The world’s first industrial test unit for the dual-fluidized-bed ultra-large-scale powder coal gasification (KSY) technology successfully passed the long-term operation test evaluation

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The world’s first industrial test unit for ultra-large-scale powder coal gasification using dual fluidized beds (KSY) technology successfully passed the long-duration operation test. Author/Source: Shaanxi Yanchang Petroleum Research Center for Efficient Utilization of Hydrocarbons. Date: October 25, 2019. Clicks: 34. At 3:08 p.m. on October 22, the world’s first 100t/d industrial test unit for ultra-large-scale powder coal gasification using dual fluidized beds (KSY) technology completed its 168-hour long-duration operation successfully. This is another major breakthrough, following the device’s successful 72-hour on-site calibration assessment by the expert committee of the Shaanxi Chemical Industry Society on April 27 this year, and the expert evaluation of the related technical achievements on August 22! This long-duration operation commenced on October 12, with material feeding starting on October 15; it was successfully completed after 7 days of operation on October 22, after which the plant was shut down on October 24. In total, the test unit was in operation with material feeding for nearly 9 days. During operation, the feeding, ash discharge, temperature control, and fluidization conditions of the unit were extremely stable. Apart from normal operations such as ash discharge, it was possible to achieve long-term operation with minimal intervention. At the same time, tests such as series load tests on feed sheets, high-temperature tests on the tar pyrolyzer, and optimization of the steam-to-gas ratio were carried out, all of which yielded excellent results. Under conditions close to the ash melting point of coal, the tar pyrolyzer ensured a uniform temperature distribution in the riser reactor, with stable fluidization without any fluctuations, resulting in very stable operation. This effectively validated the design concept of the tar pyrolyzer and raised public awareness of the gasification technology using fluidized bed systems for dry ash discharge. The successful completion of these long-duration operation tests and exploratory tuning experiments demonstrates that China’s independently developed dry-feed, dry-ash discharge, two-stage cascaded fluidized bed powder coal gasification technology has been fully validated. This has opened up a new path for the development of ultra-large-scale powder coal gasification technologies, and it has also provided a large amount of detailed and reliable data for optimizing the process package of the 5000 t/d ultra-large-scale industrial plant under development. This will undoubtedly accelerate the industrialization of the dual-fluidized bed ultra-large-scale powder coal gasification (KSY) technology.