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

Automatic Gasifiers Account Low Operation Costs

Putting tremendous emphasis on research and development, CASE has achieved highest level of automation for their Hot Gas Coal Gasifier series. Because of this, there has been reduction in operation costs accountable towards (lesser people required for operation, increase in gasification efficiency, life of equipment), thus saving huge amounts for the industry.

The automatic feature help the operator to visualize the process flow of hot gas station. The process can be visualized on the HMI screen with temperature & pressure measured at the inlet and outlet of the gasifier. Automation also include automatic water feeding in the vapour drum, measuring of number of coal feeding stokers and automation of ash removal system from the gasifier. Quantum of the gas fed through the gasifier display is an optional feature.

To know more about CASE Hot Gas Coal Gasifier, please feel free to contact our Coal Gasifier Supplier 

Putting tremendous emphasis on research and development, CASE has achieved highest level of automation for their Hot Gas Coal Gasifier series. Because of this, there has been reduction in operation costs accountable towards (lesser people required for operation, increase in gasification efficiency, life of equipment), thus saving huge amounts for the industry.

The automatic feature help the operator to visualize the process flow of hot gas station. The process can be visualized on the HMI screen with temperature & pressure measured at the inlet and outlet of the gasifier. Automation also include automatic water feeding in the vapour drum, measuring of number of coal feeding stokers and automation of ash removal system from the gasifier. Quantum of the gas fed through the gasifier display is an optional feature.

To know more about CASE Hot Gas Coal Gasifier, please feel free to contact our Coal Gasifier Supplier 

Pyrolysis Clean Gas Technology: A brief note

Pyrolysis technology in the field of gasification is something new to learn. Google says that pyrolysis is the chemical decomposition of carbon-based materials through the application of heat. It must be noted that CASE Group in India has already introduced Pyrolysis Clean Gas Technology in India. And currently, the engineering firm is busy with some of its ongoing projects. Being highly on demand in glass industry, ceramics, chemical plants, steel to name a few, the CASE is offering state-of-the art pyrolysis technology in three variants, as per user requirement.

Pyrolysis Clean Gas Technology has huge advantages over any other variants of Gasification technologies available in the world today. Engineers at CASE have clearly explained the difference between the three variants.

• 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 of Very Clean Cold Gas Station additional ESP is installed after the Indirect Cooler to further reduce tar and dust level below 25ppm. 

For more information, talk to our Pyrolysis Gasifier Manufacturers at CASE Group

Using Coal in Gasification Technology

It is known to all that coal is one such material which can compete against other fuels very effectively. But, one big concern is the 'right use of coal'.

CASE Group, a team of engineers in India understands the power of coal. Also, the increasing price of petroleum product like diesel, furnace oil, kerosene etc. has made coal-firing as primary choice, a relatively less expensive carbon-containing material.

Considering the rich Considering the rich availability of coal reserves, CASE has come up with coal gasification technology.

Today, CASE Gasifier is only gasifier which is able to replace 100% Furnace oil for stainless Steel billet heating application. Till date, CASE Group have successfully installed over 200 Gasifiers in steel industry, the application being majorly for Reheating Furnaces for Rolling Mills.

Write to us at info@casepl.com and know more.

𝐀𝐛𝐨𝐮𝐭 𝐂𝐀𝐒𝐄 𝐆𝐫𝐨𝐮𝐩

CASE Group has well-established set up in India. CASE deals in FRP Rectangular Cooling Towers, FRP Multicell Cooling Towers, FRP Intelligent Cooling Towers which came in variable color options, Hot Gas Coal Gasifier, Pyrolysis Clean Gas Coal Gasifiers, Circulating Fluidized Bed Coal Gasifiers, Pulse jet Air Pollution Control Equipment Bag House, Scale-Ban (Non Chemical Online Scale Preventor), HSS Rolls (High Speed Steel Rolls), Block Mills and Coal Briquetting machines etc. and many more.

Coal Gasifier: Why should you install this heavy equipment

CASE Coal Gasifiers are known for unmatched design, equipment durability, robust technology, world-class performance and persistent service to its clientele.

The mentioned below features which will definitely suggest you to install a CASE Coal Gasifier in your industrial set-up.

1) Gas Temperature is always between over 475° C.
2) There is no tar formation in the gasifier.
3) Technology processes both fix carbon and volatile matter present in the coal.
4) International safety norms followed.
5) Easy to operate.
6) High Calorific value of gas 1200 Nm3/Hr
7) High volume of gas for the same size as compared to other brands.
8) Prompt delivery.
9) Dedicated after sales service.

