Modeling and Simulation of Coal Gasification in A Fluidized Bed

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AIChE - Proceedings - Modeling and Simulation of Coal Gasification in a Fluidized Bed (2013 Annual Meeting)
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Catalysis and Reaction Engineering Division (18h) Modeling and Simulation of Coal Gasification in a Fluidized Bed
Jain, A., Indian Institute of Technology, Bombay (IITB) Mehra, A., Indian Institute of Technology, Bombay (IITB) Ranade, V. V., National Chemical Laboratory, Pune
Originally presented on: 11/3/2013 17:50:00 - 18:10:00
A dynamic mathematical model to simulate the continuous gasification of coal particles in a bubbling fluidized bed reactor (FBR) is presented. The bubbling fluidized bed has been modeled based on the two phase theory i.e. emulsion and the bubble phase. The emulsion phase consists of solids and the amount of gases required for fluidizing it, while the bubble phase consist of all the extra gases . The freeboard of the fluidized bed consists of gases released from the bed and entrained and elutriated solids. Heterogeneous reactions have been assumed to occur in the emulsion phase, while gas-gas reactions are assumed to occur in the emulsion and bubble phase. The model incorporates fuel devolatilization, chemical reaction kinetics, bed and the freeboard dynamics. Mathematical models based on the two phase theory have been presented before, Yan et. al (Heidenreichayb & Zhangagbf, 1998) have modeled the bubble phase and emulsion phase gases as plug flow reactor while the emulsion phase solids as a CSTR , they have also proposed the concept of ?net flow' of gases from the emulsion to bubble phase which consists of the extra volume of gases generated due to devolatilization , homogenous reaction and the heterogeneous reactions. The model was further updated with energy balance equations (Yan, Heidenreich, & Zhang, 1999). Hamel et. al
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(Hamel & Krumm, 2001) had proposed a cell model and validated the same with experimental results from laboratory scale to commercial scale gasifiers. Chejne et. al (F Chejne & Hernandez, 2002) proposed a model along with Gaussian distribution for the solids particle size. The same model was later on (Farid Chejne, Lopera, & Londoo, 2011) adopted for a pressurized gasifier wherein the high pressure effects in transport phenomena , bed-fluid dynamics , physical properties , etc. were taken into account. Later on Goyal et. al (Goyal, Pushpavanam, & Voolapalli, 2010) modeled co gasification that included coal and pet coke as feed and concluded that increase in the amount of pet coke decreased the carbon conversion and efficiency while increasing the amount of syngas produced. Most of the models have assumed plug flow for gas phase in both the emulsion and bubble phase while for the solids in emulsion phase CSTR has been assumed. In this work we try to develop a framework to capture the non-ideality in the reactor, by assuming a battery of mixing cells in series, the number of cells and hence the degree of mixing can be controlled in the model according to the residence time distribution, thereby the same framework can be used to simulate a wide range of operating parameters (i.e. laboratory to commercial scale). Apart from optimization of operating parameters the model can be used to study the effect of feed point locations, catalyst and inert material in bed, different geometric configurations and feed properties on the performance of the gasifier. The developed model is a step towards development of a multi zonal model coupled with the computational fluid dynamics based model of a gasifier.
