Multi-nozzle water-coal slurry gasification technology leads the market

Thread Content

Multi-nozzle water-coal slurry gasification technology leads the market Author/Source: Sinochem New Network Date: 10-15-2019 Clicks: 18 From September 19 to 20, 2019, a conference on the application experience of multi-nozzle opposed gasification technology was held in Zhengzhou City, Henan Province. The symposium was organized by Yankuang Group Co., Ltd. and East China University of Science and Technology, and co-hosted by Shandong Yankuang Guotuo Technology Engineering Co., Ltd. and the Clean Coal Research Institute of East China University of Science and Technology. Nearly 200 representatives from over 70 enterprises and research institutions across the country had in-depth exchanges and discussions on the application experience of the multi-nozzle opposed gasification technology, which was jointly developed and owned by East China University of Science and Technology and Yankuang Group Co., Ltd. 　　Demand continues to grow, and the application of this technology is spreading everywhere. According to statistics, since its industrial adoption, the multi-nozzle opposed water-coal slurry gasification technology has been applied in 58 projects, involving a total of 160 units. Currently, 75 gasifiers operated by 28 companies are in commercial use; the maximum coal processing capacity of these gasifiers is 3,000 tons per day, with each gasifier producing more than 200,000 Nm3/h of useful gases (CO+H2). The demonstration unit for a multi-nozzle gasification furnace with a daily processing capacity of 4,000 tons has been built at Inner Mongolia Rongxin Chemical Co., Ltd. It is currently in the trial operation phase, with commissioning expected in October 2019. 　　“Through years of effort and development, as well as the growing demand for this technology in the market, among the more than 20 coal gasification technologies available both domestically and internationally, the multi-nozzle opposed coal gasification technology holds a significant market share. In particular, it has an absolute advantage in the market for multi-nozzle gasification technologies used in coal slurry gasification on a scale of 2,000 tons or more. ”That’s what Guo Baogui, chairman of Shandong Yankuang Guotuo Technology Engineering Co., Ltd., said. 　　“The joint efforts of multiple parties have led to the widespread adoption of the multi-nozzle coal-water slurry gasification technology in China. The market penetration is continuously rising, and demand is growing steadily. ” said Professor Yu Guangsuo, a doctoral supervisor at the Clean Coal Research Institute of East China University of Science and Technology. 　　It is understood that in July 2008, after conducting multiple evaluations worldwide, the U.S.-based company VALERO paid over 100 million yuan in technology licensing fees to acquire the multi-nozzle opposed-flow gasification technology. This marked the first time that China’s large-scale chemical processing technology with independent intellectual property rights was exported to developed countries, thereby breaking the monopoly that foreign multinational corporations had maintained over the coal gasification technology market for nearly 50 years. In 2017, this technology was licensed to the South Korean company TENT, laying a solid foundation for the market application and promotion of this technology. 　　Further technological advancements: Breakthroughs achieved in the research on ultra-large reactors. The development process of the multi-nozzle opposed water-coal slurry gasification technology—from its inception, through pilot testing and industrial demonstration, to its scaling up from a 1,000-ton capacity to an ultra-large 4,000-ton scale—testifies to the growth and progress of modern coal gasification technology in China. With the support of relevant ministries and commissions such as the Ministry of Science and Technology, Yankuang Group and East China University of Science and Technology have been continuously improving and developing coal gasification technologies with independent intellectual property rights, making progress every five years. Through years of research and practical application, this technology has once again taken the lead in its adoption and promotion within the industry. 　　“During the Eighth Five-Year Plan period, East China University of Science and Technology developed a mathematical model for fluidized-bed gasification and carried out laboratory-scale tests. During the Ninth Five-Year Plan period, companies such as Yankuang Group, East China University of Science and Technology, and China Tianchen Chemical Engineering Corporation undertook pilot-scale tests on multi-nozzle gasification. During the Tenth Five-Year Plan period, Yankuang Guotai Chemical Co., Ltd. constructed a demonstration project for multi-nozzle gasification technology; in 2005, the first large-scale gasifier of the thousand-ton class using multi-nozzle opposed water-coal slurry gasification was successfully commissioned at this company, marking the beginning of the development of large-scale, efficient, and clean water-coal slurry gasification in China. 　　