Presentation on Coal Gasification

Presented By:
Avinash Tagde
Aaryan Dhabale
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Coal Resources in India & Coal as Major Source of Energy Mix
• 361 Billion Tons of coal resources is estimated by the GSI up to a depth of 1200 meter (as
of 2022).
• G9 G14 grade coal resource is around 170 Billion Tons.
• In the current financial year (April - December 2023), total production of coal in India is in
tune of 665 Million Metric Tons.
• According to the NITI Aayog's anticipated coal demand projection for 2030, coal usage will
be 1192-1325 MT.

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Future Energy Demand Scenario in India
• The country's energy demand has tripled over the last three decades and is marked by a
falling share of traditional biomass leaving coal and oil in a dominant position
• Electricity demand under the BAU scenario in 2047, will be 5,651 TWh - NITI Aayog
• Total energy Demand by 2070-18,900-22,300 Terawatt hours per year (TWh/yr)
• Coal to play a dominant role & share in primary energy to remain 29% in 2047 (Net Zero
Scenario)
• Thus, conventional ways of utilization of fossil fuel will see complete paradigm shift,
aiming towards increased efficiency and cleaner approaches, abiding by Net Zero Targets

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A possible roadmap for the introduction of new technologies involving the utilisation of
coal for energy

2020 • improvement of existing plants

• Co-firing
• CFBC systems
• Ultrasupercritical boilers
• Combustion & Gasification/ CO2 capture
• Oxyfuel combustion & CO2 capture
2050 • H2 economy

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Clean coal technologies are a key step towards near zero emissions from coal

Focus on technologies to reduce both Green House Gases and Non - Green House Gases (NOx, SO2,
Particulate Matter) emissions

• Reducing Coal Consumption

• Reducing non-GHG Emissions- Coal Gasification
• Carbon Capture & Storage

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THRUST AREA: Clean Coal Technologies (CCT)
• Major problems associated with the current coal based technologies are lower efficiency,
environmental loading and consequent damages thereof.
• Clean coal technologies are becoming popular due to high efficiency and lower environmental
impacts.
• Coal gasification has been internationally accepted as one of the most viable and effective clean
coal technology for production of synthetic fuels, chemicals, various thermal applications & power
generation. It also offers a practical means of utilizing coal for meeting stringent environment
requirements.
• Bulk coal reserves in India (about 73%) are of inferior grade non-cooking coals, with ash contents
45-50%, having moderately high reactivity & high ash fusion temperature. These coals can be
successfully utilized for gasification

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FLUIDIZED BED GASIFIER
Fluidized bed gasifiers, in which bed of coal particles is suspended by the gas flowing in
upward direction. In fluidized bed feed particles are mixed instantaneously with the particles
undergoing gasification.

Advantages:
• Uniform Particle Mixing
• Uniform Temperature Gradients
• High char recycling rate
• Less gas cleanup
• less capital costs

Disadvantages:
• Particle Entrainment
• Lack of Current Understanding
• Pumping Requirements and Pressure Drop

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ENTRAINED FLOW GASIFIER
Entrained flow gasifiers, in which pulverized coal particles and gases flow concurrently at high
speed. These gasifiers are used commonly for commercial technologies.
Advantages:
• Ability to handle practically any feed
• Syngas is free of oils and tars
• Low methane production, suitable for synthesis gas products
Disadvantages:
• High energy consumption
• High temperature and pressure
• Slagging - maintenance shutdown of units

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Selection of Gasifier: High Ash Indian Coal
• Moving Bed / Fluidized Bed Gasifiers are not suitable because of

• Limitation on Pressure range

• Poor Quality of Syn-Gas (containing undesirable components like Tars, Phenols, Ash carryover, Methane etc.)

• Handling of Large quantity of Ash

• Complex Operation & maintenance (for Fluidized Bed)

• Entrained Flow Gasifiers could be suitable option for Indian Coal

• 88% of Coal Gasifiers for Methanol production are Entrained Type (in China). China Coal has Ash content up to
30%, however Process licensors claim they can handle up to 40% Ash.

• Simpler gas clean-up / processing due to better quality of Syngas

• Syngas is at high pressure hence requires less compression for Methanol synthesis

• Ash handling is easier as it is removed as slag

• Energy Efficiency for EFG is lower as lot of energy is wasted in converting Ash in to Slag
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WHY FLUDIZED BED GASIFIER IS SUITABLE FOR INDIAN COALS?
• Suitable for high ash Indian coals.
• Better heat and mass transfer in the bed.
• The amount of tar and phenol formation is low or negligible.
• A large variety of fuels can be handled.
• The technology does not involve moving parts.
• Moderate gasifier temperatures: low Heat loss through bottom ash.
• The large fuel inventory provides safety, reliability, & stability of the process.
• Product composition is steady due to uniform conditions in the bed.
• Better turn down ratio.
• Due to in situ sulphur capture, FBG is futuristic efficient clean coal technologies.

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Indian Coal Gasification Scenario
Initiatives on Surface Coal Gasification (SCG):
• Jindal Steel and Power Ltd (JSPL) has recently put up a coal gasification facility for their DRI (steel,
manufacturing) plant in Angul, Orissa.

