Self-Design One Stage Coal Gasifier Gas Producer or Generator Gas Station

• Customization: Available
• Application Fields: Steel/Power/Construction Material Industry
• Certification: CE, ISO
• Model NO.: Gasifier Gas Producer
• Noise Level: Low
• Parts: Forced Air Cooler, Electro Detarrer, etc.
• Purpose: Gas Manufacturing
• Adaptability: Wide Range of Adaptability to Various Type of Coal
• Targeted Design: Single or Two-Stage, Purification System Optional
• Custom Made: Accept Customization
• Delivery Date: Refer to The Contract
• Machine Size: Medium
• Usage: Gas Supply for Various Types of Furnace, Kiln, etc
• Transport Package: Frame Packaging, Wooden Case Packaging, etc.
• Specification: Customized
• Trademark: PRIME
• Origin: China
• HS Code: 8405100000
• Production Capacity: 30 Sets/Year
• Package Size: 3000.00cm * 1000.00cm * 500.00cm
• Package Gross Weight: 1300000.000kg

Product Description

Product Description

Part 1  List for Equipments

List for Main Equipments of φ 3.2M Two-section Cold Gas Station (One Working, No Standby)
 

No.	Item	Spec. & main parameters	Qty.		Remarks
			total	standby
01	Coal hoist	V=1m3/time, 10m3/h	4		2t hoist
02	Coal feeding mechanism	Hydraulic top inserted plate and bottom bell jar	5		PLC programmatic control
03	Main body of gas producer	φ3200	5
04	Producer lining		5
05	Steam collecting drum	φ1500	5
06	Air check valve	DN400	5
07	Natural suction valve	φ250	5
08	Bell type valve	DN300	5
09	Cyclone dust collector	φ2000	5		Internal insulation
10	Forced air cooler	32Pcs	5
11	Cyclone detarring device	φ1200	5
12	Electro detarrer	C-39	5		Including power supply
13	Plate-shell heat exchanger	F=1500m^2	5
14	Electrostatic dust collector	C-72	5		Including power supply
15	Air blower	P=110KW	2	1
16	Gas booster	P=160KW	2	1
17	Soft water tank	φ2000×1800	5
18	Condensate pump for tar, light oil	50YW15-16	3
20	Centrifugal pump	IS150-125-315,P=30KW	3	1
22	Worm gear wafer butterfly valve	DN250  D371X-1	4	1
23	Butterfly valve	DN500	15	1	Inlet of booster
24	Butterfly valve	DN300	6	1	Outlet of booster
25	Butterfly valve	DN350	6	1
26	Electrical instruments				Including 6 frequency converters
27	Installation materials
28	Fees for guiding the installation and commissioning

Part 2 Project Profile

A  Basis of design, manufacturing and installation
1. GB50195-94 - 'Code for design of producer gas stations'
2. GB6222-2005 - 'Safety code for gas of industrial enterprises'
3. The coal for gasification should conform to the standard of (GB/T9143-2001).
4. The technical parameters and requirements provided by the customer.

B  Selection basis of gas producer
The customer will propose to install Ф3.2m two-section type gas producer, five (5) sets, to produce the energy for production. Considering the coal quality in India, the gas production forФ3.2m two-section type gas producer will be 5500~7000Nm3/h per producer, and the calorific value of gas will be not less than 1350kcal/Nm3 to ensure 8000h/a of continuous production. When the load for stable operation of the gas producer is at about 85%, it will be convenient for the operation and management of the gas station and benefit the service life of the equipment.


B1 Design principles:
1. Select advanced, mature, and reliable technology and equipment.
2. The technological proposal can fully meet product requirements and environmental protection requirements.
3. Ensure rationality of process and stability of long-term operation.
4. Combination of practice and saving investment.


