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National Coal Gasification Mission

“We have set a target to gasify around 100 million ton of domestic coal by the year 2030. Coal Gas will be used in transport & cooking while urea and steel from gasification will promote manufacturing. Latest technology can be introduced to make gas from coal and environment will be protected with coal gasification” – SHRI NARENDRA MODI, Hon. Prime Minister of India.

What is Gasification?

Gasification is a robust, proven, and versatile technology that produces syn gas (carbon monoxide (CO) + Hydrogen (H₂)) from reaction between carbon, oxygen and steam air at low to high pressure (atmospheric to 30 bar g) and temperature ranging from 1000^oC to 1600^oC.

Gasification not only captures heat but also Chemical value of feedstock like Coal.

However, Indian coal has challenges of high ash (>35%) thermal non-coking coal and high moisture (48% – 54%) lignite which calls for need most applicable technology.

Ash is removed by gravity from the gasifier and is discharged into a system for depressurization and disposal. The gasifier maintains a low level of carbon in the bottom ash discharge stream and achieves overall carbon conversions that can exceed 99%. Cold gas efficiencies of over 80% and carbon conversion of up to 99% have been repeatedly demonstrated on a commercial scale in CFB operating plants.

CFB is more fuel-flexible, utilizing low-rank and other high-ash coals, and offers higher efficiency than competing gasification technologies, due to the fluidized bed design and resulting long residence times of the reacting particles.

Fines carried over from the fluidized bed are separated from the syngas prior to heat recovery and syngas cleanup. The product syngas is essentially free of tars and oils due to the temperature and residence time of the gases in the fluidized bed, simplifying downstream heat recovery and gas cleaning operations.

CFB gasification adopts three-stage waste heat recovery process, which can recover the heat of high temperature syngas to produce high temperature and high pressure steam along with air/oxygen preheating resulting in overall high thermal efficiency.

Technology Overview

Our Partners

JINAN HUANGTAI GAS FURANCE CO. LTD.

Normal Pressure – Air Fed – Fuel

• In Operation Since 2009
• > 22 Operational plants
• Higher calorific value fuel : 1250 kcal/Nm³
• Continuous 21 month gasifier campaign

Ease of Operation & Maintenance

Shanghai Zepu Engineering Technology Co. Ltd.

HIGH PRESSURE – OXYGEN FED – DRI SYN GAS

• Patented and improvised CFB technology
• High Pressure – 3 bar to 40 bar
• Proven commercial scale plants from basic engineering, detailed engineering, and EPC solutions for clean syn gas
• Customised solution for various end-use applications such as clean DRI Syn Gas, Methanol, DME, Ammonia, Urea and SNG
• Strong R&D in line to handle low-rank coals of high ash and moisture

Technical & Economic Advantages

Government of India Incentives

CFB is the only proven commercial-scale technology for high ash Indian coal gasification projects to benefit from all Government of India incentive schemes:

• Viability Gap Funding (₹ 8500 cr)
• Dedicated Coal linkages assurance
• Notified Coal Pricing (Lower coal price than auction rates)
• 50% rebate on captive mine dedicated to surface coal gasification
• Coal Price GST waive off (~ 400 Rs/ton)

National Steel Mission – Guarantee off-take for steel makers

As India’s major contributing GDP National mission to grow to 300 million ton per annum steel production by 2030 from 127 million ton per annum as of 2024 to support strong infrastructure growth, steel producers will also be served by the proven commercial-scale CFB technology clean DRI syn gas from high ash Indian coal gasification projects. These projects will also be 100% Green Hydrogen compatible for coming decades as against Blast Furnace route which depends on high price of coking coal imports.

CFB Coal Gasification – “IN India FOR India”

Technology Selection – Why CFB?

   Commercial scale three technologies which are Fixed Bed, Entrained Flow and Fluidised Bed technologies below pros and cons:

Based on various interactions organised by the Ministry of Coal for the implementation of the National Coal Gasification mission it is evident that all major technology developers such as Thermax, BHEL and CSIR-CIMFR have chosen CFB starting with pilot scale as the most suitable technology for Indian high ash coal.

CFB Technology – How it Works?

