CSIR-CIMFR: COAL TO SYNGAS & METHANOL PROGRAM

Prakash Chavan

CSIR-CENTRAL INSTITUTE OF MINING & FUEL RESEARCH DHANBAD

CHALLENGE Ring-fence India from the import of crude (226.5 MMTPA),

Natural Gas (21.69 MMTPA), petroleum products (33.35 MMTPA). Judicious utilization of Indigenous energy resources. Reduction in carbon footprint.

POTENTIAL326.50 Billion tonne of COAL

OPPORTUNITYGASIFICATION

Clean Coal Technology towards Atma Nirbhar Bharat AbhiyanFor Methanol, DME, Liquid Fuels, Fertilizers, DRI, Power, Thermal, etc.

326.50 Billion tonne of COAL Secure, Affordable & Sustainable energy resource.

Govt. of India Initiatives for Coal Gasification

NITI Aayog Methanol Economy Task Force: (23/05/2017)Methanol using High ash Coal (Members: CIMFR, CIL, BHEL, IITD-Thermax, EIL)

Indian Coal Gasification Mission by NITI Aayog:Steering committee & Technical Standing Group (8/05/2020) to support for‘Technological Advances & Feasibility Options for Coal Gasification’.

Talcher Fertilizer Ltd. (TFL):Shortlisted Shell Gasifier (Air Products) technology for fertilizer plantusing MCL coal & Petcoke blends.

Coal India Ltd, Ministry of Coal:Coal to Methanol Plants at ECL, CCL, SECL & WCL using high ash Indiancoal.

SUMMARIZED STRATEGY

UNDERSTANDING COAL: Gasification Potential Mapping of Indian Coal

• In view of Physico-chemical properties of coal & Ash towards gasification.Gasifier suitability vis-à-vis Utilization strategy for gainful utilization of coalresource.

PILOT SCALE PFBG Plant integrated with Syngas to Methanol,

• For Techno-economic feasibility of Indian Coal Gasification towards identifiedend uses & Confidence building in the area of gasification.

• Technical inputs for Demo Scale Gasification based Plants• Technical inputs for Demo Scale Gasification based Plants

TECHNO-ECONOMIC COMPARISON of Gasification Technologies withRespect to Indian Coal

• Entrained Flow Gasifier (Shell) Demo Plants of CIL at TFL, Talcher, WCL(Wardha), SECL (Mahamaya), ECL (Sonpur Bazari, Dankuni)

• Experience in Moving Bed Gasifier (Lurgi) at JSPL, Angul• Pilot/Demo Scale PFBG at CSIR-CIMFR, BHEL, IITD-Thermax & EIL.

PFBG Pilot Scale Plants 2017-19CSIR-CIMFR, BHEL, IITD-Thermax & EIL

Proof of concept & Blueprint for Demo Plant

Indigenous Gasifier Integrated with Methanol Plant

METHANOL ECONOMY: NITI AAYOG ROADMAP

Commercial Gasifier Integrated with Methanol Plant by CIL

Entrained Flow GasifierLow ash coal, high ash coal washing/blending

Locations: TFL, Dankuni, WCL, SECL, CCL

500 TPD Coal, Demo Plants 2019-23Locations: ECL, CCL, SECL, WCL

Outcome: Blue print for 7500-25000TPD Plant

7500-25000 TPD Coal, Commercial Plants 2023-30

Locations: Different Peat Heads

OUTCOMEIndigenous PFBG Technology

Suitable for High Ash Coal

OUTCOMECommercial Entrained Flow Gasifier Low ash coal, high ash coal washing/blending

CSIR-CIMFR: Coal to Syngas & Methanol Program

250 kg/day Syngas to

Understanding Indian Coal Gasification Prospects &Suitability towards Gasification

Development of Suitable Gasifier for High Ash Indian Coal Integration of 250 kg/day Syngas to Methanol Pilot Plant

with 1.5 TPD PFBG Pilot Plant

20 kg/h PFBG (2009)

Thermo-Gravimetric Reactor (2016)

Gasification Potential Mapping MCL, CCL & ECL (2019)

1.5 TPD Oxy-blown PFBG & Gasification Centre of Excellence (2020)

Gasification Potential Mapping of WCL, SECL (2021)

Syngas to Methanol PlantAdvanced Dual Bed Gasifier (2022)

CSIR-CIMFR: Centre of Excellence for Coal GasificationBench Scale to Pilot Scale Gasification & Syngas utilization facilities.

