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Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 12, December 2013)
Biomass,
Co-gasification,
Coal,
TABLE I
PLANNED PETCOKE BASED GASIFICATION PROJECTS [1]
Plant Name
Technology
ConocoPhillips
Bhatinda IGCC
Marifu IGCC plant
Lima Energy IGCC plant
Edison Mission Energy
Sweeney Gasification
Project
Mississippi Gasification
LLC
Valero Energy Corp.
Texaco
Texaco
ConocoPhillips
GE
Product
Electricity,
Chemicals
Electricity
Electricity
Electricity
Electricity
ConocoPhillips
Electricity
ConocoPhillips
Gaseous fuels
ECUST OMB
Gaseous fuels
Petcoke,
I. INTRODUCTION
The production of petcoke has reached approximately
150 million metric ton per annum (MMTPA) for which the
United States alone is responsible for 47 % of total
production [1]. The petcoke production is anticipated to
rise by more than 70 MMTPA in 2015 [1]. On the other
hand, the demand for the petcoke is projected to reach
about 148 MMTPA till the same year [13]. Hence, there is
a challenge to create a technology that is economical and
environmentally benign to utilize the petcoke. Petcoke can
be directly utilized for power generation by combustion.
Also, petcoke can be converted into syngas by gasification
process. Gasification is the proved technology in order to
convert carbonaceous feed, such as coal, petroleum coke
(petcoke), heavy residual oil, wastes and biomass into
valuable products mainly via syngas (synthesis gas) route
[1][2]. Gasification of petcoke is a favorable technique
since it can capture most of the energy content and is
environmental friendly. Among all worldwide planned
gasification projects almost 15 % are based on petcoke as
their feedstock. Table I shows the planned gasification
projects coming up as petcoke for their main feedstock [1].
167
18
Feed
Petcoke
Petcoke
Coal
Petcoke
Biomass
Petcoke
Coal
Biomass
V. GASIFIER REACTORS
A. Entrained flow gasifier
There are principally three gasifier types that can be
used in this regard, viz. entrained flow, fixed bed and
fluidized bed gasifiers [1]. Gasification of petroleum coke
is mostly favored in entrained flow gasifiers, because high
temperature operation can result in complete carbon
conversion [1]. However, high oxygen requirements,
significant outlet gas cooling, expensive materials of
construction and special heat exchangers are the drawbacks
of this type of gasifiers [6].
169
Gasifier
Feed
Gasifying
Agents
O2
Steam
Operating
Conditions
Mentioned
only High
temp.
Entrained
flow gasifier
Petcoke
Coal
Biomass
Entrained
flow gasifier
Oil sand
Coke
Coal
(Lignite,
Bituminous)
CO2
Steam
T=
12001400 C
P=750 kPa
Entrained
Flow
Gasifier
(1T/d)
Petcoke
Coal
(Lignite)
O2
Steam
T=
14001600 C
Entrained
Flow
Gasifier
(pilot)
Petcoke
Coal
O2
T=900975C
P=0.1-2.4
MPa
Study Remarks
Using biomass in the system decreases sulphur and ash content of the blend.
Also, decreases the steam demand.
Some types of biomass such as straw contain chlorine that causes corrosion.
Also, some biomass contains potassium or calcium that reduces ash fusion
temperature.
Blending of sub-bituminous coal with coke alleviated the slagging problem
associated with the coal gasification alone.
Blending Coke with Lignite increased carbon conversion and cold gas
efficiency as compared to coke gasification alone.
Steam had a considerable effect on CO and H2 production, but CO2 did not
have much impact on carbon conversion.
Gas composition was (22% H2, 39% CO and 34% CO2) in case of petcoke
gasification alone. But it was (25% H2, 43% CO and 27% CO2) for
gasification of the blend.
Calorific value and cold gas efficiency of blend were higher than those of
petcoke alone.
When more than 70% coke was mixed with the coal, the slagging problem
associated with the coal gasification was alleviated.
170
Gasifier
Feed
Gasifying
Agents
Operating
Conditions
Study Remarks
Pressurized
Fixed Bed
Gasifier
Petcoke
Coal
Biomass
O2
Steam
T=9501000 C
P=15 atm
Stainless steel
tubular reactor
O2
Steam
T=8501000C
P=0.5-2
MPa
Pressurized
Fixed Bed
gasifier
Petcoke
Coal
(bituminous)
Biomass (OS,
EB, AS)
Petcoke
Coal
Biomass
O2
Steam
T= 1000 C
P=1-1.5
MPa
Drop-in-fixedbed Reactor
Petcoke
Coals
CO2
Steam
T=10001600C
P=1 atm
Fixed Bed
Gasifier
Petcoke
Coal
Biomass
O2
Steam
T= 1000C
C. Thermogravimetric analyzer
Thermogravimetric analyzers are used as preliminary
study tools for gasification of carbonaceous solids and their
blends. Table 4 represents a few TGA studies on petcoke
and its blends with biomass and coal. TGA analyzers can
operate at high temperature and pressures [6] [8].
Parameters such as reactivity, gasification rate, activation
energy, heating rate and temperature have been studied
with this method as shown in the Table V. Hence, they are
excellent tools for understanding of gasification behaviors
171
Gasifier
Feed
Gasifying
Agents
Operating
Conditions
T= 11001400 C
P=1 atm
Study Remarks
TGA
Analyzer
Petcoke
Coal (Anthracite)
TGA
Petcoke
Coal liquefaction
residue (CLR)
CO2
T=9001050C
P=0.1 MPa
The AAEM and iron and sulphur species in the CLR could catalyse the
gasification of the petcoke.
They observed that both catalyst loading and temperature have a significant
effect on the gasification rate.
TGA
Petcoke
Coal (Lignite)
O2
CO2
Steam
T=1000 C
Pyrolysis behaviours in CO2 environment are same for both pure and the
blends up to 700c i.e. no synergy during pyrolysis.
Burning process is somewhat delayed in oxy fuel than in O2 environment.
In O2 rich conditions, characteristic temperatures decrease and rate of
weight loss increased.
TGA
Petcoke
CO2
T= 725825C
P=0.12.1 MPa
High pressure and K loading increased the gasification rate but not
reactivity. High pressure reduces catalyst volatilization hence rises reaction
rate.
K catalyst was less effective when loaded on the char than on the raw
petcoke.
TABLE VI
FLUIDIZED BED GASIFIER STUDIES [8]
Gasifier
Feed
Bubbling
Fluidized
bed reactor
Petcoke
Biomass
Gasifying
Agents
O2
Steam
Operating
Conditions
T=9501200 C
P=0-1 bar
Study Remarks
By rising temperature carbon conversion will increase and tar formation in
the product will decrease.
Alkali and alkaline earth metals increase the petcoke reactivity during cogasification.
VI. SUMMARY
Due to low reactivity of petcoke, elevated temperature
demand and high sulphur content, the gasification of this
fuel becomes challenging and less efficient. However, high
calorific value and increasing production rate of petcoke
worldwide need an efficient utilization technology like
gasification.
Co-gasification of petcoke along with coal and biomass
is a favorable process since it brings about considerable
improvements in the gasification efficiency.
172
[10]
[11]
[12]
[13]
[14]
[15]
[16]
[17]
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