http://www3.aiche.org/proceedings/Abstract.aspx?ConfID=Annual-2013&GroupID=1794&SessionID=24735&PaperID=333669
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Figure 1 Schematic representation of Multi cell framework for a fluidized bed gasifier
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Figure 2 Typical emulsion mixing cell Figure 3 Typical bubble mixing cell
To estimate the hydrodynamic parameters the model includes set of well-known correlations to calculate the fraction occupied by the bubbles in the bed , the porosity and velocity of gas phase, the size and the velocity of the bubbles , interphase mass transfer and the heat transfer coefficients . The program of the model consists of different modules i.e. kinetics, energy equation and mass balance equations. In all there are 7 algebraic equations and 30 differential equation to be solved in each cell, ode15s solver of MATLABTM has been used to solve the set of equations with their default tolerances. The model has been first validated with the data available in literature of the commercial Winkler fluidized bed gasifier (Goyal et al., 2010).It was then used to validate the experimental work carried out with high ash Indian coal in a fluidized bed at CIMFR, Dhanbad (Chavan, Datta, Saha, Sahu, & Sharma, 2012). 18 sets of experimental runs conducted with Rajamahal coal has been validated with the model. Kinetics for the reactions have been taken from data reported in the literature (Weimer, 1981). Isothermal case was solved first and later on a loss parameter in the energy balance equation for the gas in the emulsion phase was adjusted for the non-isothermal case. It was observed that the emulsion temperature and the solids temperature were approximately same, while that of bubble phase temperature was lesser. The vapor phase temperature was more or less the same as the bubble temperature. Sensitivity analysis with respect to the modeling parameters such as diameter of bubbles, bubble voidage and diameter of bubble has been carried out. Effect of various operating parameters such as air/coal ratio, steam/coal ratio and temperature on the carbon conversion has been studied. Effect of carbon properties such as the volatile matter, fixed carbon and the ash content on the carbon conversion has also been studied.
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The simulations shows the same trend as the experimental results i.e. increase in the carbon conversion with the increase in volatile matter, air, steam and temperature, while carbon conversion decreases with increase in fixed carbon. Similarly the higher heating value (HHV) of the product gases increases with the volatile matter and fixed carbon and decreases with increase in mineral matter, air and steam.
Figure 4. Comparison of reported carbon conversion with the simulated data As shown in figure 4 comparison of reported carbon conversions from 18 experiments conducted on Rajamahal coal with the simulation results of the model shows reasonable match, the framework can now be used to study the effect of change in feed and product location, number of solids and more reactions can be included in the model to study the effect of co gasification, catalysts and inert solids on the gasification process. The developed model thus can be used to study the hydrodynamics of the reactor and to select the best operating conditions to obtain maximum carbon conversion and efficiency for the gasification of high ash Indian coal in a fluidized bed reactor. References : Chavan, P., Datta, S., Saha, S., Sahu, G., & Sharma, T. (2012). Influence of high ash Indian coals in fluidized bed gasification under different operating conditions. Solid Fuel Chemistry, 46(2), 108?113. doi:10.3103/S0361521912020048 Chejne, F, & Hernandez, J. P. (2002). Modelling and simulation of coal gasication process in fluidised bed, 81. Chejne, Farid, Lopera, E., & Londoo, C. a. (2011). Modelling and simulation of a coal gasification process in pressurized fluidized bed. Fuel, 90(1), 399?411. doi:10.1016/j.fuel.2010.06.042 Goyal, A., Pushpavanam, S., & Voolapalli, R. K. (2010). Modeling and simulation of co-gasification of coal and petcoke in a bubbling fluidized bed coal gasifier. Fuel Processing Technology, 91(10), 1296?1307. doi:10.1016/j.fuproc.2010.04.012
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Hamel, S., & Krumm, W. (2001). Mathematical modelling and simulation of bubbling fluidised bed gasifiers. Powder technology, 120, 105?112. Retrieved from http://www.sciencedirect.com/science/article/pii/S0032591001003564 Harshe, Y. M., Utikar, R. P., & Ranade, V. V. (2004). A computational model for predicting particle size distribution and performance of fluidized bed polypropylene reactor. Chemical Engineering Science, 59, 5145?5156. doi:10.1016/j.ces.2004.09.005 Heidenreichayb, C., & Zhangagbf, D. (1998). Mathematical modelling of a bubbling fluidised-bed coal gasifier and the significance of ? net flow?, 77(9), 1067?1079. Weimer, A. W. (1981). Modeling a low pressure steam-oxygen fluidized bed coal gasifying reactor. Yan, H.-M., Heidenreich, C., & Zhang, D. K. (1999). Modelling of bubbling fluidised bed coal gasifiers. Fuel, 78(9), 1027?1047. doi:10.1016/S0016-2361(99)00028-9
See more Presentations from this session: Multiphase Reaction Engineering See more Sessions in this Group: Catalysis and Reaction Engineering Division
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