“During the 11th and 12th Five-Year Plans, Yankuang Group and East China University of Science and Technology, among others, jointly carried out the development and engineering demonstration of multi-nozzle opposed water-coal slurry gasification technologies with capacities of 2,000 tons and 3,000 tons respectively. During the 13th Five-Year Plan period, they took on the research tasks outlined in the key R&D program titled “Development and Demonstration of Large-Scale Water-Coal Slurry Gasification Technologies.” They conducted research on the key technologies required for scaling up such gasification processes on an extremely large scale, as well as on methods to reduce wastewater generation. As a result, they developed an ultra-large-scale water-coal slurry gasification process capable of processing 4,000 tons of coal per day per furnace, and they also built a demonstration unit for multi-nozzle opposed water-coal slurry gasification with a capacity of 4,000 tons. 　　It is understood that Yankuang Group and East China University of Science and Technology have conducted in-depth research on the application of this technology in large-scale facilities, building on its safety, maturity, and reliability, and have achieved significant breakthroughs. A technical supervisor at Guotuo Company said that the largest gasifier currently in operation is capable of processing 3,000 tons of coal per day, with an effective gas output (CO+H2) of over 200,000 Nm3/h. The largest gasifier under construction can handle 4,000 tons of coal per day. The demonstration unit is expected to begin trial operations at Inner Mongolia Rongxin Chemicals by the end of October this year, which provides strong support for the selection of technical approaches for large-scale coal chemical plants. 　　Energy efficiency remains at the forefront; production efficiency keeps reaching new heights. Since the multi-nozzle opposed water-coal slurry gasification technology was put into industrial use in 2005, continuous efforts by the research and development teams as well as users have led to numerous upgrades, optimizations, and improvements. Through operation in multiple industrial plants, the safety, stability, reliability, and cost-effectiveness of this technology have been fully verified. 　　Technically secure, mature, and reliable. The multi-nozzle opposed water-coal slurry gasification technology has developed a complete theoretical foundation, as well as experience in engineering applications and production management. To date, 75 gasification units operated by 28 companies are using this technology, and its reliability has been proven through the operation of multiple production facilities. A large number of professionals in areas such as basic research, engineering design, technical management, and operation have been trained throughout the processes of technology development, design, construction, and production, enabling comprehensive technical support to be provided to users. 　　Advanced technology, excellent performance metrics, and low overall energy consumption. The test results from multiple operating units show that the multi-nozzle opposed water-coal slurry gasification technology can achieve a carbon conversion rate of 99%, with the effective gas composition (CO+H2) in the syngas produced by this method reaching up to 85%. Compared with domestic and international water-coal slurry gasification technologies, it exhibits lower coal consumption and oxygen consumption under the same operating conditions, by about 3%. A staged gas washing system is used, which ensures good washing efficiency; the dust content in the product gas is less than 1 mg/Nm3, so dust accumulation does not affect the lifespan of the catalysts in subsequent systems. A direct heat-exchange type flash system is employed, featuring a rational heat recovery process, high efficiency, and ease of operation and maintenance. 　　Suitable for scaling up. By using 4 nozzles for feeding, the atomization effect of the water-coal slurry is ensured, thereby increasing the conversion rate of the raw materials. The small diameter of each feeding pipeline reduces the complexity of manufacturing the pipes and valves, thus lowering costs. The load per furnace is high; the maximum daily coal input for the currently operating gasification furnaces reaches 3,000 tons, while the designed maximum daily coal input is 4,000 tons. For large-scale coal chemical plants, a high single-furnace load can reduce the number of production trains, thereby lowering overall investment and maintenance efforts. The multi-nozzle gasification technology has been serialized, resulting in a range of gasifiers with a nominal daily coal processing capacity of 1,000 tons, 1,500 tons, 2,000 tons, 2,500 tons, 3,000 tons, and 4,000 tons per furnace. Coal chemical plants of different scales can flexibly select the appropriate type of furnace to achieve an economical and rational configuration. 　　