Академический Документы
Профессиональный Документы
Культура Документы
To cite this article: Xiang Jun Liu , Wu Rong Zhang & Tae Jun Park (2001) Modelling coal
gasification in an entrained flow gasifier, Combustion Theory and Modelling, 5:4, 595-608, DOI:
10.1088/1364-7830/5/4/305
Download by: [Monash University Library] Date: 03 December 2017, At: 18:02
INSTITUTE OF PHYSICS PUBLISHING COMBUSTION THEORY AND MODELLING
Combust. Theory Modelling 5 (2001) 595608 PII: S1364-7830(01)17286-4
E-mail: liuxj@me.ustb.edu.cn
Abstract
Coal gasification processes in a slurry-feed-type entrained-flow gasifier are
studied. Novel simulation methods as well as numerical results are presented.
We use the vorticitystream function method to study the characteristics of gas
flow and a scalar potential function is introduced to model the mass source
terms. The random trajectory model is employed to describe the behaviour of
slurry-coal droplets. Very detailed results regarding the impact of the O2 /coal
ratio on the distribution of velocity, temperature and concentration are obtained.
Simulation results show that the methods are feasible and can be used to study
a two-phase reacting flow efficiently.
1. Introduction
Direct combustion of coal results in serious environmental problems. Among the current
clean coal technologies (CCT), integrated gasification combined cycle (IGCC) technology
is widely regarded as a practical coal-utilizing technology due to its advantages of high-
energy conversion efficiency and low pollutant emissions that can meet the ever more stringent
environmental regulations.
The slurry-feed-type entrained-flow coal gasifier is an effective reactor. Its advantages
over other gasification processes include high capacity, simplicity, rapid response and high
turn-down ratio. Construction of a commercial-scale IGCC power plant using this type of
gasifier has been scheduled. Nevertheless, building a commercial-scale IGCC power plant is
still risky because many aspects are not clear. Further studies of this gasification process are
highly desirable (Park 1996).
Nevertheless, it is very difficult to elaborate on the gasification process in detail even
using the most advanced testing instruments, and the challenges are the large temperature
and composition gradients, the rapid variation of the reaction rate resulting from the high
3 Author to whom correspondence should be addressed.
heating rates, and the low residence times. Alternatives to real-time experimental studies
are numerical simulations using a proper model, which enable us to gain an insight into the
operation of gasifiers.
Modelling of the coal gasification process has received significant attention over the last
two decades. Several mathematical models have been developed, in particular, for entrained
flow gasifiers. Wen and Chaung (1979) and Govind and Shah (1984) developed models for
Texacos slurry-fed entrained gasifiers. Ni and Williams (1995) developed a multivariable
model for Shells coal gasifiers. Recently, Liu et al (2000) studied numerically the gasification
process in a pressurized entrained-flow coal gasifier. Nevertheless, the majority of the
gasification models developed so far are still one dimensional and do not consider the influence
of char recycling.
Taking gas turbulence and coal particle dispersion into account, two- and three-
dimensional comprehensive pulverized coal gasification and combustion models (PCGC-2,
3) were developed by Smoot and Smith (1985) and Hill and Smoot (1993), while PCGC-2 has
been applied to bench-scale entrained-flow gasifiers (Brown et al 1988). Recently, Chen and
Downloaded by [Monash University Library] at 18:02 03 December 2017
Horio (2000) also developed a three-dimensional entrained-flow coal gasification model. The
common features of these CFD coal gasification models are that they treat the gas phase in the
Eulerian framework and solve the mass, momentum and energy conservation equations using
the SIMPLE algorithm (Patankar 1980).
For the axisymmetric flow calculation, an advantageous approach over the SIMPLE
algorithm is the vorticitystream function method (Gosman et al 1969). By defining
ur ux
vorticity: = (1)
x r
1 1
stream function: ux = ur = (2)
r r r z
the time-averaged equations for conservation of mass and momentum can be expressed in
terms of a vorticity and a stream function rather than the primitive variables p, ux and ur .
Therefore, the obstacle in the velocity field calculation is ingeniously removed by eliminating
the pressure terms (Anderson 1984).
However, the general vorticitystream function method is not directly applicable to two-
phase flow. This paper investigates the method of using the vorticitystream function to model
a two-phase coal gasification process and to fulfil the two-phase coupling calculation. In
our method, a scalar potential function is introduced to fulfil the mass source terms, and the
comprehensive model covers the two-phase turbulent flow, heat transfer and chemical reactions.
The prototype of the simulation is based on the KIER 0.5 T/D entrained-flow gasifier. Details
of the simulation method and the numerical results are presented in the rest of this paper.