About CASE Group:
CASE is a 30 years old engineering company with a well-established set up in India. CASE deals in FRP Rectangular Cooling Towers, FRP Multicell Cooling Towers, FRP Intelligent Cooling Towers which came in variable color options, Hot Gas Coal Gasifier, Pyrolysis Clean Gas Coal Gasifiers, Circulating Fluidized Bed Coal Gasifiers, Pulse jet Air Pollution Control Equipment Bag House, Scale-Ban (Non Chemical Online Scale-Preventor), HSS Rolls (High speed steel rolls), Block Mills and Coal Briquetting machines etc. and many more.

Use Producer Gas to Produce More Sponge Than Before

Are you looking forward to improve the production of sponge iron? If so, then here is an easy and affordable trick for you. Just go for CASE Coal Gasification Technology. Yes, with the help of CASE Coal Gasifier you can speed up the metabolism and produce more sponge than before.

CASE Coal Gasifier are capable of generating considerable amount of gas to speed up the metabolism process and produce more sponge. In this way industry owner will see a remarkable elevation in the profit-graph. 

It's worth informing that CASE Gasifier ensure no tar formation in the gasifier parts or in the pipeline. It is easy to operate and follows international safety norms.

In case, the operator feels hurdle in operating the gasifier machine, CASE Group offers dedicated after-sales service anytime as per the convenience of the clients.

Coal Gasifier Role in Ceramic Tile Making

Ceramic industry mostly manufactures wall and floor tiles used for interior and exterior decoration. The production of tile dates back to ancient times. But then, the process was not as famous as today it is. The invention of the tunnel kiln at around 1910 has made tile manufacturing highly automated and the art became a business at industrial scale.

Raw materials like clay minerals, chemical additives are pulverized and classified at different stages. After several steps, the tile is exposed to high heat so as to get the desired porosity and longevity.

CASE Gasifiers does the task of heat application in ceramic units. In the gasifier, the coal is converted to producer Gas (Hot or Cold) and the gas produced is used for thermal application.

The easy to operate CASE Coal Gasifier assures no tar formation in the pipeline and gasifier. The gasification process fix both carbon and volatile matter present in the coal.
CASE Gasifier are popular in the industry for their unmatched design, equipment durability, state-of-the-art technology, world-class performance and relentless service to its clientele.

How CASE Coal Gasifier works: A short note

The products of reaction change, significantly as the oxygen to fuel ratio changes from combustion to gasification conditions. Because the mixture under gasifying conditions is fuel rich, there are not enough oxygen atoms available to fully react with the feed.

CASE Coal Gasifier Plant

Consequently, instead of producing CO2, the carbon in the feed is converted primarily to Co.

The CASE  Coal gasifier has been extensively designed to incorporate the above phenomena to produce Co in abundance by controlling the parameter to achieve the optimum.

𝐀𝐛𝐨𝐮𝐭 𝐂𝐀𝐒𝐄 𝐆𝐫𝐨𝐮𝐩
CASE is a 30 years old engineering company with a well-established set up in India. CASE deals in FRP Rectangular Cooling Towers, FRP Multicell Cooling Towers, FRP Intelligent Cooling Towers which came in variable color options, Hot Gas Coal Gasifier, Pyrolysis Clean Gas Coal Gasifiers, Circulating Fluidized Bed Coal Gasifiers, Pulse jet Air Pollution Control Equipment Bag House, Scale-Ban (Non Chemical Online Scale-Preventor), HSS Rolls (High speed steel rolls), Block Mills and Coal Briquetting machines etc. and many more.

CASE Hot Gas, Multi Fuel, Gasifier

Fuel flexibility is the main feature of updraft multifuel gasifiers. These gasifiers can operate on either coal or biomass. CASE updraft gasifiers tolerate higher ash content, higher moisture content and greater size variation in fuel as compared to downdraft gasifiers.

In updraft gasifiers, gas is drawn out of the gasifier from the top of the fuel bed while the gasification reactions take place near the bottom. As the producer gas passes through the fuel bed, it picks-up volatile matter (tars) and moisture from the fuel. Therefore, the gas from the updraft gasifier contains condensable volatiles. The design and operation of the gasifiers is such that the gas comes out at 450-500°C temperature. At this temperature, most of the volatile hydrocarbons are in vapor form, which add to the energy content of the gas. It is most appropriate to utilize updraft gasifiers in close-coupled-hot gas mode for direct heating applications. However, if the application warrants, the scrubbing of gas to remove the volatiles/ tars is also carried out.

