Coal Gasification: Words by Roger Kumar, Founder-Director of CASE Group

Roger Kumar is the Founder and Managing Director of CASE Group, established in January 1993. He is a mechanical engineer graduate from the National Institutes of Technology Kurukshetra, passing out batch of 1986. CASE Group was initially conceptualized to manufacture and market ‘Scale-Ban’- A Non-Chemical Water Treatment Equipment and Water-Cooling Towers. The company started from scratch and rose to become a primary manufacturer of Non-Chemical water treatment equipment& Water-Cooling Towers.

India is a developing country and one of the lifelines of development is available energy at economical and sustainable rates.

India’s energy demands are ever increasing and is largely dependent on its crude oil imports, the rates of which are controlled by world dynamics. This unfortunately is not in control of India.

As of late, the industry in India has been under lot of stress because of constant increase in the fuel rates. Fuel comprising of Furnace oil, Propane, LDO, HFO, Natural gas etc.

There is an urgent need of indigenous energy source which is clean, economical and sustainable.

One of the sustainable, long-time solution to the above problem is Coal Gasification.

Coal gasification is not new to India. Gasifiers are widely used in our country for the last 15 years for thermal applications. In the past there were few makes which were not in line with the Indian pollution control norms and had to closedown specially in state of Gujrat.

Fortunately, there are few technologies which are very much in the market which are in line with Pollution control agencies and are advance enough to substitute all the type of present fuels economically. These gasifiers are capable to use Indian high ash coal which is readily available. Not to forget that this replacement also saves Indian government huge amount of foreign exchange apart from the effect on inflation and balance of payments.

Coal Gasifier basically is a machine which burns coal (gasifies) in controlled oxygen environment. This process converts Carbon and volatile matter in coal into CO, CH4 and H2. The mixture of these gases is called Coal gas or Synthetic gas or producer gas. This gas burns in the furnace to give thermal energy. Because the calorific value of coal gas is on the lower side, the flame temperature is comparatively low resulting in low NOx formation. Because the Sulphur in Indian coal is below 1% for most type of coal, the Sox generated is also low as compared to Furnace oil. Further desulphurization equipment can be easily installed in the downstream of gasifiers if the user is looking for very low Sulphur in process or flue. This works on the principle of capturing H2S and is much economical than installing Desulphurization equipment installed to capture SO2 after the combustion.

Today more than 1000 Coal gasifiers are in operation in India which are serving industry in the field of Steel Reheating Furnaces, Pellet Plants, Ceramic Furnaces, Glass Plants, Heat treatment Furnaces, Galvanizing plants, Aluminum Industry to name a few. The technology today is advanced with different variants of gasifiers for just about the type of applications, size, and coal quality available.

The technology is available in both fixed bed and fluidized bed. There is flexibility to use lump coal as well as coal fines with different heat values and ash contents. The modules are available today up to 100 million Kcal/hr per reactor. Further the technologies are available which are zero liquid discharge (ZLD) resulting in no adverse effect on the environment. All type of pollution whether it is air pollution, water pollution, soil pollution or noise pollution, Coal Gasifier gets a heads up.

It is pertinent to mention here that the technologies available today comes with totally automatic process controlled by PLC. Human intervention has become minimum. The safety norms in the gasifiers are today world class with zero accident rate.

So, in the nutshell, today, coal gasification in India is an advance technology and is all set to rescue the energy demands of our country indigenously and economically.

Furthermore, these coal Gasifiers are made in India and falling under Honorable Prime Minister’s “Make in India” larger plan.

Our Honorable Prime minister has given a special push to gasification in India. And why not. Coal used in Coal Gasifiers is readily available in India and is in abundance. Roughly 300 billion tons of coal is available. With Hydrogen and EV in line to make an impact, it is prudent to utilize our fossil reserves in a professional and clean manner as soon as possible. And in the process if it can also save foreign exchange, improve balance of payments, the incentive to promote coal gasification only become bigger.

Honorable Prime minister has made an ambitious statement roughly two years back to gasify 100 million tons of coal by 2030. We need to work hard in this direction to make it possible.

Coal Gasifiers apart from heating can also be used to make urea, Ammonia, fertilizers and even Hydrogen called brown hydrogen. Talcher ammonia and Urea plant already has a go from the present government. Brown hydrogen in combination with carbon capture can be a boon for the industry and can play in line with Honorable prime ministers’ commitment in COP26 at Glasgow for India to go net-zero carbon emissions by 2070!!