There is less wastewater discharge, resulting in lower environmental pressure. Due to the high carbon conversion rate, the fine ash content in the wash water is low, making slag and water separation easy; the quality of the ash water is good, the reuse rate is high, and the amount of wastewater discharged from the gasification process is low. After the high-temperature reaction, the wastewater no longer contains refractory organic substances such as phenols and tar; it can be discharged up to standard standards after simple biochemical treatment. At the same time, the coal slurry preparation unit can also use wastewater treated by biochemical methods or wastewater from other areas with high COD levels as water for slurry preparation, thereby reducing the load and costs on the wastewater treatment unit. 　　The device is easy to operate, stable, and features a high online rate. The unique pressure-driven sequential operation and fluctuation-free furnace switching technology enable the gasifier and subsequent systems to handle faults and switch gasifiers without shutting down, thereby enhancing fault resistance, increasing effective production time, and reducing the number of system shutdowns. 　　Broader prospects A continuous cycle of stable operation and innovation The gasification unit capable of processing 3,000 tons of coal per day is currently the largest in terms of furnace size among those in operation worldwide, and it features efficient and stable performance. The successful operation of the unit demonstrates the outstanding advantages of the multi-nozzle opposed water-coal slurry gasification technology in terms of scale-up and long-term safe and stable operation. 　　“During the 13th Five-Year Plan period, Yankuang Group and East China University of Science and Technology jointly undertook the research and development tasks under the key special project of the Ministry of Science and Technology titled “Development and Demonstration of Large-Scale Coal-Water Slurry Gasification Technology” as part of the initiative on “Clean and Efficient Utilization of Coal and New Energy-Saving Technologies”. They conducted research on key technologies for scaling up ultra-large-scale coal-water slurry gasification and on reducing wastewater generation. Focusing on the complex scientific issues related to the interaction between turbulent mixing and intricate gasification reactions under high temperature and pressure conditions, they established the fundamental theories necessary for making the coal-water slurry gasification process more efficient and scalable. As a result, they developed an ultra-large-scale coal-water slurry gasification process capable of processing 4,000 tons per unit, and constructed a demonstration facility featuring multiple opposed nozzles with a daily coal processing capacity of 4,000 tons. 　　Meanwhile, building on the widespread use of fully quenched multi-nozzle opposed water-coal slurry systems, they will also pursue research and demonstration on waste boiler-quenched multi-nozzle opposed water-coal slurry gasification, energy-efficient recovery technologies for high-pressure and high-temperature black water in large-scale coal gasification systems, as well as improvements to petroleum coke gasification technologies. 　　“The development of technology knows no bounds; there is no best, only better. With the support of a key research and development program, we are building a gasification unit capable of processing 4,000 tons of coal per day per furnace, and it is set to be completed by the end of this year. At the same time, with the strong support of Yankuang Group, we will also build a 2,000-ton semi-boiler-type multi-nozzle water-coal slurry gasification unit. At present, the gasification furnace has been manufactured and is scheduled to come online in the first half of next year. ” said Professor Yu Guangsuo, a doctoral supervisor at the Clean Coal Research Institute of East China University of Science and Technology. 　　Once the gasification demonstration facility capable of processing 4,000 tons of coal per day per furnace is completed, it will become the largest water-coal slurry gasification plant in the world. It will establish a set of advanced technologies for large-scale water-coal slurry gasification, signaling that China’s modern large-scale coal chemical industry has reached a world-leading level. 　　R&D Updates ● Research and Demonstration of Ultra-Large-Scale Water-Coal Slurry Gasifiers During the 13th Five-Year Plan period, Yankuang Group and East China University of Science and Technology jointly undertook the research tasks for the key project funded by the Ministry of Science and Technology under the theme of \"Clean and Efficient Utilization of Coal and New Energy-Saving Technologies\": \"Development and Demonstration of Large-Scale Water-Coal Slurry Gasification Technologies.\" This work focused on researching the key technologies for scaling up ultra-large-scale water-coal slurry gasification as well as methods for reducing wastewater generation. 　　