About us
CASE is a 30 years old engineering company with a well-established set up in India. CASE deals in FRP Rectangular Cooling Towers, FRP Multicell Cooling Towers, FRP Intelligent Cooling Towers which came in variable color options, Hot Gas Coal Gasifier, Pyrolysis Clean Gas Coal Gasifiers, Circulating Fluidized Bed Coal Gasifiers, Pulse jet Air Pollution Control Equipment Bag House, Non-Chemical Online Scale-Preventor (Scale-Ban), High speed steel rolls (HSS Rolls), Block Mills and Coal Briquetting machines etc. and many more.
For more information visit us at http://casepl.com/

How to Make Gasifier Process Cheap

Fuel price is soaring each day, not only in India but across the globe. Known to all, fuel is the heart and soul for almost all kind of industries. It is really become tough for industries to maintain the demand-supply chain. The sharply increasing price is affecting small-budget industries to a great extend.

To ease industries, CASE has come up with a unique technology which can at least minimize the production cost. Guess what? Its the coal gasification process which can be used for all kind of thermal application. Check the following points which presents the process to make gasifier process cost-effective.

• Use coal instead of fuel like petrol, diesel, kerosene etc

Coal is abundant and so industries will not face the shortage of feedstock material all the year round. Moreoever, CASE gasifier is compatible with all types of coal and it ensures no pollution as well.

• Use coal briquettes made up of waste coal fines

Do not sweep away the coal fines scattered around on site. Recycle them by making quality coal briquetes. CASE gasifier allows usage of coal briquettes which can save almost 30% of coal used in reduction process.

Till, I come up with some more tips, stay tuned.

Reduce Expensive Fuel Cost by Coal Gasifier Use

If you're worried about your expenses against the purchase of fuel for your industry, then feel a deep relief. Coal Gasifier from the house of CASE is here to replace the use of expensive fuels with cheap coal. The coal gas generated from coal has high calorific value. The generated gas as fuel can be used for thermal applications in industries.

CASE pyrolysis gasification is one such technology which accepts all kind of coal. India is reach in coal reserves. Therefore, industry owners can ensure easy and cheap availability of coal as feedstock material.

One best part of the CASE gasification technology is that there is better tar recovery in the process. The tar produced has high fluidity and so it does not get clogged in the duct of the equipment. 

To know about CASE Coal Gasifier and the gasification technology, contact engineers at CASE.

Special Features of CASE Coal Gasfier

Coal Gasifier by CASE Group comes with lots of special features. The company is pioneer in the

industry and has gained immense popularity among clients globally. It was introduced in 1993 and till date it has successfully commissioned more than 200 gasifiers. 

With CASE gasification technology, most steel industry has replaced the use of expensive fuel (furnace oil, pulverised coal, direct fed coal, propane etc) with cheap coal gas. They are able to cut down production cost and maximize their profit margin.

The success of CASE Gasification technology can be seen with a close view on site at Shivam Iron & Steel Ltd, Girdih, Jharkhand. The kind of technology is highly in use for reheating furnaces for rolling mills. 

Difference Between CASE Coal Gasifier and Other Gasifiers in the Market

CASE in its endeavor to provide gasifier technologies, introduces the replacement of coal fines used in Rotary Kiln to coal gas. This gas not only replaces the coal fines but also results in overall saving of roughly 20% of total coal used. This technology have given new life to Sponge Iron plant as this process is now viable with roughly 20MT of coal saving for 100 TPD Plant in a day.

To know more about CASE Gasifier, please click: Gasifier

Cheap Coal is Energy friendly- Do you Think??

Coal is the main source of power in the world. This natural resource provide a quarter of our primary energy and more than 40% of our electricity. For past many decades it has been serving people and will continue to do so for many years to come.

Despite the abundant availability of coal resources, the challenge, then, is how to harness coal's energy more cleanly. While global attempts to develop carbon capture and storage (CCS) have stalled, a number of countries are looking at different ways to exploit their abundant coal reserves.

Though not all are motivated by the concern of environment. Some are driven by economics and the need for independent energy resource.

Coal is mainly used in coal gasification technology. In the gasification technology, instead of instead of burning the fossil fuel, it is chemically transformed into synthetic natural gas (SNG).

The process of coal gasification is age-old but due to the recent rise in the price of gas and fuels, it has become economically important and viable.

In India, CASE coal gasifiers used in the gasification technology has earned good name and fame. The gasifier is likely to give 100% replacement of furnace oil.

Using Gasification Technology in Steel Rolling Mills

CASE Coal Gasifier in Upper India, Ludhiana

When it comes to talking about Steel Rolling Mills, one can

hardly avoid discussing about 'Heat Treatment Process' required for  heating billets and ingots. Here comes the vital role of gasification. Coal Gasification technology is primarily used for robust heating mechanism in the rolling and re-rolling mills.

