【Ten Years of Great Progress in Chemical Technology】002-2018 Yanchang Petroleum’s 10,000-ton-per-year integrated coal gasification and pyrolysis technology (CCSI)

Based on the concepts of the petroleum chemical industry, the Carbon Hydrogen Utilization Research Center of Yanchang Petroleum has independently developed an integrated technology for coal tar extraction and syngas production (CCSI). By using air as the gasifying agent, this technology enables the conversion of pulverized coal into high-quality medium- and low-temperature coal tar and syngas in a single step; 150 kilograms of coal tar and approximately 3,500 Nm3 of crude syngas can be produced per ton of coal. The yield of coal tar is over 15%; based on a coal price of 350 yuan per ton, the production cost is approximately 18.5 dollars per barrel. After thorough conversion, it can be transformed into high-value fine chemical products or clean fuel oils. The calorific value of syngas is 1200 kcal/Nm3, with an effective gas content of >35%, allowing it to be used directly as fuel in coal-fired boilers. It can also be purified through desulfurization and dust removal to serve as fuel for gas turbines for power generation. It maximizes the utilization rate, conversion efficiency, and added value of coal resources, becoming a new technical approach for modern coal chemical industry.

The core of this technology is to carry out both the pyrolysis of coal and the gasification of semi-coke within the same reactor, using air and water vapor as gasifying agents. Coal powder undergoes rapid pyrolysis in the upper pyrolysis zone, producing coal tar and semi-coke particles; these semi-coke particles then return to the lower gasification zone where they are converted into syngas. Due to the unique fluidization state and temperature gradient distribution within the reactor, the diffusion rate of pyrolysis reaction products is increased, unstable free radicals are saturated, and secondary reactions of tar are reduced, resulting in a significant increase in tar yield. Innovative product separation processes and specialized equipment have been developed to address the global challenge of online separation of pyrolysis oil, gas, and dust, thereby raising the technology for the selective and graded utilization of coal to a higher level. Since October 2012, after two years of pilot studies at Yanchang Petroleum’s Hydrocarbon Center, 38 operational tests were conducted in 2014 using a cold-state simulation test setup. In August 2015, a 10,000-ton industrial test facility for CCSI technology was built in Xingping, Shaanxi, by CCCC. The facility underwent 5 coal-firing tests in total, achieving 772 hours of continuous and stable operation, and generating a large amount of experimental data that laid a solid foundation for the industrialization of this technology. At the end of last year, a 72-hour on-site evaluation conducted by the China Petroleum and Chemical Industry Federation showed that the yield of coal tar was 17.12% (with a dry distillation yield of 158%), and the energy conversion efficiency was as high as 82.58%. The content of useful gases in the syngas (CO + H2 + CH4 + hydrocarbons) was 35.11% when air was used for gasification, and 47.07% when 30% oxygen-enriched air was used; all these values met or exceeded the design specifications. Recently, the **Energy Bureau issued the ‘13th Five-Year Plan for Demonstrative Projects in the Advanced Processing of Coal Industry’, which designates integrated coal tar extraction and syngas production (CCSI) projects as new demonstration projects for the value-added utilization of low-grade coal. By producing oil products, natural gas, chemicals, and electricity simultaneously, it is possible to maximize both the utility and economic value of coal. In August 2012, Yanchang Petroleum began laboratory-based research on CCSI technology. As of March 2017, the industrial testing facility of CCSI had carried out a total of 6 feeding tests, with all performance indicators meeting or exceeding the design specifications. At present, Yanchang Petroleum has preliminarily completed the process package design for a million-ton-scale CCSI industrial plant, with plans to build industrial demonstration plants in Yulin and the Guanzhong region.

New achievements have been made in the engineering trials of the CCSI at the Yanchang Petroleum Hydrocarbon Efficient Utilization Technology Research Center. Author/Source: Date: 2018-05-24 Clicks: 1456 In mid-May, the CCSI unit at the Yanchang Petroleum Hydrocarbon Research Center conducted its eleventh engineering trial under conditions of pure oxygen oxidation and loads of 80%-100%, achieving continuous and stable operation. This experiment is of great milestone significance. The important technical achievements of the experiment are as follows: 1. The integrated coupling of the gasification field and the pyrolysis field under pure oxygen gasification conditions was mastered, as well as the mutual response and regulation relationships among various process parameters under high-rate cycling of the three types of materials. 2. The patented and proprietary equipment in the unit, such as the pulverized coal conveying feed system, gasification reactor, lift tube pyrolysis reactor, primary/secondary cyclone separators, high-efficiency multi-tube cyclone separators, and continuous ash discharge system, are operating well. The design concepts have been realized in terms of process technology, and their advancement and reliability have been fully verified through operation. 3. It enabled long-term operation without human intervention, verifying the rationality and advancement of the reactor system’s automatic control devices; this laid the foundation for the application of advanced APC intelligent control systems in industrial demonstration projects utilizing integrated pyrolysis/gasification reaction systems. 4. The effective gas components of the syngas exceed the design values, indicating good prospects for industrial application. 5. Based on actual operation conditions, technologies for zero wastewater discharge from the gasification island and complete recovery of sludge were developed, thereby further optimizing the CCSI process at a deeper level and accelerating the progress toward efficient conversion and clean utilization of coal. This feeding operation marks a new stage in the industrialization of CCSI technology. At present, the development of the million-ton-scale CCSI process design package (under oxygen gasification conditions) is nearing completion. In accordance with the requirements of the State Council’s 13th Five-Year Plan for Energy Development, an industrial demonstration project will be constructed in the Qingshui Industrial Park in Yulin, Shaanxi, during the second half of this year.

【Ten Years of Great Progress in Chemical Technology】003-2023: 400,000 tons per year of PVC produced via the calcium carbide method without the use of mercury https://bbs.hcbbs.com/forum.php?mod=viewthread&tid=3593911 (Source: Haichuan Network – Chemical Industry Updates)