For a steady two-phase reacting flow, the gas-phase continuity equation can be expressed as:
dmk
( V ) = Spm = nk (3)
k
dt
where Spm , nk and mk denote the mass source term, the particle number density, and the particle
mass, respectively. In addition,
V = u + w
(4)
( u) = 0. (5)
Modelling coal gasification in an entrained flow gasifier 597
Terms Equations
Mass ( V ) = Spm
Momentum ( V V ) = P + 23 k + F + Spv
= e ( V ) + ( V ) T
e
Energy ( V h) = h + QR + Sph
h
( e
Turbulent energy ( V k) = 3 k V + V +
2
k
k
Dissipation rate ( V ) = 23 C1 C3 V +
(
+ C1 V C2
k
Downloaded by [Monash University Library] at 18:02 03 December 2017
Terms Equations
Momentum duk /dt = ug + ug uk /r g
dvk /dt = vg + vg vk /r
xk = uk dt
rk = vk dt
Ev1 Ev2
mv = mc 1 Bv1 exp + 2 Bv2 exp
RTk RTk
Ev1 Ev2
dmc /dt = mc Bv1 exp + Bv2 exp
RTk RTk
mhr = mCOx + mCCO2 + mCH2 O + mCH2
1
1 1 1 1
mci = ai + + 1 Pi Pi
kdiff,i ks,i Y 2 kdash,i Y
dTk ln(1 + B)
Energy mk Ck = dk2 T 4 Tk4 + dk N u (T Tk )
dt B
mw Lw mv1 7h1 mv2 7h2 + mci Ql
l
RH2 O denotes the quantity of gas originating from moisture evaporation. The evaporation
rate is calculated based on the diffusion model (Smoot 1993). Rdev is the quantity of gas
originating from coal de-volatilization. It is modelled as a pair of parallel first-order irreversible
reactions (Kobayshi 1977). i is the proportion of evolved volatile. For Kideco coal, the
compositions of CO, CO 2 , H2 and CH4 are 40.02%, 27.5%, 20.12% and 12.36%, respectively
(Lee and Park 1998). m n=1 Ri is the total source term of each species caused by homogeneous
and heterogeneous reactions. In the following sections we introduce how to calculate this term.
Modelling coal gasification in an entrained flow gasifier 599
gas; Pi Pi is the effective partial pressure of the ith component, taking into account the
reverse reaction effect.
The chargas heterogeneous reactions considered in this paper include the charO2
reaction, the charsteam reaction, the charCO2 reaction and the charhydrogen reaction.
Calculations of kdiff , ks , Pi Pi in equation (13) are listed in table 3. Products of the
charO2 reaction are CO and CO2 . However, experimental results show that [CO]/[CO2 ] =
2500 exp(6249/T ) (Arthur 1951) which implies that the content of CO2 is much less and
could be neglected when the temperature is higher. In this paper, we consider the production
of CO only.
Table 3. Rate expressions for the chargas heterogeneous reactions. (Ts and Tg are the temperatures
of the char particle and gas, respectively.)
CharO2 reaction (Wen and Chaung 1979) C + 21 O2 CO ks = 8710 exp (17 967/Ts )
4.26 Tg 1.75
kdiff = 0.584 Pt dp
Tg 1800
Pi Pi = PO2
CharCO2 reaction (Dutta et al 1977) C + CO2 2CO ks = 247 exp (21 060/Ts )
Tg 0.75
kdiff = 7.45 104 Pt dp
2000
Pi Pi = PCO2
Table 4. Rate expressions of homogeneous reactions. (A is the species factor of CO, H2 and CH4 ;
P is the total pressure; Tg is the gas temperature; Mv is the molecule weight of the fuel species;
Cv and C0 are the proportions of fuel gas and oxygen.)
= 1 PCO2 PH2
xCO = PCO /P ; xCO
Pt keq PH2 O
keq = exp (36 893 + 7234/(1.8T ))
Downloaded by [Monash University Library] at 18:02 03 December 2017
where CR is a constant of the EBU model, fi is the concentration of CO, CH4 and H2 ,
respectively, for each reaction.
For each reaction, these two reaction rates introduced above are compared, in the
computational solution procedure, and the smaller of them is taken to represent the effective
controlling rate, i.e.
Ri = min Ri,EBU , Ri,k . (15)
4. Method of solution
Using the vorticitystream function method, the gaseous governing equations listed in table 1
are rewritten and the corresponding general form can be expressed as:
c c
a b r b r
x r r x x x r r
1 1 > 1 >
S= =
r z r z r
2
Downloaded by [Monash University Library] at 18:02 03 December 2017
ux ur 2 ur 2 ux ur 2
Gk = 2e + + + + .
x r rx r x
A non-uniform 3051 grid system is used in this paper. The convection and diffusion terms
are discretized using the upwind and central-difference schemes (Patankar 1980), respectively.
