gasification technology for rolling mills_ppt
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GASIFICATION TECHNOLOGY FOR
SUBSTITUTION OF FURNACE OIL IN REHEATING
FURNACES OF ROLLING MILLS
B. V. RAVI KUMAR
Director, Cosmo Powertech Pvt. Ltd.Near J ain Public School, Devpuri, Dhamtari Road,Raipur – 492 015, Tel: 0771- 5011262, Fax: 0771-5013016
Email: [email protected]
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Cosmo Powertech Pvt. Ltd. : Activities
R & D and commercialization of coal and biomass gasifiers
Commercial utilisation of gasifiers for
- Substitution of furnace oil in steel rolling mills, steel wire units, aluminiummelting / heating, refractories, etc.
- Small scale power generation
Contract R & D in Iron & Steel sector
Process & energy related consultancy
Work in progress on pyrolysis of coal & biomass
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What is Gasification?
GASIFIER(Partial oxidation process)
Solid Fuel
Air or
oxygen ,
steam
Gaseous Fuel
Ash or slag
Solid fuel converted into clean combustible gas by partial oxidationprocess
Gasifiers are available, which can accept woody biomass, rice husk,agricultural residues and coal as input fuel
Efficiency of conversion varies in the range 60-85%, depending upontype of gasifier design and fuel
Composition of Gas: CO: 10-20%, H2: 10-20%, Hydrocarbons: 1-6%,
CO2:6-12%, N2: 45-55% (for air gasification)
Calorific Value of Gas: 1000-1300 kCal / Nm3 (for air gasification)
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Where Can the Gasifier be Used?
Fuel Gas
Cooling/
Cleaning
Diesel
Engine Gen.Power
Gasifier
Diesel
Fuel Gas
Cooling/
CleaningGas Engine
Generator Power
Gasifier
Fuel Gas
Oil Fired
EquipmentHeat
Gasifier
Gas for
Chemical and Metallurgical
Processes
Fuel Gas
Gas
ConditioningGasifier
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Relevance of Gasification Technology
Solid fuel, when converted into gas, becomes compatible for substitution of liquid fuels in most of the applications – INCLUDING ROLLING MILLREHEATING FURNACES
Gas generated from coal or biomass would be much cheaper thanpetroleum based oil in most parts of India
On an average, 4 kg of solid biomass / coal can give gas equivalent to 1 litreof petroleum fuel. The price of 4 kg solid fuel may vary between Rs. 3.00-6.00 whereas 1 litre of diesel costs Rs. 20.00-22.00 and 1 litre of FO costsRs. 10.00-13.00
Gas combustion is less polluting as compared to direct solid fuel burning oreven furnace oil combustion
Financial savings to individual users, cleaner environment to society, foreignexchange savings to the Nation
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Types of Gasifiers
Moving bed gasifiers
Entrained flow gasifiers
Fluidized bed gasifiers
Moving Bed Gasifiers
Fuel bed moves gradually downwards counter-current or co-current to theflow of gases
Fuel required to be in lumps, fines not suitable
Suitable for both coal & biomass Gasifying medium could be air or oxygen
Ash disposal could be dry or in slag form
Flexible to changes in capacity utilisation, fuel type and fuel size
Examples: Lurgi Dry Ash & BGL Slagging Gasifiers
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Entrained Flow Gasifiers
Pulverized fuel flows co-currently with gases
Fuel required to be pulverized form
Suitable for coal only as it is difficult to pulverize biomass
Gasifying medium is usually oxygen
Operate at very high temperatures, > 1000 C
Ash disposal is usually in slag form
Examples: Shell, Destec and Texaco Gasifiers
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Fluidized Bed Gasifiers
Fuel suspended in gasifying medium (air), air & solid fuel particles together
behave like a fluid
Fuel required to be in small particles (usually less than 5 mm)
Suitable for both coal and biomass
Gasifying medium is usually air Reactor temperatures are generally maintained less than 1000 C
Ash disposal is usually in dry form
Examples: HTW , MBEL Gasifiers
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COSMOMULTIFUEL UPDRAFT
GASIFIERS
Developed and commercialized
for substi tution of petroleum
fuels in industrial furnaces
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Cosmo Multi-Fuel Gasifiers : Features
Convert coal, wood or briquettesof agro residues into producergas
Coal of any grade up to 35% ash
content acceptable
Fuel size: 20-200 mm forbiomass and 25-75 mm for coal
No change in gasifier required
while switching the grade of coalor from coal to wood orbriquettes
Substitute FO, LDO, Diesel or
LPG in furnaces, kilns, hot airgenerators, thermic fluid heatersetc.
