Effect of slag composition on corrosion resistance of high chromia refractory bricks for industrial entrained-flow gasifier

The slag composition corresponding to different coals varies significantly,which directly affects the operation of industrial entrained-flow gasifier and the service life of refractory bricks.In this study,the corrosion resistance of several typical coal slags for gasification on high chromia refractory bricks was comparatively investigated by static laboratory crucible tests and thermodynamic simulations.The results demonstrated that the corrosion degree of high chromia refractory bricks by different coal slags was high-Ca/Na slag>high-Fe slag>high-Si/Al slag.The surface structure of the refractory was relatively flat after corrosion by high-Si/Al slag,and the primary corrosion reaction was the partial dissolution of the matrix by the slag.High-Fe slag was prone to the precipitation of iron phases as well as the formation of(Mg,Fe)(Al,Cr)_(2)O_(4)composite spinel layer at the slag/refractory interface.The high-Ca/Na slag was susceptible to react with the refractory to yield a low melting point phase,which led to the destruction of the matrix structure of the refractory and an isolated distribution of particles.In addition,the monoclinic ZrO_(2) in the refractory reacted with CaO in the slag to formed calcium zirconate,which loosened its phase toughening effect,was the primary factor that aggravated the refractory corrosion.

Comparison of Combustion Characteristics of Tars Produced with Tobacco Stem Biomass Gasification

In order to study the combustion characteristics of tar in biomass gasifier inner wall and gasification gas,“tobacco stem semi-tar inside furnace”,“tobacco stem tar inside furnace”and“tobacco stem tar out-of-furnace”were subjected to thermogravimetric experiments,and the combustion characteristics and kinetic characteristics were analyzed.The result shows that“tobacco stem semi-tar inside furnace”has the highest value and“tobacco stem tar out-of-furnace”is has the lowest value on ignition characteristics,combustion characteristics and combustible stability;“tobacco stem semi-tar inside furnace”has the lowest value and“tobacco stem tar outside furnace”has the highest value on burnout characteristics;“tobacco stem tar outside furnace”has the highest value and“tobacco stem tar inside furnace”has the lowest value on integrated combustion characteristics.

Three Stage Equilibrium Model for Coal Gasification in Entrained Flow Gasifiers Based on Aspen Plus

A three stage equilibrium model is developed for coal gasification in the Texaco type coal gasifiersbased on Aspen Plus to calculate the composition of product gas, carbon conversion, and gasification teml^erature. The model is divided into three stages including pyrolysis and combustion stage, char gas reaction stage, and gas p.hase reaction stage. Part of the water produced in thepyrolysis and combust!on stag.e is assumed to be involved inthe second stage to react with the unburned carbon. Carbon conversion is then estimated in the second stage by steam participation ratio expressed as a function of temperature. And the gas product compositions are calculated from gas phase reactions in the third stage. The simulation results are consistent with published experimental data.

Refractories Utilizability for Slagging Gasifiers

Slagging coal gasification process became a highlight of coal chemical industry in China during the last decade. Refractory lining＇ s life of slagging gasifiers is one of the most critical factors for a cost - effective operation. The paper introduces current status of coal gasification in China, lining structure of slagging gasifiers and performance of refractory lining. It also summarizes the major factors impacting on refractory wear in slagging coal gasifiers in four Chinese chemical plants, based on ten years of industrial experience. The utilizability is discussed in terms of cost -effectiveness of high chromia refractories and possibility of the alternatives.

Numerical Simulation of Thermal Stress Field of Water-cooled-wall Pulverized-coal Gasifiers

A local thermal stress model of water-cooled-wall pulverized-coal gasifier was built, and ANSYS was used to simulate the stress field in the gasifier operation to research the damage of refractories and slag layer caused by the thermal stress. The results reveal that:（1） the maximum stress of water-cooled-wall gasifier appears at the interface between anchor nails and refractories as well as the interface between refractories and the slag layer, and the maximum stress of slag layer appears on the surface of the slag layer;（2） the increase of slag layer thickness can significantly reduce the thermal stress at the interface between anchor nails and refractories, but increase the thermal stress between slag layer and refractories;（3） when the therma I conductivity is 2-6 W · m-1 · K-1, the thermal stress increases rapidly with the increase of the thermal conductivity, but when the thermal conductivity is 6-10 W · m-1 · K-1, the thermal stress is basically stable;（4） the higher the cooling rate, the faster the decreasing speed of the temperature and thermal stress.