Grinding, sorting, shredding, and/or drying may be required to bring the feedstock up to the gasifier feed system’s standards of <10 mm particulate size.

The prepared feedstock is pneumatically supplied to the CFB gasifier vessel, which is a bubbling in circulating fluidized bed reactor. The feedstock combines with air/oxygen and steam as gasification in the fluidized bed, uniform temperature of 1000 ^oC is maintained to provide high carbon conversion and non-slagging conditions for the feedstock’s ash. The CFB gasification process is carried out as partial oxidations as gasification of feedstock with agglomeration and separation of ash.

Technology Features & Advantages

Adaptability of CFB Syn Gas

The syngas is subsequently processed for use in a variety of applications, including direct reduced iron (DRI) steel production, methanol, fertilizers like ammonia, Urea, further ammonium nitrate, substitute natural gas (SNG) and di-methyl ether. Pre-combustion carbon capture CFB Gasification in syngas cleaning systems downstream of the gasification process makes it useful for CO₂ removal as raw material for downstream products and potential to make it carbon neutral technology solution.

Compatibility with downstream DRI Licensors

   CFB technology has full flexibility of H₂/CO ratio, CO₂ removal adjustment as required by all global DRI technology providers offering wide adaptability for the complete technical and commercial optimisation for steel makers.

Flexibility of CFB offering

CFB gasification adopts oxygen-enriched gasification, and the N₂ content in syngas can be effectively controlled below 5% or lower. CFB gasification pressure is high avoiding any downstream compression requirement, and the CH₄ content in the syngas can be up to Controlled ideal for DRI steel-making feedstock.

Compatibility with downstream DRI Licensors

CFB technology has fully aligned requirement of H₂/CO ratio, and CO₂ removal adjustment as required by all global DRI technology providers offering wide adaptability for the complete technical and commercial optimisation for steel makers.

Optimized process configuration

Commercial DRI Plant – Ready for offering

0.5 MTPA DRI – Vertical Shaft Kiln

Clean DRI Syn Gas Process

CFB offers the flexibility of a partial water shift gas process unit for the downstream vertical shaft kiln. Also, this technology is capable for using wide range of O₂ purity from Air Separation unit and CO₂ removal unit required levels.

Conclusion

    DEV ENERGY with its successful Turnkey project design and implementation proven solution provider has delivered > 23 years and is committed to taking National Gasification mission on a fast implementation model with low capital cost using a Circulating Fluidised Bed Technology with commercial scale projects. We are also well aligned with the “Make in India” model even with China Partners as maximizing local manufacturing and minimum proprietary scope (<5%) with no technology transfer fee requirement due to Dev Energy exclusive partnerships already in place. With experienced & qualified EPC solution provider not only can coal gasification projects on fast track but also provide after sales service and operational success for sustainability of high ash Indian coal gasification with CFB.

References

1. https://pib.gov.in/PressReleasePage.aspx?PRID=1999220
2. https://coal.gov.in/sites/default/files/ncgm/ncgm21-09-21.pdf
3. https://www.netl.doe.gov/carbon-management/gasification#:~:text=Gasification%20enables%20remediation%20of%20wastes,net%2Dzero%20energy%20system%20basis.
4. https://pib.gov.in/PressReleasePage.aspx?PRID=1944388

Importance Of Secondary Steel Sector

Secondary steel provides a convincing answer for sustainable practices. Recycling and rerolling methods not only reduce environmental impact they also ensures high-quality goods that fulfil industrial requirements. As the construction industry prioritizes sustainability, using secondary steel is critical for a greener future. That is where secondary Steel Melting Shop (SMS) becomes critical to achieve this.

Steel is one of the most competitive sectors. The makers must be efficient and cost-competitive with main producers that create steel from iron ore. To manufacture molten steel, the secondary steelmaking process must employ electric arc or induction furnaces. In India, approximately 45% of steel is manufactured utilising induction furnaces with two major raw materials – Sponge iron and Scrap steel. The primary expense of producing steel is melting, hence the cost efficiency of the SMS becomes critical.

Heart Of An Efficient Sms Process

• High Power Density 
• High Melt Rate 
• High Yield l Low Heat time 
• Low Power Consumption Per Ton 
• Less Pollution 
• Longer Life of Equipmen

SMS that uses scrap as their primary raw material face significant challenges since scrap is never constant and processing.