The source terms are also linearized. The finite-difference equations are solved using the
GaussSeidel under-relaxation iteration (Atkinson 1978). The particle equations are solved
using the Gill method (Lambert 1973).
The solution of the particle equations is coupled with the gas phase. Overall convergence
of the two phases is achieved using an iteration procedure. The initial procedure is to iterate
the gas field calculation, and the solution obtained with convergence is used to calculate the
particle momentum, mass and energy equations. A fixed number of iterations for the gas-phase
calculation is again performed using the source terms updated by the particle calculation. Final
convergence is achieved when the gas-phase variables do not change significantly following
the particle calculations.
Figure 1 shows the schematic diagram of a slurry-feed-type entrained-flow coal gasifier located
at KIER (bench-scale unit, 0.5 T/D). It is 2.05 m in height, and the diameter is 0.2 m. Figure 2
shows the arrangement of the burner. The slurry is discharged from the central hole while
oxygen issues from the surrounding eight holes. For the simplicity of simulation, the oxygen
nozzles are considered as an equivalent annulus with the same area as the eight holes. Therefore,
the burner arrangement as shown in figure 3 is used in the simulation and the geometric
dimensions are listed in table 6.
Three cases are simulated in which the O2 /coal ratio (wt/wt) takes values of 0.79, 0.89
and 1.01, respectively. The other operating parameters are listed in table 7. We simulate
H1 H2 D1 D2 D3 D4 D5
2050 50 200 60 13.28 12 3
602 X J Liu et al
Downloaded by [Monash University Library] at 18:02 03 December 2017
the gasification of Kideco coal. The burner is designed to introduce an ejecting angle
and a high velocity difference between the primary slurry flow and the secondary oxygen
flow. Consequently, the slurry is immediately affected by the secondary oxygen flow with
high speed and then divided into droplets of different size as soon as it is discharged into
the gasifier. In the simulation, we consider the slurry water and the coal particles as one
Modelling coal gasification in an entrained flow gasifier 603
phase, and then convert the slurry water into the moisture content of the coal-slurry particle.
The corresponding approximate analysis of coal-slurry particles is calculated and shown in
table 8.
Experimental results (Lee and Park 1998) show that the coal-slurry particles to be
calculated in this type of burner can be divided into 11 groups according to their initial
diameters, which are 10, 20, 30, 40, 50, 60, 70, 80, 90, 100 and 110 m, respectively. The
number of tracing trajectories for each group depends on its mass percentage. Fifty-nine
trajectories are calculated in this paper.
6. Calculated results
consumed by coal combustion, and eventually no O2 remains in the lower section (1.22.05 m)
(the blank area denotes the zero contour level). The concentration distributions of CO, H2 ,
CH4 and CO2 (volume fraction, dry basis) shown in figures 4(d)(g) indicate that the four gas
compositions are mainly produced in the middle section (0.31.2 m, the high-temperature area
as shown in figure 4(b)). The concentrations of these four gases remain constant in the lower
section (1.22.05 m).
606 X J Liu et al
Table 9. Comparison of experimental and calculated compositions for the product gases.
CH4 CO2 CO H2
Calculated data 0.0144 0.32 0.385 0.28
Experimental data 0.0035 0.34 0.42 0.23
Table 9 compares the calculated product gas compositions with experimental data (Lee
and Park 1998). The differences for CO2 , CO and H2 are within 5%, and very low fractions
of CH4 are obtained in experiment as well as in simulation.
The effects of O2 /coal ratio (wt/wt) on the gasification process are shown in figures 5(a)(e).
Downloaded by [Monash University Library] at 18:02 03 December 2017
Three typical cases with O2 /coal ratios of 0.79, 0.89 and 1.01 are simulated. The concentrations
of gas composition at the centreline of the gasifier are studied.
Figure 5(a) shows that the distinct peak O2 concentration region in the top section reduces
as the O2 /coal ratio increases. This implies that the diffusion of O2 flow is intensified by
increasing its flow rate. Figures 5(b)(e) show the concentrations of the other four gas species.
Their distributions are nearly constant in the lower section of 1.22.05 m since combustion
and gasification reactions mainly occur outside this section.
Figures 5(a)(e) shows that the O2 /coal ratio has a significant effect on the gas product
distribution. An increase in the O2 /coal ratio leads to a reduction in H2 and CO concentration,
but results in an increase in the CO2 concentration. In addition, the variations of the
concentration distribution at the centreline imply that the O2 /coal ratio also affects the
concentration distribution of each gas species in the gasifier.
7. Concluding remarks
In this paper the two-phase coal gasification process in a slurry-feed-type entrained-flow gasifier
is simulated numerically using the vorticitystream function method, and a scalar potential
function is introduced for a two-phase reacting flow. The calculated results are reasonable
and are in agreement with the experimental results. The model and mathematical methods
employed in this paper are viable.