News Source: https://www.cxooutlook.com/coal-gasification-an-indigenous-and-sustainable-solution-for-indias-industrial-energy-demands/?fbclid=IwAR2Jh-1gJ-DC1zjsDRB36_XLcSS_FIb-W54grWMaQWQvkM4gYx6kn32ZXxc

CASE Pyrolysis Coal Gasifier Control Room

 

The above mentioned video has been taken from the control room of Gasification Plant. CASE Pyrolysis Clean Gas Technology is popular in India and abroad. 

Though being lower in CAPEX & OPEX, it has huge advantages over any other variants of Gasification technologies available in the world today.in case of Pyrolysis Hot Clean Gas Station Indirect Cooler is not used and gas is available at 150 ℃ . In case of Pyrolysis Clean Cold Gas Station Indirect Cooler is installed after the Electrostatic Precipitator bringing down the temperature of gas upto 40 ℃. In case user requirement is of Very Clean Cold Gas Station additional ESP is installed after the Indirect Cooler to further reduce tar and dust level below 25ppm. All the above three variants gas can be pressurized to any pressure as per user requirement.

Popular Features of Pyrolysis Clean Coal Gasifiers

• All types of coals can be used. Bituminous coal and lignite coal can be used as the raw material for gasification.
• Coal is carbonized at low temperature in pyrolysis section and tar thus produced is of low viscosity with high fluidity.
• On account of the low viscosity and high fluidity of Tar, the chances of tar being clogged in the duct before the Purifying equipment does not exist.
• Fully automatic PLC controlled system adds to ease of Operation and lower OPEX 

Coal Gasifier Installation At Maniram Steels in Raipur India

 

CASE is extremely proud to inform all their existing and prospective clients that entire coal gasifiers series is being manufactured in India. Two state- of-the-art well-equipped factories are 100% dedicated to the manufacturing of these gasifiers. This gives us immense pride in conforming to our country’s philosophy of an “AatmaNirbhar Bharat. CASE is a registered supplier of state-of-the-art coal gasification technology. 

The simplest and most POPULAR GASIFIERS from the basked of CASE. Hot Gas Coal Gasifiers are a darling of the Secondary Steel Industry, primarily, Rolling Mills, Galvanizing Units, Strip Mills, Forging Units etc. By adopting these Gasifiers the Industry has been able to reduce their respective manufacturing costs with respect to fuel. Heat Energy generated through the combustion of Coal Gas is the cheapest the industry can get thus reducing their product manufacturing costs. It is estimated that a Steel Mill using alternate high-cost fuel like HFO, FO, PROPANE, LNG, NG etc. for their Heating Applications can save up to 40% on the fuel cost by merely shifting to Coal Gasification Route.

For more information, please contact our coal gasifier manufacturer

Pyrolysis Clean Coal Gasification: Video by CASE Group

 

Pyrolysis Clean Coal Gasification which happens to fall under the category of SBCG (Static Bed Coal Gasification) has been able to address mostly all of the environmental challenges faced by the gasification industry. This design ensures a Zero Liquid Discharge (ZLD) process by which all the phenolic water generated in the process is treated and used back (re-cycled) in the gasification process cycle. This takes care of the Phenolic Water concern. The tar generated in the process is professionally handled in underground concrete tanks. The tar has high fluidity and can be combusted and used as a fuel for the plants thermal applications. The coal ash generated during the gasification process is granular in form and in no way be held responsible for cause any form of air pollution. This coal ash can be used as land fill or can be used as an aggregate for making cement blocks. Thus we can see choosing the right technology not only helps the end user in preventing further damage to their environment but also save millions and millions of rupees for themselves and for the nation.

To get more videos like this, kindly subscribe to our YOUTUBE Channel:  https://www.youtube.com/user/casegroup123

Biomass Gasification Market Trends 2021

The escalating demand for rural electrification is primarily driving the India biomass gasification market. In line with this, the launch of several initiatives by public and private bodies to provide electricity in rural areas across the country is further bolstering the market growth. Moreover, the rising need to reduce the utilization of conventional fossil fuels owing to their adverse environmental consequences is acting as another significant growth-inducing factor. Apart from this, the increasing investments by numerous government bodies in the development of multifaceted biomass gasifier-based power plants that produce electricity with locally available natural resources, including cotton stalks, wood chips, agro-residues, etc., are also catalyzing the market growth. In addition to this, the elevating levels of industrialization, coupled with the extensive research and development (R&D) activities to introduce hybrid solar-biomass gasification systems, are expected to fuel the India biomass gasification market over the forecasted period.