Suitable for 25-1000 litres/hour of liquid fuel substitution
Producer gas generated from thegasifier has a calorific value of 1100-1300 kcal/Nm3 and
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Suitable for 25-1000 litres
/hour of liquid fuelsubstitution
75-85% conversionefficiency
Cosmo Updraft Gasifiershave fuel flexibility, operatewith higher efficiency andgive higher flametemperatures as compared
to downdraft gasifiers
Smoke less than FO,pollution decreases
Substantial savings-paybacknormally less than one year
2.2-4.2 kg. Coal (dependingupon grade or 3.5-4.0 kg drywood can substitute 1 litre of
FO/LDO/Diesel
Flexibility of operation withoil retained
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Oxidation Zone
In the oxidation zone, just above the grate, oxygen in air reacts with carbon:
C + O2 ------> CO2 + heat
Also, the steam, which enters the reactor along with air, reacts with
carbon to produce CO & H2 :
C + H2O + heatÅ-----------ÆCO + H2
Temperatures in the oxidation zone are of the order of 1000-1200 0C.
Reduction Zone
CO2, coming from oxidation zone, reacts at the hot carbon surface:
C + CO2+ heatÅ--------Æ 2CO
Steam (H2O), which escapes un-reacted from the oxidation zone, reacts
here with carbon:
C + H2O + heatÅ--------Æ CO + H2
Reduction zone temperatures are in the range 600-1100 0C.
Pyrolysis Zone
Here, at temperatures between 150-600 0C, volatile matter of fuel is liberated. Fixed carbontravels downwards in the reactor and takes part in reduction and oxidation reactions. Volatilematter, which is a mixture of several hydrocarbons, travels upwards, mixed with gas and comesout of the gasifier as part of producer gas.
Drying Zone
Moisture in the fuel is liberated.
Updraft Gasification
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SCHEMATIC OF CUA-SERIES UPDRAFT GASIFIER
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Gasifiers for Furnace Oil Substitution in Individual
Roll ing Mill Furnaces
Most rolling mills are in the range of 5 to 15 tons / hour output capacity
Furnace oil substitution requirement is presumed to be in the range of 200 to 750 litres / hour
For such capacities, air blown, moving bed gasifiers are likely to be mostsuitable
For rolling mills in the regions away from coal mines, the option of biomass may be more viable
Entire furnace oil substitution possible
To take care of contingencies, oil burners are also retained
Installation of a gasifier of appropriate capacity as near to the furnace aspossible
Insulated gas piping of suitable size from gasifier to the furnace
Suitable combustion air system with minor modifications in piping
No major changes in the original equipment (i.e. furnace, kiln, etc.)
