Manipulation of gasification coal feed in order to increase the ash fusion temperature of the coal enabling the gasifiers to operate at higher temperatures

Coal is a crucial feedstock for South Africa’s unique synfuels and petrochemicals industry and used by Sasol as a feedstock to produce synthesis gas via the Sasol-Lurgi Fixed Bed Dry Bottom (FBDB) gasification process. The ash fusion temperature (AFT) gives detail information on the suitability of a coal source for gasification purposes, and specifically to which extent ash agglomeration or clinkering is likely to occur within the gasifier. Ash clinkering inside the gasifier can cause channel burning and unstable operation.Sasol-Lurgi FBDB gasifiers are currently operated with the philosophy of adding an excess of steam to the process to control the H₂/CO ratio of the syngas produced, but indirectly also to control the maximum gasifier temperature below the AFT of the coal. An opportunity exists to increase the AFT of the coal fed to the gasifiers by adding AFT increasing minerals to the coal blend before it is fed into the gasification process. For the aim of this study a South African coal source was investigated, as being used by the gasification operations in Secunda.With the specific aim of this study, to increase the AFT, the determination of the AFT of the coal blends where acidic components such as silica (SiO₂), alumina (Al₂O₃) and titania (TiO₂) were added was conducted. The Al₂O₃ had the biggest and most significant effect on the AFT with the least addition to the coal blend. The effect of SiO₂ and TiO₂ were very similar, but the effect was much smaller and further Al₂O₃ was needed to increase the AFT to a similar AFT level in comparison to the SiO₂ used. Kaolinite, roof and floor components (containing mainly Al₂O₃ and SiO₂) were also added, also showing an increase in the AFT with up to 4 mass% addition. Another observation was that the AFT was non-additive (not a linear weighted calculated average) and not the weighted average AFT as was expected for the other coal properties such as the ash content, for example. The ash slagging characteristics is a non-additive property of individual coal sources in the blend and therefore difficult to predict.In general it can be concluded that the unique opportunity exists to increase the AFT, was tested, proven and mechanistically outlined in this study on the coal source fed to the Sasol-Lurgi FBDB gasifiers. The AFT can be increased to >1350 °C by adding AFT increasing minerals or species to the coal blend before it is fed into the gasification process. By increasing the AFT, the direct effect will be that steam consumption can be decreased, which in turn will improve carbon utilization.