Request a set of shell gasification operation data

Introduction to the Shell gasification process: Coal from the coal yard and limestone are mixed in a certain ratio using weighing feeders, then fed into a coal grinder for mixing. Hot air is used to remove the moisture from the coal, and after that, the mixture passes through a bag filter. The dried coal powder is stored in a coal powder silo. The coal powder coming out of the powder bin passes through a lock-hopper device, where it is pressurized to 4.2 MPa using nitrogen. Driven by this nitrogen, it is sent to the burner and enters the gasification furnace along with steam and oxygen for combustion. The reaction temperature ranges from 1500°C to 1700°C, with a pressure of 3.5 MPa. The gas exiting the gasification furnace is cooled to 900°C by cold gas supplied by a quenching compressor located at the top of the furnace. After that, the gas passes through heat exchangers in the gas transfer pipeline and syngas coolers to recover heat, resulting in a temperature of 350°C. Finally, it enters a high-temperature, high-pressure ceramic filter to remove 99% of the fly ash from the syngas. The gas exiting the high-temperature and high-pressure filter is divided into two streams: one stream enters the quench gas compressor where it is compressed to serve as quench gas, while the other stream goes to the Venturi scrubber and scrubbing tower, where high-pressure process water is used to remove the ash from it and reduce its temperature to 150°C before it proceeds to the conversion stage of the gas purification unit. The slag generated within the gasification furnace flows along the inner wall of the furnace to the slag pool at its bottom; there it solidifies into glass-like slag upon contact with water. This slag is then transferred through collectors and slag lockhoppers to a slag dewatering tank on a regular basis, and from there it is removed using a slag skimmer and sent to a slag disposal site where it is sold as a commodity. The fly ash collected in the high-temperature and high-pressure filter is stripped in a fly ash stripping tower and cooled to 100°C before being fed into a fly ash storage tank. Some of the fly ash is returned to the coal grinder, while the rest is sold as a product. Forced water circulation is provided within the membrane wall of the gasifier and in each heat exchanger by pumps; the steam generated at 5.4 MPa enters the drum together, and after steam-water separation, it proceeds to the main steam pipe. This process has the following characteristics: 1. It has a wide range of coal compatibility; no special requirements are imposed on the activity of the coal. More than a dozen types of coal have been gasified at the Demkolec power plant, with normal operation achieved in all cases. However, from the perspective of economic efficiency, taking into account factors such as the amount of flux added, oxygen consumption, and the need to protect the water-cooled walls, it is necessary to select the coal type appropriately. 2. Due to the use of a membrane-type water wall structure, a layer of refractory material is applied to the inner surface of the water wall; the slag serves to protect the water wall, resulting in a long service life and reduced maintenance needs. 3. Due to the high gasification temperature and high carbon conversion rate, the carbon content in the ash and slag is low, resulting in no environmental pollution. 4. The device features a high degree of automation, being composed of a DCS and an ESD (safety protection) system; numerous interlock protection systems are in place to ensure the safety of the equipment and operators. III. Main Design Technical Parameters
1. The chemical composition of the coal is as follows (on a dry, ash-free basis): C: 88.86%, H: 3.95%, O: 4.80%, N: 1.83%, S: 0.55%, Cl: 0.01%. On an as-fired basis, the composition is as follows: fixed carbon: 40.03%, volatile matter: 34.1%, moisture: 8.53%, ash: 25.87%. The lower heating value is 24.98 MJ/kg, and the ash melting point is 1410°C.
2. Key consumption figures and technical characteristics: The plant is designed to produce 200,000 tons of synthetic ammonia per year, which corresponds to an effective gas output of CO + H2 of 55,000 Nm3/h. The following amounts are required: coal: 39.8 T/h, limestone: 2.48 T/h, oxygen (99% purity): 20,400 Nm3/h, ultra-high pressure nitrogen (80°C, 7.2 Mpa): 12,000 Nm3/h, high-pressure nitrogen (40°C, 5.2 Mpa): 8,000 Nm3/h, low-pressure nitrogen (40°C, 0.6 Mpa): 4,500 Nm3/h, steam (265°C, 4.5 Mpa): 2 t/h, and by-product steam (250°C, 5.4 Mpa): 50 t/h. The gas composition in the output stream is as follows: CO: 55.3%, N2: 9.0%, H2: 19.1%, CO2: 2.2%, H2O: 14%, H2S: 1000 ppm, at a temperature of 150°C and a pressure of 3.25 MPa. 3. The main technical and economic indicators (based on the consumption of raw gas required to produce 1 ton of synthetic ammonia) are as follows: Sequence Number, Name, Specification, Unit, Consumption. 1. Raw coal, Moisture content

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