Focusing on the complex scientific issues related to the interaction between turbulent mixing and complex gasification reactions under high temperature and pressure, they have mastered the fundamental theories necessary for making the water-coal slurry gasification process more efficient and scalable. As a result, an ultra-large-scale water-coal slurry gasification process capable of handling 4,000 tons per furnace has been developed, along with a demonstration unit featuring multiple nozzles arranged in opposition to each other, capable of processing 4,000 tons of coal per day. The demonstration unit has been built at Inner Mongolia Rongxin Chemical Co., Ltd. and is scheduled to undergo trial operation with feedstock input soon. 　　●Research and Demonstration on the Waste Boiler–Quenching Type Multi-Nozzle Opposed Water-Coal Slurry Gasification: Building on the widespread use of fully quenching type multi-nozzle opposed water-coal slurry systems, Yankuang Group and East China University of Science and Technology have continued their research on gasification technologies, and are currently working on the development of gasification technology using a waste boiler–quenching process for multi-nozzle opposed water-coal slurry gasification. 　　The furnace design has been completed, the process software package was developed in December 2017, and the fabrication of the gasifier is finished. The industrial demonstration plant is being built at Yanzhou Coal Industry Yulin Energy Chemical Co., Ltd.; it involves the construction of a waste-boiler/quench gasification furnace capable of processing 2,000 tons of coal per day per unit. Commissioning for testing is expected to take place by the end of March 2020. The waste boiler-quench gasification technology will further improve the energy efficiency of gasification units. 　　●Technological advancement – Energy-efficient recovery technology for high-pressure and high-temperature black water in large-scale gasification systems. Yankuang Group and East China University of Science and Technology continue to invest funds and human resources to improve and enhance multi-nozzle gasification technology. 　　They innovatively proposed a new process for the efficient recovery of energy from high-pressure and high-temperature black water in large-scale coal gasification systems. By enhancing heat and mass transfer processes, they resolved the issues related to scale-up in engineering applications, thereby improving the system’s energy efficiency and ensuring the long-term stable operation of large-scale coal gasification systems. This technology has been successfully applied to the black water treatment unit of large-scale water-coal slurry gasification systems capable of processing 3,000 tons per day, thereby enabling the efficient and stable operation of such large gasification facilities. 　　They also invented an efficient tray-type hot water evaporation tower, integrating the phase-change and transfer processes and enabling its use in large-scale projects. Compared with similar foreign technologies, this technology saves 10 million yuan in investment per series. 　　Furthermore, they invented internal components for evaporation hot water towers featuring a swirl flow field and a impinging gas-liquid transfer interface, which enhanced the heat and mass transfer processes within the tower. Operations of large-scale coal-water slurry gasification units capable of processing 3,000 tons of coal per day showed that the operational cycle of the evaporation hot water tower increased from 6 months to over 15 months. 　　●Technological advancement – petroleum coke gasification: The R&D teams from Yankuang Group and East China University of Science and Technology have conducted years of theoretical and engineering research on petroleum coke gasification, and have found a way to utilize petroleum coke efficiently and cleanly through multi-nozzle gasification technology. 　　This technology was applied to the coal-coke gasification unit at Ningbo Zhongjin Petrochemical Co., Ltd. Using coal and petroleum coke as raw materials, the unit produces fuel gas and feedstock gas. On May 24, 2015, it was successfully put into operation, marking the successful trial run of China’s first low-pressure entrained-flow gasification unit that uses petroleum coke as its main raw material for producing fuel gas and hydrogen. The concentration of the coke slurry fed into the furnace ranged from 58% to 60%, while the content of useful components in the water-gas mixture stood at 79.5%–80.49%. The gasification system operated stably, with a maximum proportion of petroleum coke used being 100%. 　　●The organic integration of coal chemical industry and petrochemical industry. As one of the **seven planned large-scale integrated refining and petrochemical projects, the coal-to-hydrogen unit within Hengli Petrochemical (Dalian) Refining & Chemical Co., Ltd.’s 20-million-ton/year integrated refining and petrochemical project adopted the multi-nozzle opposed water-coal slurry gasification technology. A total of six upgraded multi-nozzle opposed water-coal slurry gasifiers with a diameter of 3.88 meters were constructed. 　　