Steel Technology 

Scrap can be treated using three basic methods: shearing, baling, and shredding. The process identification is determined by the kind of raw steel scrap, its density, size, cleanliness level, furnace size, furnace power density, and other factors. There are numerous types and sizes of equipment available to process scrap from 1 to 100 tonnes per hour.

The majority of the cost of producing steel is power. Dev Energy has been actively focusing on power reduction, including its dynamics and its relationship to scrap processing. The time required for melting is determined by the scrap’s form, density, and size. Improper input scrap leads to longer melting times and increased power usage.

The aim is to process the scrap in the right settings with technology that matches the type of scrap.

Shredder- Hammer Mill

The Hammer Mill Shredders have output density of almost 1.4 ton/m3 with metal recovery of up to 98%. The operation cost of ~ INR 700 /t makes it savings super star for steel scrap melters.

Steel Technology

Innovative solutions in fumes extraction system from the house of Dev Energy results in high dust removal efficiency and clean gas dust concentration is achieved with minimum work zone emissions.

DEV ENERGY developed and deployed a Dog House based fumes extraction system for induction furnaces, collecting more than 95% of the fumes and total power usage is ~10kwh/t.

Scrap steel has a large amount of galvanised and painted material that is high in zinc, and the dust recovered typically contains up to ~ 40% of this zinc. This dust can be sold on the market. This converts the DEV ENERGY provided pollution control system into a revenue-generating system rather than an expenditure.

The key performance parameter in compliance of PCB Norms is for the Dog House to suck > 95% fumes and the Bag House f iltration to remove the SPM and exhaust through chimney only under norms.

Scrap Pusher compliments the Dog House system to help SMS furnaces achieve the required melting rate. It has hydraulic operation and rotation on Slew bearing. The telescopic boom on hydraulic motor makes it first choice for users.

parameters cannot be defined, therefore the technologies need to adapt to this variable environment. 

The entire process, from scrap purchasing to melting, must be linked with the desired outcome.

 Dev Energy has acquired competence in providing unique turnkey solutions for effective scrap separation, processing, and feeding into the furnace. This feeding system must also be connected with the pollution or flue control system used during the melting process.

Scrap Processing

 The scrap processing machines must be selected with reference to the type of scrap that the SMS can source. The machines must be complemented by appropriate scrap unloading and segregation systems. After the scrap is treated, the melt shop design and equipment should be able to feed it into the furnace. Dev Energy offers a full variety of turnkey solutions for scrap unloading, segregation, scrap processing and scrap handling and feeding.

 Box Shear

Box shears are ideal for processing a huge variety of scraps. The machine can take all the input scrap and convert it into output of density ~ 1 ton/m3.

The operational cost of ~ INR 250/t makes it the wisest choices for users.

 The perfect implementation of superior shredders and shears reduces the power consumption by up to ~ 8% and heat time by up to ~ 10% resulting in overall ~ 10% net cost savings.

 Fumes Extraction System (FES)

 The National Green Tribunal (NGT) rules and the more stringent Pollution Control Boards (PCBs) have compelled SMS retailers to investigate and reassess flue control system technology. The present devices can only absorb up to ~ 60% of emissions and cannot fulfil government standards. Because they are intended for exceptionally high working pressure, their operating costs are quite expensive.

 Scrap Charging Trolley which is remote controlled and runs at speed of ~ 30 MPM with VFD DRIVE helps feed the scrap to furnaces without the need for Dog House to be moved. Both back-front and side-travel option are available for versatile layout design.

 By achieving desired parameters at the outlet of fumes extraction system the workers can do work more efficiently. Higher Yeilds becomes possible once the above mentioned systems are installed and utilised regularly.

Conclusion

Dev Energy is a prominent and reliable provider of end-to-end operational cost reduction solutions for secondary steel melting plants, including scrap processing, scrap feeding and fume extraction systems. With a proven solution offering spanning more than two decades, we have lowered our clients’ production costs while increasing compliance with PCB standards in tighter emission specification limits. Overall, we are devoted to continuing to increase production efficiency in the secondary steel melting shops business.