• 20 kg/h Air-blown PFBG Pilot Plant• 1.5 TPD Oxy-blown PFBG Pilot Plant• Cold/Hot Fluidization study facilities• Thermo-gravimetric Reactor• High Pressure Micro Reactor for Syngas Processing• Bench Scale High Pressure Reactor for Syngas Processing• 250 kg/day Syngas to Methanol Pilot Plant (Ongoing)• Advanced Dual Bed Gasifier (ADBG) for tar free syngas and C1, C2 gases (Ongoing)

State of the art Analytical Hub for gasification and syngas utilization.• Physico-chemical Characterization Facilities for Coal, Ash, Syngas, Catalyst, etc• Physico-chemical Characterization Facilities for Coal, Ash, Syngas, Catalyst, etc• Gasification Potential Mapping of Indian Coal & Utilization Strategy.

CFD & Aspen Plus Process Modeling & Simulation Laboratory.

Gasification Training & Skill Development Centre.• For Industry, Academic & R&D Institutions.

GASIFICATION POTENTIAL MAPPING OF INDIAN COAL

CSIR-CIMFR & CMPDIL (under the aegis of NITI Aayog)

Coal characterization matrix in view of Physico-chemical properties of coal & Ashcharacteristics towards gasification.

Gasifier suitability vis-à-vis Utilization pattern & gasification strategy for gainfulutilization of coal resource.

Proximate & Ultimate

Gasification Potential Mapping of Indian Coal for MCL (18), CCL (7) & ECL(5) area hasbeen completed & report submitted to NITI Aayog in December 2019.

Gasification Potential Mapping

Hot & Cold Strength

CV & Caking

Propensity

Surface Properties

Ash Properties

& Slag Viscosity

Gasfication Reactivity.

INDIAN COAL RESOURCE

ASH TYPE

HIGH ASH CONTENTCoal reserves (~73%) are of inferior grade non-cooking coals &

Ash contents 45-50%

ASH TYPERefractory Nature with High Ash Fusion Temperature >1300 OC

REACTIVITYModerate to high reactivity

MECHANICAL STRENGTHModerate to High Cold & Hot Strength

Gasification Option Washing & Crushing Gaps and Key Issues

OPTION-1: EntrainedFlow Gasifier (Shell) forlow ash coalHigh ash coal washingfrom 45% to 20%

Washability Yield: <60%,Net loss: >20%,CAPEX: Rs.500 crore for5-10 MMTPA plantOPEX: Rs. 1000-1500/tonne of coal

Syngas Yield: 0.9–1.0tonne/tonne of feed coalCO=37%, H2=26%, CH4<1.0%EFG tested up to 20% ash.High AFT (>1300oC)T15, T25 (>1400oC)Low thermal efficiency

OPTION-2: MovingBed Gasifier (Lurgi

Washability Yield: ~65%,Net loss: ~15%,

Syngas Yield: 0.9–1.1tonne/tonne of feed coal

INDIAN COAL: GASIFICATION OPTIONS, GAPS & KEY ISSUES

Bed Gasifier (LurgiFBDB) for low/mediumash coalHigh ash coal washingfrom 45% to 30%

Net loss: ~15%,CAPEX: Rs.500 crore for5-10 MMTPAOPEX: Rs. 1000-1500/tonne of coal

tonne/tonne of feed coalCO=23%, H2=37%, CH4:9%Selective feed particle size(>8mm)~3% fuel loss in Tar, LiquidsCAPEX for tar/liquid handlingfacility

OPTION-3: FluidizedBed GasifierLow/medium/high ashcoal

NA Syngas Yield: 1.1–1.2tonne/tonne of feed coal*CO: 27%, H2: 27%, CH4: <2%Proven technology not availableLower carbon conversionAgglomeration /clinker formation

CSIR-CIMFR MISSION

Understanding Indian Coal Gasification Prospects &Suitability towards Gasification

Development of Suitable Gasifier for High Ash Indian Coal Development of Suitable Gasifier for High Ash Indian Coal

Integration of 250 kg/day Syngas to Methanol Pilot Plantwith 1.5 TPD PFBG Pilot Plant

20 Kg/H Air Blown Pressurized Fluidized Bed Gasification Facility (TRL-5)

AIR BLOWN PFBG ACHIEVEMENTS Addressed operational issues: fuel

feeding, ash agglomerates, ashextraction

Established operational philosophy tohandle high ash coal in PFBG.