Accordingly, a coal gasifier is used in rolling mills to heat billets which is then converted into different shapes and sizes for various applications. Steel in the form of billets and ingots undergo heat treatment to be turned into angles, channels, rounds of steel of different sizes for industrial purposes. 

Why use Gasification for Heating Treatment in  Rolling Mills

Known to all, the heat treatment in industries and manufacturing units can be done by using furnace oil or any other kind of fuel. However, the rising fuel price has left industries in panic situation. Sensing the need of hour, experts have come up with an inexpensive alternative solution- The Coal Gasification Technology.
Advantages of using Coal Gasfier in Steel Rolling Mills

Coal Gasifier utilizes the natural resource- coal to generate producer gas for heating process. A beneficial point is that India is rich in coal reserves and producer gas can be generated easily by means of coal gasfier.

This innovative technology was initiated by CASE Group in India. The group was first of its kind to introduce the technology which ensures replacement of 100% furnace oil with producer gas.

Kudos to the CASE Group!!!

Don’ts in Gasification Plant

Coal Gasification Plant in India

Today, I’ll unfold some special instruction to be followed in the gasification plant. After installation on site, the equipment demands proper care and precautions. Take a look at the things to avoid in and around a gasifier site.

• Do not smoke in the area of the gasifier.

•  Do not carry lighter and match box or any other inflammable material while on the gasifier platform.

• Do not sleep or rest in and around the equipment.

• Do not poke without protective mask on.

• Do not open the poking holes of the equipment when the combustion blower of is shut off.

• Do not poke the gasifier without the steam let off in the poking holes

• Do not inhale Producer Gas

• Do not close the combustion blower of the furnace immediately after the secondary water seal is closed.

• Do not keep the pokers and probe rods in red hot condition.

• Do not stand close to the water seal after it has been closed

• Do not enter into the ducting for maintenance and cleaning

• Do not weld any portion of ducting or any gas carrying elements immediately after closing the water seals.

• Do not try to seal the leakages on any elements, when in operations by any means

• Do not clean the burners immediately after the shut down

• No unauthorized person should be allowed in the vicinity of the gasifier

• No modification should be carried out without the express consent of the supplier

Now, if you’re striking your brain with loads of queries, then go contact the engineers who are specialized in coal gasification technology. Well, you may give a quick knock at the door of CASE Group. The company is a leading supplier of coal gasifiers across the globe. They offer complete package including the supply of equipment, planning, erection, installation and after-sales services.

To verify the aforesaid words, just check: Gasifiers in Steel Industry

Coal Gasifier for 100% Replacement of Furnace Oil in Steel Industry

CASE Coal Gasification technology is one of its kind to replace the use of 100% furnace oil in steel industry. 

It is for the first time in the world that steel industry can cut fuel cost by 60 % while increasing productivity. The producer gas generated by the CASE Coal Gasifier are much cheaper as compared to furnace oil and other fuel products required for heating purposes. Moreover, the technology assures no pollution and no tar formation.

To verify the above mentioned words, you may take a tour to Yash Forgings located in Nagpur, Maharashtra and other existing clients of CASE Group

Till date, the company has installed more than 200 gasifiers across the globe. If you are looking for a better investment, then it is high time to contact a reliable and authentic company, just like CASE

As of now, you may watch the video to take an important call for your business.

Less Coal Consumption in Iron and Steel Industry

CASE Coal Gasifier in Yash Forgings Nagpur

“Coal consumption in the iron and steel industry may decrease considerably from 7% in 2010 to 2011 to 5% in 2031 to 2032”- as per the recent study by the experts. 

However, cement sectors, electricity sectors and other related industries will continue to consume the coal in bulk and may show an increase in the use of this natural resource. Cement sector may show a rise from 3% to 5% over the next two decades while other sectors may count a rise to 30%.

Expert says that the coal production in India has increased rose by 28.5% from 431 million tonnes in 2006 to 2007 to 554 million tonnes in 2011 to 2012 but approximately 84 million tones meet the import demands. 

Therefore, it has been estimated that by the end of 12th Five Year Plan, coal demand may rise to 682.1 million tonnes whereas supply is projected at 492.2 million tones. This will require the import of around 189 million tonnes of coal to meet the industries demand.

The rising demand of coal among industries have led to the development of unique technologies by engineering companies. Of the many, CASE Group in India has come up with coal gasifier which are capable of generating considerable amount of gas for combustion. 

CASE Coal Gasifier is first of its kind in the world, which cut fuel cost by half and ensures increase productivity in the forging industries.

Source: Business Lines.com