required
No effect on the original process
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Solid Fuel to Furnace Oil Conversion Ratios
Calorific Value of Solid Fuel
(kcal/kg)
Quantity of Solid Fuel Required
to Substitute 1 litre FO
(kg)
3000
3500
4000
4500
5000
5500
6000
6500
4.5
3.9
3.4
3.1
2.7
2.5
2.3
2.1
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Economics of Gasifier Installation
The landed price of solid fuel, in equivalent energy terms (say in Rs. per 1000kcal) varies greatly over different parts of the country. Some indicative examples
are in the following Table:
Fuel / Location CalorificValue
(kcal/kg)
LandedPrice
(Rs./ton)
Price inRs./1000
kcal
1500
3500
1200
0.405
0.636
0.343
3700
5500
3500
D-grade coal in Central India
B-grade coal in North India
Biomass in South India
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Assumptions for Calculation of Payback Period
Capacity of gasifier : 5 million kcal/hour (equivalent to 500litres / hour oil)
Investment (excluding coal handling) : Rs. 9.00 million (Rs. 90 lacs)
Furnace oil substituted : 400 litres / hour
Price of furnace oil : Rs. 13.00 / litre
Operating hours : 12 hours / day
Interest : 9 % flat
Payback Period for Different Values of Solid Fuel Price
Solid Fuel Price(Rs./1000 kcal)
0.25 0.30 0.35 .0.40 0.45 0.50 0.55 0.60 0.65 0.70
2.00 2.561.651.401.211.070.960.870.790.73Payback Period
(years)
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Environmental Aspects
Gas burns with cleaner flame : lower dust emissions (evident frominvisible smoke from chimney
Biomass has negligible sulphur and even Indian coal has lower sulphurcompared to furnace oil for equivalent energy output : lower SO2
emissions
CO is a result of incomplete combustion, better mixing of gas & airpossible, with good combustion control lower CO is expected
When biomass is used as fuel, net CO2 additions to atmosphere arezero
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Centralized Gasification Facility for a Cluster of
Rolling Mills
Gasification activity can be de-linked from individual mills
Individual mills can draw gas from distributed gas grid
Gas generation facility could come up as a co-operative venture or asseparate business entity
Gasification Technology (entrained flow or moving bed or fluidized flow)needs to be made depending upon the envisaged size of plant, demandvariation over the day, characteristics of the fuel available,etc.
A detailed techno-economic study would be required to ascertain variousinfluencing parameters
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Thermal Applications of Gasifiers
Heating of Steel in Rolling Mill Rolling Mill Furnace
Tunnel Kiln for Stoneware PipesCO2
Manufacturing
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Site : M/S R. R. Ispat Ltd., Urla Industrial Area,
Raipur (Chattisgarh), India
Capacity & type of : 5 million kcal/hourgasifier installed Multi-fuel updraft
Month & year of : March, 2000commissioning
Fuel used in : D-grade coal (about 30% ash)gasifier
Fuel substi tuted : Fuel oil
Application : Steel reheating for hot rolling
Operating duration : 24 hours / day
M/S R. R. Ispat Ltd. is a steel rolling mill producing 6 to 32 mm diameter rounds and TMT bars. The production capacity of the mill is 10-15 tons /hour. Before installation
of the gasifier, fuel oil was being utilised to heat
steel billets / ingots up to rolling temperature(11500C). The maximum fuel oil consumptionwas about 500 litres / hour. Now, fuel oil hasbeen completely substituted by producer gasgenerated from coal. The maximum coal
consumption (D-grade coal) is about 2000 kg /hour. The fuel cost of heating steel has comedown by 40-45%.
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Site : M/S Unique Structures & Towers Ltd.,
Urla Industrial Area, Raipur (Chattisgarh), India
Capacity & type of : 1.25 million kcal/hougasifier installed Multi-fuel updraft
Month & year of : October, 2001
commissioning
Fuel used in gasifier : Wood or rice husk
Fuel substituted : Fuel oil
Application : Steel reheatingfor hot rolling
Operating duration : 8-12 hours / day
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The gasifier has been installed here under an R&D project, carried out in collaboration
with Indian Institute of Technology, Mumbai and sponsored by Ministry of Non-conventional Energy Sources, Govt. of India.
M/S Unique Structures & Towers Ltd. produces a range of products, which includeangles, channels, rounds & flats in 16 – 150 mm size. The production capacity of the
plant is 5-8 tons / hour steel and it normally operates on 8 hours / day basis. Thefurnace is fired 2-4 hours before start of rolling. Originally, the reheating furnace of themill was fired by with fuel. The average fuel oil consumption was about 280 litres /hour. The gasifier substitutes about 50% of the original oil consumption. To substitute140-150 litres /hour of fuel oil, 500-600 kg / hour of wood or 700-750 kg / hour of rice
husk is being consumed. The reduction in fuel costs is 20-30% depending upon therelative prices of oil & biomass.