Main Influencing Factors on Service Life of High Chrome Refractories for Coal Water Slurry Gasifiers

The main characteristics of high chrome refractories for coal water slurry gasifiers were introduced. The damage mechanism of the refractories was analyzed by observing the microstructure of the used high chrome refractories with the aid of SEM. The main influencing factors on the service life of the refractories were summarized.

Implementation of a Demoisturization and Devolatilization Model in Multi-Phase Simulation of a Hybrid Entrained-Flow and Fluidized Bed Mild Gasifier

A mild gasification process has been implemented to provide an alternative form of clean coal technology called the Integrated Mild Gasification Combined Cycle (IMGCC), which can be utilized to build a new, highly efficient, and compact power plant or to retrofit an existing coal-fired power plant in order to achieve lower emissions and significantly improved thermal efficiency. The core technology of the mild gasification power plant lies on the design of a compact and effective mild gasifier that can produce synthesis gases with high energy volatiles through a hybrid system: utilizing the features of both entrained-flow and fluidized bed gasifiers. To aid in the design of the mild gasifier, a computational model has been implemented to investigate the thermal-flow and gasification process inside this mild gasifier using the commercial CFD (Computational Fluid Dynamics) solver ANSYS/FLUENT. The Eulerian-Eulerian method is employed to model both the primary phase (air) and the secondary phase (coal particles). However, the Eulerian-Eulerian model used in the software does not facilitate any built-in devolatilization model. The objective of this study is therefore to implement a devolatilization model (along with demoisturization) and incorporate it into the existing code. The Navier-Stokes equations and seven species transport equations are solved with three heterogeneous (gas-solid) and two homogeneous (gas-gas) global gasification reactions. Implementation of the complete model starts from adding demoisturization first, then devolatilization, and then adding one chemical equation at a time until finally all reactions are included in the multiphase flow. The result shows that the demoisturization and devolatilization models are successfully incorporated and a large amount of volatiles are preserved as high-energy fuels in the syngas stream without being further cracked or reacted into lighter gases. The overall results are encouraging but require future experimental data for verification.

Employment of Two-Stage Oxygen Feeding to Control Temperature in a Downdraft Entrained-Flow Coal Gasifier

The traditional practice of employing a two-stage coal-fed gasification process is to feed all of the oxygen to provide a vigorous amount of combustion in the first stage but only feed the coal without oxygen in the second stage to allow the endothermic gasification process to occur downstream of the second stage. One of the merits of this 2-stage practice is to keep the gasifier temperature low downstream from the 2nd stage. This helps to extend the life of refractory bricks, decrease gasifier shut-down frequency for scheduled maintenance, and reduce the maintenance costs. In this traditional 2-stage practice, the temperature reduction in the second stage is achieved at the expense of a higher than normal temperature in the first stage. This study investigates a concept totally opposite to the traditional two-stage coal feeding practices in which the injected oxygen is split between the two stages, while all the coal is fed into the first stage. The hypothesis of this two-stage oxygen injection is that a distributed oxygen injection scheme can also distribute the release of heat to a larger gasifier volume and, thus, reduce the peak temperature distribution in the gasifier. The increased life expectancy and reduced maintenance of the refractory bricks can prevail in the entire gasifier and not just downstream from the second stage. In this study, both experiments and computational simulations have been performed to verify the hypothesis. A series of experiments conducted at 2.5 - 3.0 bars shows that the peak temperature and temperature range in the gasifier do decrease from 600?C - 1550?C with one stage oxygen injection to 950?C - 1230?C with a 60 - 40 oxygen split-injection. The CFD results conducted at 2.5 bars show that 1) the carbon conversion ratio for different oxygen injection schemes are all above 95%;2) H2 (about 70% vol.) dominates the syngas composition at the exit;3) the 80% - 20% case yields the lowest peak temperature and the most uniform temperature distribution along the gasifier;and 4) the 40% - 60% case produces the syngas with the highest HHV. Both experimental data and CFD predictions verify the hypothesis that it is feasible to reduce the peak temperature and achieve more uniform temperature in the gasifier by adequately controlling a two-stage oxygen injection with only minor changes of the composition and heating value of the syngas.

