nozzle opposed water-coal slurry gasification furnaces, and its operating condition directly affects the overall performance of the gasification unit. Although the service life of the burners in the multi-nozzle water-coal slurry gasification technology has currently reached a high level, Yankuang Guotuo continues to work on extending the lifespan of these burners, reducing the number of shutdowns of the gasification units, and thus helping customers save on production costs and maintenance expenses. 　 　　It is understood that Yankuang Guotuo has developed process burners with various structural designs and special end materials. Multiple industrial tests have been conducted to date, yielding satisfactory results. The new type of water-coal slurry burner is currently in the process of production, with deployment expected in 2018. Once in use, it will help extend the service life of these burners. After successful industrial application, it will be brought to market, thereby effectively addressing the issue of limited service life of process burners and significantly increasing the operating cycle of gasification furnaces. 　 　　Currently, the multi-nozzle opposed water-coal slurry gasification technology jointly developed by Yankuang Group and East China University of Science and Technology has become a mainstream and advanced coal gasification technology. Its technical advantages have been highly recognized within the industry. In the future, both parties will continue to improve existing technologies, actively promote the development of new technologies, and provide corresponding technical services. They will offer advanced technologies and top-notch services to the coal chemical industry, thereby ensuring the safe, stable, long-term, and efficient operation of users’ facilities. 　　Independent R&D: Gasification technology reaches new heights. Guo Baogui said that Chongkuang Guotuo and the Clean Coal Research Institute of East China University of Science and Technology continue to work on improving existing coal gasification technologies, while also pursuing research and development in areas such as ultra-large-scale gasifiers, water-coal slurry concentration, lignite utilization, pulverized coal gasification, multi-nozzle gasifiers with water-cooled walls for water-coal slurry, as well as evaluation and analysis related to coal gasification, thereby ensuring the sustainable development of this technology. Dun Baogui stated that currently, Yankuang Guotuo has established an excellent team featuring close integration of industry, academia, and research, as well as an internationally first-class research and development base. The company will continue to increase its investments and maintain close cooperation with its clients. It will also keep pursuing technological development and innovation in the field of coal gasification, striving to elevate the multi-nozzle opposed coal gasification technology to even higher levels. 　　Yankuang Water-Coal Slurry Gasification and Coal Chemicals **Engineering Research Center Co., Ltd. (referred to as the Center Company) is a **-level engineering research center approved for establishment by the former **Planning Commission. It was officially founded in August 1995, with the former Yankuang Lunan Fertilizer Plant serving as its backing institution. The central company is a wholly-owned subsidiary of Yankuang Group; it was established on October 28, 2014, in the Jinan High-Tech Zone. Yankuang Guotuo is its holding subsidiary. 　　It is understood that the central company has successively established various technology research and development platforms, including those for coal gasification research, coal type evaluation research, ultra-clean coal research, and environmental protection research in the field of coal chemical industry. Among them, the coal gasification R&D platform has successfully developed technologies and products such as multi-nozzle opposed water-coal slurry gasification, pressurized coal gasification, and a new type of coal powder mass flow meter. It also features simulation training laboratories, including a four-nozzle water-coal slurry gasification simulation management system and a coal gasification simulation training management system, which are used to train personnel involved in gasification processes, thereby enhancing their capabilities in areas such as startup and shutdown operations, normal operation, accident handling, and emergency response. 　　Wang Zhenhua, head of the central company, said: “The high-level coal chemical R&D platform that has been established by the company possesses the capability to carry out various research and development tasks. Currently, it is involved in 1 national project, 2 provincial or ministerial-level projects, and 7 external research projects. This platform serves as a bridge for industry collaboration; the company has carried out joint research with numerous enterprises and research institutions, and some of the results obtained have already been applied in industrial production.” ”　 　　In addition, the central company and Yankuang Guotuo have also carried out research on related supporting technologies for gasification units. The graywater system of coal water slurry gasification units often faces problems such as pipeline scaling and blockages during operation. Xu Chao, the gasification supervisor at Anhui Hua Yi Chemical Co., Ltd., compared this to thrombosis in humans, saying that graywater scaling can affect the long-term stable operation of the gasification units. ”In response to this, Pan Rong, deputy general manager of Yankuang Guotuo, said, \"It is of great significance to develop a composite green and efficient scale-inhibiting agent with excellent scale-inhibition properties, good high-temperature resistance, and high cost efficiency, taking into account the characteristics of gasification ash water, in order to address the issues that hinder the long-term safe operation of the system.\" ”At present, Yankuang Guotuo is working together with well-known domestic universities and research centers to develop this technology. 　　Wang Zhenhua explained that the high-performance scale-inhibiting dispersants developed currently exhibit good temperature resistance in high-alkalinity and high-hardness gray water environments, with a scale-inhibition rate of over 85%. The formulated products have already been put into industrial use at Inner Mongolia Rongxin Chemical Co., Ltd., and the gasification system is operating well at present. In addition, the newly developed water treatment agents are about to be put into use. 　 　　Yankuang Guotuo is developing a wireless intelligent monitoring system for flammable and toxic gases. This technology not only enhances the functionality of traditional wired detection systems for such gases, but also saves users money on installation costs and materials. It can be installed in any location where it is needed on-site, thereby greatly facilitating the monitoring and measurement of hazardous substances in those areas. This product is capable of competing with traditional wired detection systems for flammable and toxic gases. With continuous additions and optimizations of its functions, it can replace existing conventional detection systems, thereby driving the development of the industry for such detection systems. It also provides technical and product support for the construction of smart and digital factories.