Read complete news at: https://www.einnews.com/pr_news/555318784/india-biomass-gasification-market-2021-size-share-trends-and-forecast-2026

Automatic Gasifiers Cut Operational Costs

CASE Cold Pyrolysis Gasifiers are fully automatic PLC controlled system which adds to ease of Operation and lower OPEX (Operational Expenditure). The gasifiers are running successfully in Automatic Steel Furnaces, Pellet Plants, Glass Plants and other industrial plants, worldwide.

Popular Features of CASE Cold Pyrolysis Gas Station

• Single gas outlet. Gas composition does not Fluctuate- consistent gas.
• All purifying equipment are in series- low on CAPEX.
• Less purifying equipment with simple schematics low on OPEX.
• Higher purity of gas as all purifying equipment are in series.
• Higher gas thermal value.
• Usage of gas sensible heat to preheat the incoming coal.
• Higher level of pyrolysis – higher conversion of volatile matter of coal to CnHm.
• Suitable for very critical heating curves ±2 ℃ variations.
• No refractory used in gasifier. Thus, frequent cleaning not required.
• 100% recirculation of water condensate – zero liquid discharge technology.
• Tar & water does not mix at any point as they come out from different discharge points of gasification progress.
• Tar fluidity is very good. This enables tar to be pumped for any utility or outside sale.
• Gasifier is in line with environment protection agencies CPCB, SPCB & MOEF & CC.

For more information, please feel free to contact our gasifier technologist. Write to us at info@casepl.com

Challenges in Coal Gasification Industry | CASE Group

The advent of Coal Gasification into the Indian Industry was seen as a major fuel source and a perfect substitute for high-cost fuels which were then being used for the thermal application during manufacturing of items like steel, glass, ceramics, chemicals, aluminum etc. The manufacturing of finished products, fuels such as HFO, Natural Gas, LNG, Propane etc. were being used in large quantities. Coal Gasification not only substituted these industrial fuel but also set a benchmark for new and upcoming industry to exploit and explore the possibility of using coal gas as their primary process fuel.

With it came the challenges of handling an environmentally non- friendly raw material "Coal". During the process of coal gasification, the management of by-products such as tarry wastes, phenolic water, coal ash, coal dust etc. were also required to be addressed.

Coal gasification has seen a metamorphosis in technology development. Primarily, two variants are prevalent in the Indian Industry- Static Bed Coal (SBC) Gasification and Fluidized Bed Coal (FBC) Gasification. Depending on the application and magnanimity of the project and commercial challenges, the gasification technologist recommends and selects the desired variant.

Pyrolysis Clean Coal Gasification which happens to fall under the category of SBC Gasification has been able to address mostly all of the environmental challenges faced by the gasification industry. This design ensures a Zero Liquid Discharge (ZLD) process by which all the phenolic water generated in the process is treated and used back (re-cycled) in the gasification process cycle. This takes care of the Phenolic Water concern. The tar generated in the process is professionally handled in underground concrete tanks. The tar has high fluidity and can be combusted and used as a fuel for the plants thermal applications. The coal ash generated during the gasification process is granular in form and in no way be held responsible for cause any form of air pollution. This coal ash can be used as land fill or can be used as an aggregate for making cement blocks. Thus, we can see choosing the right technology not only helps the end-user in preventing further damage to their environment but also save millions and millions of rupees for themselves and for the nation.

It is a known fact that Coal Gasification implemented in the correct way will result in enormous savings and will narrow the huge gap on India's Balance of Payments (mainly because of crude oil imports reduction).

                                                                                 By Rahuel George, CountryHead of CASE Group

About the Author 

Rahuel George has an experience of more than 15 years in the coal gasification industry. He is the CountryHead of CASE Group, an organization known for setting up most of the available technologies in the field of coal gasification. He has successfully handled and executed numerous "Hot Gasifier", "Pyrolysis Clean Gas" Technology  projects in India and abroad. He has been a lead member is setting up Coal Gasification as a cost effective fuel for "Glass Industry" and "Porcelain Insulators Industry", these projects being first of their kind in the world.