On February 15, 2019, the gasifier in Hengli Petrochemical’s 2 million tons per year integrated refining and chemical processing project’s coal-to-hydrogen facility was successfully commissioned after its first feed operation. This is the largest coal slurry gasifier of its kind in operation worldwide, with an effective gas (CO+H2) production capacity of 200,000 Nm3/h per unit. Currently, the gasifier is operating at full load, with stable performance and excellent technical indicators. The product gas generated by the gasification unit put into operation by Hengli Petrochemical serves as feed gas for both hydrogen production lines and related chemical processing lines. It is a typical example of integration between modern petrochemical and coal chemical industries. 　　The successful operation of this ultra-large gasifier has enabled a significant leap in the scale of coal-water slurry gasification technology. It has provided valuable experience for over 10 ongoing projects involving multi-nozzle opposed-flow coal-water slurry gasifiers, where each gasifier is designed to produce at least 200,000 Nm3/h of effective gas, including projects by Wanhua Chemical, Inner Mongolia Rongxin, Inner Mongolia Huineng, and Zhejiang Petrochemical. 　　Application examples
Jiangsu Linggu Chemical Co., Ltd.:
Coal gasification furnaces with a daily coal processing capacity of 2,000 tons

In the first phase of its large-scale fertilizer plant, Jiangsu Linggu Chemical Co., Ltd. constructed two multi-nozzle opposed-flow coal-water slurry gasification furnaces, each capable of processing 2,000 tons of coal per day. These furnaces were put into operation for the first time on June 15, 2009. Throughout 2011, they operated for a total of 357 days, producing 460,000 tons of ammonia. In 2012, they ran for 352 days, and in 2013, for 355 days. In the second phase of the project, another multi-nozzle gasifier with a daily coal processing capacity of 2,000 tons was constructed; it was put into operation on November 3, 2015 and operated throughout 2016. The gasification unit and the entire production system of Linggu Chemical operate efficiently and stably. The first-phase unit produces 1,350 tons of ammonia per day, while the second-phase ammonia production unit generates 1,600 tons per day, resulting in excellent economic benefits. 　　The China Petroleum and Chemical Industry Federation organized an evaluation expert team to conduct a 72-hour continuous industrial operation test on the multi-nozzle opposed water-coal slurry gasification technology at Linggu Chemical from November 25 to 28, 2011. The assessment results show that the device was able to operate at full load continuously for over 72 hours, with accurate measurement and analysis, meeting the requirements for evaluating chemical industry equipment. Its operational data and calculation results are accurate and reliable; its gasification performance meets and exceeds the specified criteria, with an effective gas composition of 82.9%, a specific oxygen consumption of 352 Nm3 O2/1000 Nm3 (CO+H2), a specific coal consumption of 568 kg/1000 Nm3 (CO+H2), a cold gas efficiency of 74.9%, and a carbon conversion rate of 99.2%. 　　The device features a uniquely designed high-pressure nitrogen protection system, which ensures the safe operation of the gasification unit during startup and shutdown phases. It also employs pressurized simultaneous start-up technology and flue gas reversal technology without fluctuations, thereby enhancing its fault tolerance. These technologies reduce the consumption of oxygen and raw coal during flue gas reversal, minimizing fluctuations in the production system during such transitions. As a result, the system operates more stably and achieves greater economic efficiency. 　　At the same time, this device is also one of the most efficient and stable among currently operating devices of similar type, demonstrating the advantage of multi-nozzle opposed gasification furnaces in terms of their ease of scaling up and their ability to operate stably and safely over long periods. 　　The performance and technical specifications of this device are at the international leading level. Compared with other coal-water slurry gasification technologies at home and abroad, its technical features and advantages are as follows: (1) It boasts high gasification efficiency and advanced technical parameters; compared with a single-nozzle coal-water slurry gasification unit that also uses Inner Mongolia Shenhua coal, it results in a 3.1 percentage point increase in the effective gas content, a 11.4% reduction in oxygen consumption, and a 2.1% reduction in coal consumption. 　　(2) It features a high carbon conversion rate; compared with a single-nozzle coal-water slurry gasification unit that also uses Inner Mongolia Shenhua coal, the carbon content in the coarse slag is reduced by about 10 percentage points, and that in the fine slag is reduced by about 12 percentage points. The coarse and fine slag have low carbon content, and the ash content in the gas and liquid streams is low, which facilitates the efficient operation of the entire gasification unit and reduces valve wear. 　　(3) The nozzles work well in coordination, allowing for flexible load adjustment and strong adaptability in the vaporization furnace; the technical specifications of larger-scale units are advanced, which facilitates the development of larger-scale installations. 　　