B2 Advantages of two-section gas producer:
1. Relax the standard of coal for gasification charging into the producer.
2. Compared with a one-section gas producer with corresponding dimensions, the calorific value of gas could be increased by about 10%.
3. The gasification efficiency will be about 5% higher than that of a one-section producer.
4. The tar generated for recovery is light tar, which has good fluidity, easy to deliver, and has high utility value.
5. Strong ability to adapt to the change in load, and furnace condition is stable, labor intensity is lower.
6. The processing system is simple, and the equipment is compact and the floor space is less.
7. The environment for operation and in the station area is better than that of a one-section producer.
8. The raw material for gasification is bituminous coal, and the economic benefit is good.


C  Reference table for the content of each component of producer gas (bituminous coal for firing)

Item	Volumetric component of dry gas(%)							Density (kg/ Nm^3)	LHV (KJ/Nm^3)
	CO2+H2S	O2	CmHn	CO	H2	CH4	N2
%	3~7	0.1-0.3	0.2-0.4	25-30	11-15	1.5-3	47-54	1.1~1.13	5020~6280
Remark: The coal for gasification should abide by ' Quality standard of the coal for gasification of Atmospheric fixed bed gas producer' (GB9143-2001); Please abide strictly by this standard to avoid problems occur during operation in the future.

Part 3 Gas producing principle and process description

1. Gas producing principle of two-section gas producer:
A gas producer is divided into an ash layer, oxidation layer, reduction layer, dry distillation layer and dry layer. The gasification agent (air + steam) is sent into the producer from the bottom of the producer, there will have the following chemical reactions in oxidation-reduction layer:

  C+O₂=CO₂+Q            C+CO₂=2CO-Q     
          C+H₂O=CO+H₂-Q         C+2H₂O=CO₂+2H₂-Q        CO+H₂O=CO₂+H₂+Q

2. Process description
Use coal hoist to feed the coal into the coal bin, and feed the coal into the chamber of gas producer via stoker. After that the coal will carry out drying and dry distillation in dry distillation section of the gas producer. The coal will move down slowly with the temperature rising gradually, and then arrive at gasification section after 10-12 hours. In dry distillation section, the heat generated by part of ascending gas in gasification section will release the moisture in the coal, tar and most of sulfide will also be dry distilled out, and then the hydrocarbon will be generated which will form the top gas with part of ascending gas in the gasification section. The semi-coke shape coal char entering gasification section will produce the gas after gasification reaction. One part of the gas produced will go upwards to dry distillation section, and another part will form lower gas in the gasification section.
The top gas will leave gas producer and enter into electro detarrer after passing through cyclone detarring device to remove the tar carried by gas, and then mix with lower gas.
After most of dust is removed by cyclone dust collector, the lower gas will enter into the air cooler through the wet disk valve. After air cooling, the gas temperature will be decreased to about 150-180ºC from 400-500ºC, and then mix with the top gas.
The mixed gas will enter the electrostatic dust collector to remove the dust and light oil in the gas, and be cooled further to normal temperature through indirect cooler.
The mixed gas will be delivered to the desulfurization system to remove the sulfur after pressure increasing by gas booster, and then the clean gas will be conveyed to kiln for use at last. The coal tar, light oil and condensate separated from the electro detarrer, electrostatic dust collector and scrubber will enter into the separating pond. After separating, the coal tar and light oil can be supplied externally, and also can be used with condensate together as fuel for boiler. The condensate also can mix with pulverized coal to make into coal water slurry for fuel use.

3. Final indexes of gas:
Gas output :                  5500-7000Nm³/h
Gas Calorific value:           ≥6061 KJ/Nm³
Dust content in gas:           ≤25 mg/Nm³
Tar content in gas:             ≤20 mg/Nm³
H₂S content in gas:             ≤50 mg/Nm³
Gas temperature at station outlet: 35~45ºC

Part 4  Brief description for structure of gas producer and technical parameters

1. Advantages of two-section producer:
1) Compared with a one-section gas producer with corresponding dimensions, the calorific value of gas could be increased by about 10%.
2) Produce two types of gas with different heat values, which can use separately or in mixed-use.
3) Two-section producers can recover the tar and light oil.
4) The coal varieties can be loosened appropriately.