Evaluated Gasification performanceof high ash coal, Biomass & blends

Copyright & Indian Patent (TRL-5).

Electrically heated alloy reactor

installed in 2008-09

Fuel Feed Rate : up to 20 kg/h

Temperature: up to 1000 oC

Pressure : up to 3 kg/cm2

Syngas Composition: (Vol.%)

CO: 15-22, H2: 15-20, CH4: 1-2,

CO2: 10-12, N2: 48-55

Heat Value: 1000-1200 kcal/Nm3

Carbon Conversion : up to 93%

Yield : 2.2-2.5 Nm3/kg of fuel

1.5 TPD Oxy-blown Pressurized Fluidized Bed Gasification Facility (TRL-6)

UPSCALING CHALLENGES &STRATEGY

Address operational problems:Ash agglomeration & withdrawal

Oxy-blown:Establish successful operation withOxygen & Steam.

Operational Philosophy:Establish operational philosophy forEstablish operational philosophy forOxy-blown PFBG with high ash coals.

OXY BLOWN PFBG DETAILS TARGETED OUTCOME

CSIR-CIMFR design. Refractory Lined Gasifier Fuel Feed Rate : up to 1.5 TPD Gasifying Agents : Air/Oxygen & Steam Temperature: up to 1050 oC Pressure : up to 10 kg/cm2

Facility is dedicated to the nation on17/11/2020

Syngas Composition: (Vol.%)CO: 27-35, H2: 27-35, CH4: 2-5,CO2: 15-18, N2: 10-15

Carbon Conversion : >93%

Syngas Yield: 1.2-1.5 Nm3/kg fuel

Design copyright & Indian Patent

TRIAL EXPERIMENT GRAPHS

Startup in Combustion Mode Gasification Mode Shutdown Mode

ACHIEVEMENTS TILL DATE Established 1.5 TPD PFBG Pilot Scale Facility Conducted Trial experiment in Air-blown mode with CO: ~11% and H2 ~12%

Parameter Experimental Value Range

Coal Flow Rate, kg/h 10-30

Air/O2 Flow Rate, kg/h 40-50

Steam Flow Rate, kg/h 10-13

Gasifier Temperature, oC 900-1050

Gasifier Pressure, atm atm

Bed Height, mm 200-275

Ash withdrawal Rate, kg/h Intermittent

Syngas Yield, kg/kg coal 2-2.5

Max. Syngas Composition, % CO=11, H2=12, CO2=13 & CH4=2

Max. Syngas CV, kcal/Nm3 927

Carbon Conversion, % >90

To establish operation in Oxy-blown mode with High AshIndian Coal addressing operational issues.

Establish operational philosophy for oxy-blown PFBG

Understanding Gasification Prospects of Indian CoalResource and Generation of Techno-economic Data

NEXT TARGETS

Achieve carbon conversion > 93 %

Integration of Syngas micro-cleaning, conditioning and 250kg/day syngas to Methanol Pilot Plant with 1.5 TPD PFBG PilotPlant

Establish Centre of Excellence for Gasification

250 kg/day COAL SYNGAS TO METHANOL (CoSynol) PROGRAM

Methanol Synthesis

H2S CO2

Coal

Syngas Conditioning

Methanol

Coal Gasification & Syngas Cleaning

Coal required for 1 tonne Methanol: 3.5 to 4.5 tonne

Total Cost of Methanol will depend upon Coal Cost & Capacity of the Plant

METHANOL COST ESTIMATES

Mission Mode Activity under ‘CSIR Mission Directorate’

OUTCOME OF PFBG PILOT PLANT PROGRAM

Indigenously developed 1.5 TPD PFBG Facility is a milestoneachievement as a part of "Methanol Economy Program" and animportant step towards “Atmanirbhar Bharat Abhiyan” of Govt. of India.

Outcome:

PFBG 1.5

TPD

Gasification potential & techno-economics vis-à-vis utilizationprospects of high ash Indian coal for downstream applications suchas Methanol/chemicals, fertilizers, DRI, Thermal applications, etc.

Inputs for the development of Demo Scale PFBG suitable for IndianHigh Ash Coal resource.

director@cimfr.nic.inpdchavan@cimfr.nic.in