(4) Multiple nozzles enable pressurized continuous feeding and smooth furnace reversal, which facilitates long-term stable operation of the entire plant. 　　(5) The flow field is well-designed, and the thermocouples have a long service life, providing important guidance for the stable operation of the gasification unit. The slurry nozzle with a pre-coating structure results in lower pressure, which in turn reduces the pressure of oxygen and slurry entering the gasification furnace, thereby helping to decrease the energy consumption of the gasification unit. The composite bed washing and cooling technology offers excellent heat and mass transfer performance, as well as stable liquid levels, avoiding the problems of water and ash contamination in the syngas that are common in other technologies. The staged preliminary purification process for syngas is energy-efficient and efficient, resulting in lower system pressure and a longer service life for the subsequent conversion catalysts. The slag treatment system utilizes direct heat exchange technology, enabling high heat recovery efficiency; it overcomes the issues of scaling and blockage in equipment, thus reducing the need for maintenance of related equipment. 　　Inner Mongolia Rongxin Chemical Co., Ltd.: Gasification furnaces with a capacity of 3,000 tons of coal per day. For the first phase of its 1.8 million tons per year methanol production facility, Inner Mongolia Rongxin Chemical Co., Ltd. built three multi-nozzle opposed-type water-coal slurry gasification furnaces with a capacity of 3,000 tons of coal per day. These furnaces were completed and put into operation on June 24, 2014, and have since been operating stably. The project has been operating at full capacity since August 16, 2015, with a daily methanol production of around 3,200 tons. 　　The Petrochemical Federation organized an on-site evaluation expert team to conduct a 72-hour continuous operation test on the aforementioned facility at Rongxin Chemical from September 23 to 26, 2015. The assessment data show that, compared with the performance figures of 2,000-ton-class multi-nozzle opposed water-coal slurry gasification units, the carbon conversion rate of this unit has increased from 99% to 99.63%. Under high-load operating conditions, the gasification process exhibits excellent performance; the gasification unit is safe, reliable, highly automated, and offers flexible operation control. By combining scientific production management practices, it is possible to achieve stable, efficient, and optimal operation of the unit. 　　In addition, the technical features and advantages of the 3,000-ton class multi-nozzle opposed water-coal slurry gasification technology are as follows: (1) The multi-nozzle opposed water-coal slurry gasification technology boasts high gasification efficiency and advanced technical specifications. 　　(2) The multi-nozzle opposed gasification nozzles exhibit good synergy, enabling flexible load adjustment and strong adaptability in the gasification furnace; the carbon conversion rate in ultra-large-scale units reaches 99.63%, with advanced technical specifications and prominent advantages in terms of scale. 　　(3) The flow field in the gasification furnace is well-designed, and the structure of the refractory bricks at the dome has been optimized, which effectively extends their service life. Based on the assessment results and the rate of thinning of the heat-resistant bricks, it is expected that these bricks can last for over 10,000 hours, providing an important guarantee for the stable operation of the gasification unit. 　　(4) The water-coal slurry nozzle with a pre-coating structure reduces the pressure drop caused by oxygen and the coal slurry, as well as wear; its service life reaches 102 days. This not only extends the lifespan of the burner but also helps to reduce the energy consumption of the gasification unit. 　　(5) By adjusting and optimizing the relative dimensions of the hot-face bricks, backing bricks, and insulating bricks, the furnace volume of the gasifier was increased, thereby enhancing the gas production rate. 　　The evaluation expert group also assessed the wastewater discharge from the gasifier and the efficiency of cold gas production. Preliminary assessment results show that the wastewater discharge volume from the gasifier is low (50.3 m3/h), and the composition of the wastewater is simple, making it easy to treat through biological methods; the efficiency of cold gas production reaches 75.2%, which is better than that of similar gasification units. 　　The gasification unit capable of processing 3,000 tons of coal per day is currently the largest coal-water slurry gasification unit in the world in terms of furnace size, and it operates efficiently and stably. The successful operation of this demonstration unit fully demonstrates the outstanding advantages of the multi-nozzle opposed water-coal slurry gasification technology in terms of scale-up and long-term safe and stable operation.