• Coal India Limited (CIL), GAIL (India) Limited, Rashtriya Chemical Fertilizers Limited (RCF), and
Fertilizer Corporation of India Limited (FCIL) have formed a joint venture to build a new coal
gasification-based fertiliser complex (Ammonia Urea Complex) at Talcher

Green Field Projects

Coal is available for next 30 years with 25% ash content

• Andal, West Bengal (1.5 MT)

• Mahamaya Coal Mines, M.P (1.5 MT)

• Chandrapur, Maharashtra (0.7 MT)

(as per the information received from Ministry of Coal, Government of India)

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Coal Gasification Projects in India
Coal India Limited (CIL) has taken up several projects which are under different stages of execution

• Coal to Urea Project at Talcher (Odisha) through. Talcher-Fertilizers Limited (T.FL), a Joint Venture
company of CIL, GAIL, Rashtriya Chemicals & Fertilizers (RCF) and The Fertilizer Corporation of
India Limited(FCIL)- Commissioning expected in FY 2024-25.

• Three Coal-to-Chemicals Project at WCL, MCL and ECL is under various tendering stage.

• Lignite-to-Methañol/DME Project at Cuddalore at NLC in Neyveli. Under feasibility Studies.

• The implementation of Surface Coal Gasification initiatives is aimed to enhance utilization of coal
reserves.

• CIL's subsidiaries, WCL, MCL and ECL have also planned the gasification projects (first two for
Ammonium Nitrate & ECL for Syn gas) which are under the various stage of implementation for
various types of gasification products.

• Ministry of Coal aims at gasification of 100 MT of coal by 2030 as per National Coal Gasification Mission.

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 Benefits of Coal Gasification Technology

• Promotes alternative usage of domestic coal in an eco-friendly manner

This process is around 17 to 20% more efficient than conventional coal-burning to produce electricity. Hence, it reduces the
dependency on coal mining for energy generating power plants.

• Hydrogen Economy
It can be used in hydrogen fuel cell production because gasification of coal is one method that can produce power liquid fuel
chemical and hydrogen.

• Reduce Fiscal Deficit

Use of more domestic Coal for energy uses will reduce imports of coal, urea, crude oil, and gas, reducing the fiscal deficit.

• Decrease Transportation Cost

Transporting gas is a lot cheaper than transporting coal.

• Greater Efficiency than Conventional Coal-Burning

It can effectively use the gases twice: the coal gases are first cleansed of impurities and fired in a turbine to generate
electricity. Then, the exhaust heat from the gas turbine can be captured and used to generate steam for a steam turbine-
generator.
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 India's Coal Gasification Potential
India's coal is largely dominated by inferior coal (80%), found in the depth of 300-1200 m. and 40 billion tons of lignite coal,
most of which are found below 300 m.

The study found that Fifteen different sites in India in the states of Maharashtra, West Bengal, Jharkhand, Andhra Pradesh,
Gujarat, Rajasthan, and Tamil Nadu have been suitable for UCG.

Challenges
• Environmental concern:
As many of the coal blocks are in ecologically sensitive areas, environmental safety is a concern.

• Suitable coal deposit:

Though technically feasible, the number of sites geologically and hydrologically suitable are limited.

• Inconsistent supply of syngas:

Both the flow and heating value of gas fluctuate.

• Economies of scale:
Without economies of scale operation, the project will render uneconomical.

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GAPS AND KEY ISSUES FOR DEVELOPMENT OF INDIGENOUS GASIFICATION
TECHNOLOGY
• Un burnt carbon through bottom ash of PFBG leads to lower carbon conversion efficiency and environmental
issues

• Low & fluctuating calorific value of generated gas: Un attractive insufficient for several thermal applications and
for gas turbine electricity generation.

• Lack of sufficient operational experience needed for confidence buildup and reliable scale-up

• Operational problems such as ash agglomerates and clinker formation in bed with high ash coals leading to
failure of the process.

• Tar formation and subsequent problems arising in syngas cleaning and utilization

• Generation of fines (undersize coal) due to selective size requirement in Fixed Bed gasifier.

• Unavailability of gasification kinetic data required for performance study and mathematical modeling purpose.

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 Future growth of coal-based projects will depend on several factors
• ECONOMICS (production and capital costs), competitiveness of coal-based chemicals and government
support.

• GOVERNMENT POLICY for the supply security of domestically available coal for coal gasification
industry.

• REGULATION or standards for blending of coal for chemical applications.

• AVAILABILITY of land, water and related infrastructure.

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 Way Forward
A. Setting up demonstration plants to scale up Indigenous technology

• Promoting public private partnership with provision of VGF for production of methanol, ammonia and
hydrogen
• Setting up plants to produce methanol in tune of 300-500 TPD.
• Introducing PLI scheme for setting up Coal Gasification Plants

B. Rationalizing the pricing of coal for gasification on the following parameters:

• Taxations
• State Cess
• Transportation and handling charges

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 THANK
YOU :)

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