2. Structure of φ3.2m two-section producer:
1) Stoker
The stoker will adopt hydraulic drive, which is the coal feeding device with the structure that a rotary drum on top, inserted plate in the middle and a bell type at the bottom. This kind of structure could effectively avoid gas leakage. During coal feeding, firstly the bottom bell is closed, the middle inserted plate is open when the top rotary drum is open, the coal will be fed into the stoker from the feed bin depending on the self-weight of the coal, and then the top rotary drum is closed, and the middle inserted plate is also closed at the same time, and the bottom bell is open, all the coal will fall into the producer, finally bottom bell is closed, thus a coal feeding cycle is completed. The coal feeding process can realize PLC programming automatic control.

2) Main body of producer
The main body of producer consists of refractory bricks, water jacket, grate, base disc, inlet bellows, etc
The dry distillation section will be laid by high quality refractory bricks. The material for inner ring plate of water jacket will select 20g, and Q235-A for outer ring plate, so as to ensure enough safety for gas station. The water jacket is connected with steam header, the natural circulation system of softened water is formed from up and down. The softened water goes into the steam header at first, and then descends into the water jacket from steam header. The water-vapour mixture is generated after heating, and goes to the steam header via riser pipe. The steam separated by water separator will be used as gasification agent. Only when supply of softened water stops for temporarily maintaining the production, the water used in water jacket could be allowed to use running water for a short period.
The base disk consists of ratchet wheel and ash disk. The ratchet wheel and grate are fixed on the base disk. The grate installed by our company was produced through years of research and design, so as to ensure uniform distribution of air at gas producer bottom; and ash removal on both sides also could avoid the offset during gas producer's operation and reduce the air blasting resistance, therefore reduce the carry-away matters, it benefits for the purification of gas. The antifriction bearing is installed below the ash disk, the grate is turning at the time when the ash disk is rotating, the ash residue will fall into the ash disk. The ash residue will be broken by small ash knife and be removed out of the ash disk by big ash knife. The inlet bellows in middle and water seal circle below the ash dish will form the water sealing.

3. Ash removal device
The main body of a producer consists of refractory bricks, water jacket, grate, base disc, inlet bellows, etc.
The dry distillation section will be laid with high-quality refractory bricks. The material for the inner ring plate of the water jacket will select 20g, and Q235-A for the outer ring plate, to ensure enough safety for the gas station. The water jacket is connected to the steam header, and the natural circulation system of softened water is formed from up and down. The softened water goes into the steam header at first and then descends into the water jacket from the steam header. The water-vapour mixture is generated after heating and goes to the steam header via a riser pipe. The steam separated by the water separator will be used as a gasification agent. Only when the supply of softened water stops temporarily maintaining the production, the water used in the water jacket could be allowed to use running water for a short period.
The base disk consists of a ratchet wheel and an ash disk. The ratchet wheel and grate are fixed on the base disk. The grate installed by our company was produced through years of research and design, to ensure uniform distribution of air at the gas producer's bottom; ash removal on both sides also could avoid the offset during the gas producer's operation and reduce the air blasting resistance, therefore reduce the carry-away matters, it benefits for the purification of gas. The antifriction bearing is installed below the ash disk, the grate is turning at the time when the ash disk is rotating, and the ash residue will fall into the ash disk. The ash residue will be broken by a small ash knife and removed from the ash disk by a big ash knife. The inlet bellows in the middle and the water seal circle below the ash dish will form the water sealing.
The main body of a producer consists of refractory bricks, water jacket, grate, base disc, inlet bellows, etc.
The dry distillation section will be laid with high-quality refractory bricks. The material for the inner ring plate of the water jacket will select 20g, and Q235-A for the outer ring plate, to ensure enough safety for the gas station. The water jacket is connected to the steam header, and the natural circulation system of softened water is formed from up and down. The softened water goes into the steam header at first and then descends into the water jacket from the steam header. The water-vapour mixture is generated after heating and goes to the steam header via a riser pipe. The steam separated by the water separator will be used as a gasification agent. Only when the supply of softened water stops temporarily maintaining the production, the water used in the water jacket could be allowed to use running water for a short period.
The base disk consists of a ratchet wheel and an ash disk. The ratchet wheel and grate are fixed on the base disk. The grate installed by our company was produced through years of research and design, to ensure uniform distribution of air at the gas producer's bottom; ash removal on both sides also could avoid the offset during the gas producer's operation and reduce the air blasting resistance, therefore reduce the carry-away matters, it benefits for the purification of gas. The antifriction bearing is installed below the ash disk, the grate is turning at the time when the ash disk is rotating, and the ash residue will fall into the ash disk. The ash residue will be broken by a small ash knife and removed from the ash disk by a big ash knife. The inlet bellows in the middle and the water seal circle below the ash dish will form the water sealing.
The ash removal adopts double ash knives. The ash is cleaned on both sides, and the ash is evenly discharged, which can effectively prevent the partial operation of the furnace caused by the uneven ash discharge. The provided ash knives are bi-directional spiral surface tire punching coil forming, which can effectively reduce the ash discharge resistance. The ash removal machine is driven by hydraulic pressure and has a ratchet pawl structure. When cleaning dust, the hydraulic station controls the swing hydraulic cylinder to reciprocate, so that the pawl drives the ratchet wheel to complete the stepping of the ash tray to achieve the purpose of dust removal. The cleaning speed of the ash removal machine could realize stepless speed regulation by adjusting the one-way throttle valve of the hydraulic station. Compared with the worm gear structure, the cleaning driving force of this structure all acts on the tangential direction of the ratchet, with no excess power loss, high mechanical efficiency, and no radial runout, extending the service life of the ratchet.