煤炭地下气化的敏感性地质因素探讨

相对于地面煤化工装置,煤炭地下气化(UCG)炉体为地质体,地质条件准确认识是推进UCG气化成功的关键前提。为了最大限度避免煤炭地下气化选区选址地质风险,以贵州复杂地质条件为例,系统探讨其煤炭地下气化的敏感性地质因素。通过收集梳理贵州煤炭资源勘查资料,建立归一化的参数分级赋值、参数权重向量算法、参数权重积算法等数学模型,准确获取研究区地质参数量化数据;基于由26个地质因素构成的地质参数集,采用数理统计方法,识别地质风险关键因素对复杂构造区煤层UCG可行性的交叉影响,查明建炉可行性、过程易控性、气化安全性、开发经济性“四性”指标敏感性地质风险源。结果表明:“四性”指标地质参数的敏感性有所差异,建炉可行性、过程易控性、气化安全性、开发经济性的地质因素敏感性依次变弱,UCG可行性对建炉可行性的依赖性最强,过程易控性次之,其他两个条件离散性相对较大,敏感性明显降低;就敏感性程度而言,26项地质参数中最为敏感的是煤的坚固性系数,其他8个主控地质因素分别是煤层厚度、煤层倾角、煤厚变异系数、夹矸厚度系数、断层指数、煤层埋深、奥亚膨胀度和黏结指数,影响建炉可行性、过程易控性两个方面。就贵州UCG敏感性地质因素来说,UCG项目成功与否的关键在于建炉可行性,气化炉选址应优先考虑构造发育特征及其对煤层条件的影响;为持续推进煤炭地下气化产业发展,下一步或可立足于我国煤炭资源特性及赋存条件实际,以“四性”认识为基础建立统一的UCG地质风险评价准则,进而为典型地质条件先导性试验区选址提供科学依据。

沸腾床渣油加氢裂化装置投产对重油制氢装置的影响

沸腾床渣油加氢裂化装置投产后,将溶剂脱沥青装置的原料由常减压装置洗涤油和减压渣油调整为渣油加氢裂化装置未转化油,作为重油制氢装置原料的脱油沥青性质由此发生变化。对比重油制氢装置原料油性质、主要操作参数、技术经济指标、气化炉运行周期等参数,结果表明,渣油加氢裂化装置投产后,以脱油沥青为原料的重油制氢装置气化炉油气分布更均匀,气化单元有效气含量提高2.12个百分点,有效气产率提高0.20个百分点,碳转化率提高0.18个百分点,氢气产率提高1.21个百分点,吨氢标油能耗下降140 kg,装置各项技术经济指标均有较大幅度提升,气化炉烧嘴运行周期明显延长。

煤气化渣资源化利用综述

随着“双碳”目标的推进,社会对煤气化渣处理的关注与需求日渐紧迫。综合过往研究,介绍了煤气化渣的主要来源与排渣方式,并分别对比了粗渣与细渣在形貌、粒度组成、矿物物相、化学组成等方面的性质特点,为实现其“减量化、资源化、无害化”利用提供了理论依据。基于气流床煤气化粗渣、细渣显著的性质差异,探索了两者不同的资源化处理方式,并分析了当下利用途径存在的局限性。粗渣具有优秀的水化活性与火山灰活性,在矿井回填、路基填筑、水泥与混凝土骨料、陶粒材料以及墙体材料等中低值利用领域应用广泛,但存在重金属浸出风险、经济效益低等问题。细渣中残炭含量丰富,主要采用重选法与浮选法进行可燃体回收与灰渣分离。但其较高的细粒级含量降低了重选分选精度,复杂的炭-灰结合形态提高了浮选回收难度。同时细渣孔隙结构发达,比表面积高达258.29 m^(2)/g,具有一定的吸附能力,在土壤改良、催化剂载体、化工原料、陶瓷材料、吸附材料等领域应用潜力巨大,但高值化处理工艺复杂,成本较高,工业应用难度较大。针对这些问题,需基于煤气化渣的物化性质,探索大规模消纳与高值化利用相结合的途径,实现对煤气化渣分类分级的资源化利用。此外,需结合现场生产实践,探索煤气化渣就地解决的处理方法以降低运输成本,以及在其产生工艺过程中进行物化性质的诱导改善处理。