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Site : M/S Nahta Metals & Air Products,Urla Industrial Area,
Raipur (Chattisgarh), India
Capacity & type of gasifier installed : 0.50 million kcal/hour
Multi-fuel updraft
Month & year of commissioning : May, 2002Fuel used in gasifier : wood
Fuel substituted : Fuel oil
Application : CO2 manufacturing
Operating duration : 24 hours / day
M/S Nahta Metals & Air Products manufacture carbon dioxide (CO2) for the soft-drinks industry and for inert gas welding applications. The unit was manufacturing180-200 kg / hour of CO2 by burning 65-75 litres / hour of fuel oil. Now, fuel oil has
been replaced by producer gas generated from wood. After installation of thegasifier, about 200-210 kg / hour of wood is being consumed to produce the sameamount of CO2. The savings achieved in fuel costs are more than 50%.
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Site : M/S Sunil Steel Wires, Bhanpuri ,
Raipur (Chattisgarh), India
Capacity & type of : 0.50 million kcal/hourgasifier installed Multi-fuel updraft
Month & year of : May, 2002commissioning
Fuel used in gasifier : D-grade coal (about 30%
ash) or wood
Fuel substituted : Fuel oil
Application : Annealing & galvanizing of steel wires
Operating duration : 24 hours / day
M/S Sunil Steel Wires produce galvanized steel wires of various gauges. They have2 production lines of for continuous annealing and galvanizing operations. Originally
fuel oil was being used for these operations. Theconsumption of fuel oil was 0-80 litres / hour. Afterinstallation of the gasifier, fuel oil has been replacedby producer gas generated from 200-250 kg / hour of either wood or D-grade coal. Switching from wood to
coal or vice-versa is done without any interruption inthe operation. The savings in fuel costs are morethan 50%.
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Site : Mahakoshal Potteries, Katni (M. P.), India
Capacity & type of gasifier installed : 0.25 million kcal/hour
Multi-fuel updraft
Month & year of commissioning : November, 1999
Fuel used in gasifier : B-grade coal
(about 20% ash)
Fuel substituted : Fuel oil
Application : Baking of refractory bricks
Operating duration : 24 hours / day
M/S Mahakoshal Potteries produce refractory bricks. The baking of bricks (1150-12500C) is done in a tunnel kiln, which was originally fired by fuel oil. The gasifierwas installed to substitute 50 % of the original fuel oil consumption of 50 litres /hour. The gasifier is now substituting 25-30 litres /hour of fuel oil by producer gasgenerated from 65-80 kg /hour of B-grade coal. The savings in fuel costs are of
the order of 20%.
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Site : M/S Perfect Stoneware Pipes,
Gwarighat Road, Jabalpur (M. P.), India
Capacity & type of gasif ier installed : 0.50 million kcal/hourWood - Downdraft
Month & year of commissioning : May, 1996Fuel used in gasifier : wood
Fuel substituted : Fuel oil
Application : Baking of stoneware pipes
Operating duration : 24 hours / day
M/S Perfect Stoneware Pipes produce stoneware pipes for sanitary piping. These pipes are baked in tunnel kiln at temperatures up to 11000C. The Kiln was
fired by about 80 litres / hour of fuel oil. The gasifier consumes 160-180 kg / hourof wood and generates producer gas to substitute about 45-55 litres / hour of fueloil. The savings in total fuel costs are in the range of 20-30%.
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Site : M/S Kesari Metals Ltd., Urla Industrial Area,
Raipur (Chattisgarh), India
Capacity & type of gasifier installed : 0.10 million kcal/hour
Wood - Downdraft
Month & year of commissioning : September, 1998
Fuel used in gasifier : wood
Fuel subst ituted : Fuel oil
Application : Heating of aluminum ingots
Operating duration : 8-10 hours / day
M/S Kesari Metals Ltd. produce aluminum extrusions of various shapes & types. Forextruding, aluminum ingots are heated up to a temperature of 4500C, which was doneby firing 10-12 litres / hour of fuel oil. After installation of the gasifier, the fuel oil hasbeen substituted by producer gas generated from 30-35 kg / hour wood. The savingsin the fuel costs are more than 50%.
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