Part 5  Selection of Major equipments in gas station

1. Gas producing and purification section
1) Gas producer
Feature:two-section type, feed coal discontinuously by hydraulic top inserted plate and bottom bell, ash removal through hydraulic driving the ratchet wheel and pawl.
Function: the coal reacts in this equipment under the action of gasification agent (air, steam), and produce qualified gas.
Specification:YM3.2
Qty.: 5 sets
2) Cyclone dust collector
Function:pre-remove the dust in lower gas.
Specification:φ2000 type
Qty.: 5 sets
Gas processing capacity:4000 Nm³/h·set
Dust collection efficiency:60~80%
3) Forced air cooler
Function:decrease the gas temperature upto 150-180ºC from 400-500ºC by means of indirect contact between air and gas.
Specification: 32 pipes
Qty.: 5 sets 
Gas processing capacity:6500 Nm³/h· set
Gas inlet temp.:400~500ºC
Gas outlet temp.:150~180ºC
4) Cyclone detarring device
Function:pre-remove par of tar in top gas, so as to relieve the working burden of electro detarrer.
Specification:φ1200 type
Qty.:5 sets
Gas processing capacity:3000 Nm³/h·set
Detarring efficiency:60-80%
5) Wet disk valve
Function:cut off lower gas with system when failures or maintenance.
Specification:φ1000 type
Qty.:5 sets
6) Electro detarrer
Function:catch and remove the tar in top gas, to ensure the cleanness of gas.
Specification:C-39 type
Qty.:5 sets
Gas processing capacity:2500Nm³/h·set
Gas flow rate: 0.71m/s
Detar efficiency:98~99%
7) Electrostatic dust collector
Function:carry out secondary detarring and dedusting after top and lower gas mixing here.
Specification:C-72 type
Qty.:5 sets
Gas processing capacity:6500 Nm³/h·set
Gas flow rate:0.93m/s
Dedusting efficiency:95~97%
8) Indirect cooler
Function:top and lower gas will mix here. Under the condition of not directly contacting with cooling water, the gas temperature will be decreased to precipitate the condensate in the gas with the saturation temperature drop.
Specification:F1500 plate-shell type
Qty.:5 sets
Gas processing capacity:6500 Nm³/h·set
Gas inlet temp.:150~180ºC
Gas outlet temp.:35-45ºC
9) Gas booster
Function:deliver the clean cold gas to customer after boosting.
Parameters:Q=27700m³/h  P=13630Pa  N=160KW
Qty.:2 sets(2 working, 1 standby)
10) Air blower
Function:supply the air for gasification of producer.
Specification:9-26No5.6A
Parameters: Q=36189m³/h  N=110KW
Qty.:2 sets,one for standby
3. Water circulation in gas station
1) Amount of cooling water in indirect cooler:100t/h
   Water temperature: t_inlet=35ºC    t_outlet=45ºC
2) Type selection of equipments
Select 3 sets of IS150-125-315 water pumps, one for standby.
Parameters: Q=200m³/h H=32m N=30KW