BGL气化炉除CH_(4)的操作模拟研究

氮肥行业中BGL气化技术应用前景好,但该技术生产的合成气中CH_(4)含量较高,无法满足合成氨原料要求。本研究充分考虑气化反应特性,拟在BGL气化炉设第二喷嘴,通过二次补燃的方式去除CH_(4)。进而,在已建立的新型BGL气化炉模型基础上,探究了二次补燃去除合成气中CH_(4)的效果。研究表明:补燃剂进料量为第一喷嘴进料量的25%时,出口气体中CH_(4)含量降至1%以下,且碳转化率大于99%。通过提高第一喷嘴进料蒸气比例可获得用于合成氨生产的高氢碳比合成气。

水煤浆气化炉协同处理过程中有机物排放特征——以多环芳烃和二噁英为例

采用工业化试验对水煤浆气化炉协同处理蒽醌染料、精馏残渣、废活性炭、废有机溶剂等多源有机废物过程中多环芳烃(PAHs)和二噁英(PCDD/Fs)的排放特征进行研究.结果表明,协同处理有机废物不会对水煤浆气化炉的气化压力、气化温度和小时产气量产生显著影响,但合成气中CO和CO_(2)的气体体积分数较空白工况有所变化,CO的气体体积分数由40.9%下降至31.5%,而CO_(2)气体体积分数则由23.4%增加至31.0%,主要原因可能是有机废物的引入使得气化炉燃烧更充分;协同工况下气态排放物中PAHs和PCDD/Fs分别以萘和低氯代同系物为主,其中PAHs和PCDD/Fs的总毒性当量分别在0.12–0.49ng-TEQ/m^(3)和1.22–3.82pg-TEQ/m^(3)之间,较空白工况下PAHs(0.06–0.11ng-TEQ/m^(3))和PCDD/Fs(1.34–2.97ng-TEQ/m^(3))的总毒性当量无明显增加,且仍远低于相关标准限值;协同工况下固态样品中PAHs和PCDD/Fs分别以低、中环和低氯代同系物为主,硫磺(0.49ng-TEQ/kg)和炭黑(0.37ng-TEQ/kg)的PAHs总毒性当量,以及碳酸氢铵(8.3pg-TEQ/kg)的PCDD/Fs总毒性当量分别高于其他固态样品的PAHs和PCDD/Fs总毒性当量.协同工况下固态样品中PAHs和PCDD/Fs的总毒性当量较空白工况均无明显增加,环境风险可控.

干煤粉气化炉烧嘴偏置角度变化下的烧嘴罩性能优化研究

介绍了华能公司IGCC机组干煤粉气化工艺,针对干煤粉气化炉一段烧嘴水平偏置改造后,产渣量大幅提升,导致烧嘴罩发生漫渣、泄漏的问题,通过采取提高烧嘴罩探入深度、优化配煤方式控制气化炉产渣量、改造粉煤给料罐底锥稳定煤线波动等措施,进一步提升了烧嘴罩运行的稳定性,基本避免了烧嘴罩发生漫渣、泄漏现象。

灰渣处理方法在煤制合成氨造气系统运行中的应用

通过对高压蒸汽锅炉及气化炉灰渣处理系统相关流程介绍,指出煤制合成氨灰渣处理装置生产过程存在的诸多问题,针对问题采取措施并制定出灰渣处理最佳优化方案,解决生产运行瓶颈问题,达到提高企业经济效益及社会效益目的。