Moreover, the calculated results show that the O2 /coal ratio has a significant influence
on the product gas distribution. An increase in the O2 /coal ratio decreases the H2 and CO
concentration but increases the CO2 concentration in the product gas. The O2 /coal ratio also
affects the concentration distribution of each gas species in the gasifier.
Acknowledgments
This work is sponsored by the Scientific Research Foundation for Returned Overseas Chinese
Scholars, State Education Ministry, Peoples Republic of China. The authors would like to
thank KIER for supplying gasifier parameters. We are also grateful to the anonymous reviewers
for their extremely constructive reviews, which improved the paper significantly.
Modelling coal gasification in an entrained flow gasifier 607
Appendix
Table A1. The model constants and parameters for gas and particle phases.
References
Anderson D A 1984 Computation Fluid Mechanics and Heat Transfer (New York: Hemisphere)
Arthur J A 1951 Reactions between carbon and oxygen Trans. Faraday Soc. 47 164
Atkinson K E 1978 An Introduction to Numerical Analysis (New York: Wiley)
Brown B W et al 1988 Measurement and prediction of entrained-flow gasification processes AIChE J. 34 435
Chen C X and Horio M 2000 Numerical simulation of entrained flow coal gasifiers. Part 1: modeling of coal gasification
in an entrained flow gasifier Chem. Eng. Sci. 55 3861
Dobner S 1976 Modeling of entrained bed gasification: the issues EPRI (Palo Alto, CA) p 15
Dutta S et al 1977 Reactivity of coal and char, 1 in carbon dioxide atmosphere Ind. Eng. Chem., Process Des, Dev.
16 20
Gosman A D and Lockwood F C 1972 Incorporation of a flux model for radiation into a finite difference procedure
for furnace calculations 14th Int. Symp. on Combustion p 661
Gosman A D, Pun W M, Runchal A K, Spalding D B and Wolfshtein M 1969 Heat and Mass Transfer in Recirculating
Flows (New York: Academic)
Govind R and Shah J 1984 Modeling and simulation of an entrained flow coal gasifier AIChE J. 30 79
Hill S C and Smoot L D 1993 A comprehensive three-dimensional model for simulation of combustion system:
PCGC-3 Energy Fuel 7 874
Kobayashi H, Howard J B and Sarofim A F 1977 Coal devolatilization at high temperatures 18th Int. Symp. on
Combustion p 411
Lambert J D 1973 Computational Methods in Ordinary Differential Equations (New York: Wiley)
Launder B E and Spalding D B 1972 Mathematical Models of Turbulence (New York: Academic)
Lee J G and Park T J 1998 Reference for Computer Simulation of BSU Gasifier in KIER Coal Gasification Research
Team KIER
Liu G S et al 2000 Modeling of a pressurised entrained flow coal gasifier: the effect of reaction kinetics and char
structure Fuel 79 1767
Ni Q and Williams A A 1995 Simulation study on the performance of an entrained-flow coal gasifier Fuel 74 102
Park T J et al 1996 Status of coal gasification R&D in KIER 1st ChinaKorea Joint Workshop in Coal Utilization
Technology (Beijing) p 155
Patankar S V 1980 Numerical Heat Transfer and Fluid Flow (New York: Hemisphere)
Shuen J S, Chen I D and Faeth G M 1983 Evaluation of a stochastic model of particle dispersion in a turbulent round
jet AIChE J. 29 167
608 X J Liu et al
Siminski V J, Wright F J, Edelman R B, Economos C and Fortune O F 1972 Research on Methods of Improving
the Combustion Characteristics of Liquid Hydrocarbon Fuels AFAPL TR 72-4 vol 1 and 2 (Wright Patterson
Air-Force Base, OH: Air Force Aeropropulsion Laboratory)
Singh C P P and Saraf D N 1977 Simulation of high-temperature watergas shift reactors Ind. Eng. Chem., Process
Des. Dev. 16 313
Smoot L D 1993 Fundamentals of Coal Combustion (Amsterdam: Elsevier)
Smoot L D and Smith P J 1985 Coal Combustion and Gasification (The Plenum Chemical Engineering Series) (New
York: Plenum)
Spalding D B 1971 Mixing and chemical reaction in steady confined turbulent flames 13th Int. Symp. on Combustion
p 649
Wen C Y 1968 Noncatalytic heterogeneous solid fluid reaction models Ind. Eng. Chem. 60 34
Wen C Y and Chaung T Z 1979 Entrainment coal gasification modeling Ind. Eng. Chem. Process Des. Dev. 18 684
Zahradnik R L and Grace R J 1974 Chemistry and physics of entrained coal gasification Coal Gasification (Advances
in Chemistry Series no 131) p 126
Downloaded by [Monash University Library] at 18:02 03 December 2017