Key breakthrough achieved in the development of 5,000-ton/day gasification furnace: Successful pilot test of ultra-large transport bed gasification technology

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Key breakthrough achieved in the development of 5,000-ton/day gasification furnace: Pilot test successful for ultra-large transport-bed gasification technology / Author/Source: China Chemical Industry News / Date: November 7, 2016 / Clicks: 45. In late October, the ultra-large transport-bed gasification technology (KSY), independently developed by the Hydrocarbon Efficient Utilization Technology Research Center of Yanchang Petroleum Group, achieved continuous and stable operation of an industrial test unit with a capacity of 100 tons per day in Xingping, Shaanxi; all indicators and parameters met the specified requirements. This means that reliable data has been obtained, marking a key breakthrough, in the development of the process package for the world’s largest gasification unit with a coal feeding rate of 5,000 tons per day. The 100-ton/day industrial test unit (with a designed coal feeding rate of 5,000 tons/day after scaling up) began hot-commissioning trials for coal feeding on October 8; the first attempt at feeding coal was successful, and the entire process was operational smoothly, with a coal feeding load of 50% ； After 14 days of continuous stable operation, a large amount of operational data and valuable experience were obtained. At present, the Yanchang Petroleum Hydrocarbon Center is optimizing and improving this facility; a new round of operation with feedstock will be carried out, and efforts are being made to develop process packages for larger-scale industrial facilities capable of handling 5,000 tons of coal per day. It is expected that industrial demonstration and the promotion of these technologies will be completed during the 13th Five-Year Plan period. At that time, it will not only be possible to significantly reduce the number of gasifiers in large-scale coal chemical projects, but it will also be feasible to build large-scale gasification facilities at coal mines or within coal chemical parks to produce syngas on a centralized basis. The syngas can then be delivered in a unified manner according to the needs of various enterprises, thereby replacing the transport of coal with the transport of gas. 　 “To address issues such as the fact that Transport Bed Gasification (TRIG) technology can only use lignite as a feedstock and has a limited market potential, we independently developed a two-stage conversion unit, resulting in the more advanced KSY gasification technology. ”Li Dapeng, the first coal chemical industry expert at Yanchang Petroleum Group and director of the Hydrocarbon Center, said. The KSY technology combines a riser reactor, a fluidized bed reactor, an efficient multi-stage centrifuge, a continuous vacuum ash discharge system, a fluidized bed waste boiler, and a PCD high-efficiency ultra-clean dust removal system to form a complete innovation system for gasification. It features a wide range of applicable feedstocks, extremely large processing capacity, low construction and operation costs, as well as high efficiency, cleanliness, and energy conservation. According to Li Dapeng, the KSY gasification technology is suitable for lignite and low-grade bituminous coal, and it can process low-quality coal with an ash content as high as 40%. This overcomes the existing limitation that the ash content in coal used for gasification must not exceed 20%, and it also provides a new way for the efficient utilization of semi-coke powder. The gasification furnace has a long operating cycle and requires simple maintenance; the accompanying IGCC power generation plants do not need an air separation system, resulting in significant advantages in terms of construction and operation costs ； It mainly consists of a transport bed gasification unit and a two-stage conversion system, which couple the first and second reactors together. In the second fluidized bed reactor, the high-frequency circulation of solid particles raises the reaction temperature to around 1200°C, thereby addressing issues such as tar residue, high methane content, and low carbon conversion rate in conventional fluidized bed gasification. As a result, the syngas produced has a high yield and good quality. Furthermore, this gasification technology uses dry ash discharge, produces no black water, and requires no water cooling.