熔渣气化炉喷嘴燃烧区行为的数值模拟研究

燃烧区是熔渣气化炉的重要区域,其对熔渣气化炉的工作状态具有明显影响。基于双欧拉模型探究了燃烧区的速度场、温度场和组分场的分布特征及燃烧区空腔的形成过程。研究发现:工业级熔渣气化炉燃烧区呈“羽”状,其先向炉中心延伸再斜向上发展;气体在熔渣气化炉中心区域的流动速度为2.5 m/s左右,但未形成“高速对撞区”;高温区出现在燃烧空腔外表面附近特别是正对喷嘴且靠近炉中心的区域,该区域的温度可以达到约2000℃;氧气主要分布在气化剂喷嘴前端约0.5 m的空腔内,一氧化碳的分布区域与水蒸气在空间上有较大程度重叠,二氧化碳主要在喷嘴前端空腔外壳附近生成,氢气浓度较高的区域则出现在燃烧区对应空腔的上沿;沿喷嘴轴线方向,气体温度呈先升至峰值再逐渐下降的趋势。随着气化剂流量的增大,燃烧温度极大值出现的位置逐渐朝炉中心处移动,并呈较明显的线性变化规律。

气化炉激冷室堆焊层开裂原因

在对某气化炉进行定期检验过程中,发现气化炉激冷室内壁堆焊层存在大量树枝状裂纹,激冷水进口接管处出现穿透性裂纹。采用宏观观察、水质分析、金相检验、扫描电镜及能谱分析等方法对气化炉开裂原因进行分析。结果表明:气化炉底部黑水中含有大量氯离子,激冷室不锈钢堆焊层中镍元素含量较少,且气化炉长期在高温及应力条件下服役,最终导致堆焊层发生应力腐蚀开裂。

F-T固废黏附特性调控及成浆特性研究

F-T固废由含油铁基废催化剂和稳定渣蜡组成,含有55%~65%的蜡质组份,属于危废。文中通过将F-T固废与水煤浆气化装置煤粉进行共混复配,研究了F-T固废黏附特性调控,添加F-T固废的水煤浆表观黏度、静态稳定性等成浆性能,为在气化装置上掺烧F-T固废,实现资源化利用提供了可靠的实验数据。结果表明:添加烷基酚聚氧乙烯醚或十二烷基苯磺酸钠,可以有效改善F-T固废的黏附特性;相同成浆浓度下,含有F-T固废的水煤浆表观黏度随固废含量增加而增大;当添加10%F-T固废,水煤浆最大成浆浓度由62.2%下降到了60.7%。

煤气间接冷却改造后脱硫系统副盐升高的原因分析及对策

传统固定层常压间歇式气化炉半水煤气采用循环水直接冷却,存在有害物质向空气中逸散的问题。根据国家环保政策要求,山西晋丰煤化工有限责任公司将煤气直接冷却改造为间接冷却。改造后,煤气循环水有害气体逃逸问题得以解决,但煤气中氰化氢被带往一次脱硫工段,并形成硫氰酸钠副盐,造成脱硫塔堵塞与物料消耗过高。介绍了硫氰酸盐的形成机理,并重点就脱硫溶液分盐技术和NHD溶液脱硫技术两种改造方案进行了分析。

生物质蒸汽汽化制氢的优势及其特性探究

通过汽化剂的种类来确定蒸汽汽化制氢的效果;分析了温度、蒸汽/生物质的质量比(S/B)2种影响因素对生物质蒸汽汽化制氢中气体成分和H_(2)/CO(氢气与一氧化碳的体积分数比)的影响;最后,从催化剂的种类及其改性的角度来分析生物质蒸汽汽化效果。结果表明,以水蒸汽为汽化剂的生物质汽化制氢技术的产氢质量较好,而且适当的汽化温度和S/B对生物质蒸汽汽化制氢具有较好的效果,传统的金属催化剂通过改性的方法可以获得更好的催化效果,且尽可能规避了未改性前的不足。