GASIFICATION TECHNOLOGY FOR SUBSTITUTION OF FURNACE OIL IN REHEATING FURNACES OF ROLLING MILLS

B. V. RAVI KUMAR Director, Cosmo Powertech Pvt. Ltd. Near Jain Public School, Devpuri, Dhamtari Road, Raipur 492 015, Tel: 0771- 5011262, Fax: 0771-5013016 Email: cosmo_powertech@yahoo.co.in

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, aluminium melting / 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

What is Gasification?
Solid Fuel

GASIFIER
(Partial oxidation process) Air or oxygen , steam Ash or slag Gaseous Fuel

Solid fuel converted into clean combustible gas by partial oxidation process 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 upon type 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)

Where Can the Gasifier be Used?

Diesel Gasifier
Fuel Gas

Cooling/ Cleaning

Diesel Engine Gen.

Power

Gasifier
Fuel Gas

Cooling/ Cleaning

Gas Engine Generator

Power

Gasifier
Fuel Gas

Oil Fired Equipment

Heat

Gasifier
Fuel Gas

Gas Conditioning

Gas for Chemical and Metallurgical Processes

Relevance of Gasification Technology

Solid fuel, when converted into gas, becomes compatible for substitution of liquid fuels in most of the applications INCLUDING ROLLING MILL REHEATING FURNACES Gas generated from coal or biomass would be much cheaper than petroleum based oil in most parts of India On an average, 4 kg of solid biomass / coal can give gas equivalent to 1 litre of petroleum fuel. The price of 4 kg solid fuel may vary between Rs. 3.006.00 whereas 1 litre of diesel costs Rs. 20.00-22.00 and 1 litre of FO costs Rs. 10.00-13.00 Gas combustion is less polluting as compared to direct solid fuel burning or even furnace oil combustion Financial savings to individual users, cleaner environment to society, foreign exchange savings to the Nation

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 the flow 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

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

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

COSMO MULTIFUEL UPDRAFT GASIFIERS

Developed and commercialized for substitution of petroleum fuels in industrial furnaces

Cosmo Multi-Fuel Gasifiers : Features

Convert coal, wood or briquettes of agro residues into producer gas Coal of any grade up to 35% ash content acceptable Fuel size: 20-200 mm for biomass and 25-75 mm for coal No change in gasifier required while switching the grade of coal or from coal to wood or briquettes Substitute FO, LDO, Diesel or LPG in furnaces, kilns, hot air generators, thermic fluid heaters etc. Suitable for 25-1000 litres/hour of liquid fuel substitution Producer gas generated from the gasifier has a calorific value of 1100-1300 kcal/Nm3 and

Suitable for 25-1000 litres /hour of liquid fuel substitution 75-85% conversion efficiency Cosmo Updraft Gasifiers have fuel flexibility, operate with higher efficiency and give higher flame temperatures as compared to downdraft gasifiers Smoke less than FO, pollution decreases Substantial savings-payback normally less than one year 2.2-4.2 kg. Coal (depending upon grade or 3.5-4.0 kg dry wood can substitute 1 litre of FO/LDO/Diesel Flexibility of operation with oil retained

Oxidation Zone
C + O2 ------> CO2 + heat

Updraft Gasification

In the oxidation zone, just above the grate, oxygen in air reacts with carbon:

Also, the steam, which enters the reactor along with air, reacts with carbon to produce CO & H2 : C + H2O + heat -----------CO + 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 + heat -------- 2CO Steam (H2O), which escapes un-reacted from the oxidation zone, reacts here with carbon: C + H2O + heat -------- 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 carbon travels downwards in the reactor and takes part in reduction and oxidation reactions. Volatile matter, which is a mixture of several hydrocarbons, travels upwards, mixed with gas and comes out of the gasifier as part of producer gas.

Drying Zone
Moisture in the fuel is liberated.

SCHEMATIC OF CUA-SERIES UPDRAFT GASIFIER

Gasifiers for Furnace Oil Substitution in Individual Rolling 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 most suitable 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 as possible 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

Solid Fuel to Furnace Oil Conversion Ratios

Calorific Value of Solid Fuel (kcal/kg) 3000 3500 4000 4500 5000 5500 6000 6500 Quantity of Solid Fuel Required to Substitute 1 litre FO (kg) 4.5 3.9 3.4 3.1 2.7 2.5 2.3 2.1

Economics of Gasifier Installation

The landed price of solid fuel, in equivalent energy terms (say in Rs. per 1000 kcal) varies greatly over different parts of the country. Some indicative examples are in the following Table:

Fuel / Location

Calorific Value (kcal/kg) 3700 5500 3500

Landed Price (Rs./ton) 1500 3500 1200

Price in Rs./1000 kcal 0.405 0.636 0.343

D-grade coal in Central India B-grade coal in North India Biomass in South India

Assumptions for Calculation of Payback Period

Capacity of gasifier Investment (excluding coal handling) Furnace oil substituted Price of furnace oil Operating hours Interest : 5 million kcal/hour (equivalent to 500 litres / hour oil) : Rs. 9.00 million (Rs. 90 lacs) : 400 litres / hour : Rs. 13.00 / litre : 12 hours / day : 9 % flat

Payback Period for Different Values of Solid Fuel Price

Solid Fuel Price (Rs./1000 kcal) Payback Period (years) 0.25 0.73 0.30 0.79 0.35 0.87 .0.40 0.96 0.45 1.07 0.50 1.21 0.55 1.40 0.60 1.65 0.65 2.00 0.70 2.56

Environmental Aspects

Gas burns with cleaner flame : lower dust emissions (evident from invisible smoke from chimney Biomass has negligible sulphur and even Indian coal has lower sulphur compared to furnace oil for equivalent energy output : lower SO2 emissions CO is a result of incomplete combustion, better mixing of gas & air possible, with good combustion control lower CO is expected When biomass is used as fuel, net CO2 additions to atmosphere are zero

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 as separate business entity Gasification Technology (entrained flow or moving bed or fluidized flow) needs to be made depending upon the envisaged size of plant, demand variation over the day, characteristics of the fuel available,etc. A detailed techno-economic study would be required to ascertain various influencing parameters

Thermal Applications of Gasifiers

Heating of Steel in Rolling Mill

Rolling Mill Furnace

CO2 Manufacturing

Tunnel Kiln for Stoneware Pipes

Site : M/S R. R. Ispat Ltd., Urla Industrial Area, Raipur (Chattisgarh), India Capacity & type of : 5 million kcal/hour gasifier installed Multi-fuel updraft Month & year of commissioning Fuel used in gasifier Fuel substituted Application : March, 2000 : D-grade coal (about 30% ash) : Fuel oil : 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 consumption was about 500 litres / hour. Now, fuel oil has been completely substituted by producer gas generated from coal. The maximum coal consumption (D-grade coal) is about 2000 kg / hour. The fuel cost of heating steel has come down by 40-45%.

Site : M/S Unique Structures & Towers Ltd., Urla Industrial Area, Raipur (Chattisgarh), India

Capacity & type of gasifier installed Month & year of commissioning Fuel used in gasifier Fuel substituted Application

: 1.25 million kcal/hour Multi-fuel updraft : October, 2001

: Wood or rice husk : Fuel oil : Steel reheating for hot rolling : 8-12 hours / day

Operating duration

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 Nonconventional Energy Sources, Govt. of India. M/S Unique Structures & Towers Ltd. produces a range of products, which include angles, 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. The furnace is fired 2-4 hours before start of rolling. Originally, the reheating furnace of the mill 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 substitute 140-150 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 the relative prices of oil & biomass.

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 Fuel used in gasifier Fuel substituted Application Operating duration

: : : : :

May, 2002 wood Fuel oil CO2 manufacturing 24 hours / day

M/S Nahta Metals & Air Products manufacture carbon dioxide (CO2) for the softdrinks industry and for inert gas welding applications. The unit was manufacturing 180-200 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 the gasifier, about 200-210 kg / hour of wood is being consumed to produce the same amount of CO2. The savings achieved in fuel costs are more than 50%.

Site : M/S Sunil Steel Wires, Bhanpuri, Raipur (Chattisgarh), India Capacity & type of gasifier installed Month & year of commissioning Fuel used in gasifier Fuel substituted Application Operating duration : 0.50 million kcal/hour Multi-fuel updraft : May, 2002 : D-grade coal (about 30% ash) or wood : Fuel oil : Annealing & galvanizing of steel wires : 24 hours / day

M/S Sunil Steel Wires produce galvanized steel wires of various gauges. They have 2 production lines of for continuous annealing and galvanizing operations. Originally fuel oil was being used for these operations. The consumption of fuel oil was 0-80 litres / hour. After installation of the gasifier, fuel oil has been replaced by 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 in the operation. The savings in fuel costs are more than 50%.

Site : Mahakoshal Potteries, Katni (M. P.), India

Capacity & type of gasifier installed :

0.25 million kcal/hour Multi-fuel updraft

Month & year of commissioning Fuel used in gasifier

: :

November, 1999 B-grade coal (about 20% ash)

Fuel substituted Application Operating duration

: : :

Fuel oil Baking of refractory bricks 24 hours / day

M/S Mahakoshal Potteries produce refractory bricks. The baking of bricks (115012500C) is done in a tunnel kiln, which was originally fired by fuel oil. The gasifier was 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 gas generated from 65-80 kg /hour of B-grade coal. The savings in fuel costs are of the order of 20%.

Site : M/S Perfect Stoneware Pipes, Gwarighat Road, Jabalpur (M. P.), India

Capacity & type of gasifier installed Month & year of commissioning Fuel used in gasifier Fuel substituted Application Operating duration

: : : : : :

0.50 million kcal/hour Wood - Downdraft May, 1996 wood Fuel oil Baking of stoneware pipes 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 / hour of wood and generates producer gas to substitute about 45-55 litres / hour of fuel oil. The savings in total fuel costs are in the range of 20-30%.

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 Fuel used in gasifier Fuel substituted Application Operating duration

: : : : :

September, 1998 wood Fuel oil Heating of aluminum ingots 8-10 hours / day

M/S Kesari Metals Ltd. produce aluminum extrusions of various shapes & types. For extruding, aluminum ingots are heated up to a temperature of 4500C, which was done by firing 10-12 litres / hour of fuel oil. After installation of the gasifier, the fuel oil has been substituted by producer gas generated from 30-35 kg / hour wood. The savings in the fuel costs are more than 50%.

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