Part 6 Service, Construction and Quality Assurance

A. Service commitment
1) Seller commits that the materials of contract goods, process, performance and other aspects will accord with the indexes of each item stipulated in the contract, and guarantee that the goods could be in normal service after installation and commissioning.
2) After the acceptance from Buyer, the quality guarantee period is one year. (Except wearing parts).
3) Within the quality guarantee period, Seller's engineer shall give a written response within 2 hours after receiving notes if the equipment has faults. If needs Seller go to site to solve the problem, the Seller shall go to site to make the site service at fastest speed by the most convenient transportation. If the operation of Buyer's personnel doesn't accord with the relevant technical requirements in 'Operation Instruction' of gas producer provided by Seller which will cause the damage or adjustment of gas producer and its auxiliary equipment, Buyer shall pay the costs for travelling, board and lodging on his own account; otherwise Seller shall pay the above costs.
4) Seller shall guarantee to conduct lifelong service for contract goods.

B. Project quality and safety guarantee measures
1) Project quality assurance measures
1.1 Quality assurance for components manufactured in the factory and purchased parts:
1.1.1 During the manufacturing of components made in factory, the shift leader, designers, and responsible person for the in-plant quality of the project group will together make the supervision and inspection in various stages. After the manufacture is completed, the inspector dispatched by the company will go to make an overall test and inspection. Issue the certificate if the products are qualified, and then leave the factory. The equipments without certificate shall be resolutely prohibited to enter the construction site.
1.1.2 For purchased parts, the products from the manufactures with a strict quality control system will be selected as a priority. The purchased parts entering the plant must have complete certificates. The purchasing staff shall be seriously responsible for the project group, and the related responsible person for quality from the project group have the right to question the quality and performance of purchased parts or ask to make the replacement.
1.2 Guarantee for non-standard manufactured parts on site and installation quality:
1.2.1 Materials quality control:
The applied materials, welding rods and so on which are purchased at the site must have qualified certificates and material inspection list, so as to ensure the quality of whole the materials.
1.2.2 The quality responsible person on site and head of the installation team will be overall responsible for the non-standard components and installation quality. Carry out strict supervision and inspection regularly according to relevant national codes. Make a final system test strictly to ensure the installation quality of the whole project.
2) Safety guarantee measures:
One special safety inspector will be set for the whole project. The safety inspector appointed for this project shall be with abundant construction experience on gas, good safety awareness and sense of responsibility.
Equip with appropriate quantity of fire extinguishers on construction site. The safety inspector will be responsible for the arrangement and checking of fire extinguishers.
3) Safety guarantee for hot-state operation and gas delivery
The hot test only can be done after the pressure test, leakage test and cold test is completed for the whole system, and no potential safety hazard for the system itself is confirmed. The process of gas delivery under hot state shall be strictly carried out according to operation instruction and safety code, the whole process shall be done under the supervision of safety inspector.

Case Studies
 

 

Company Profile

Company Profile

Vision
With dees of rapid development and accumulation, China has been perfect and mature on technology and management in various industrial areas, shaping a complete processing manufacturing industry with competitive price, well known for its excellent skill, high efficiency and hardworking team with qualification for personnel dispatching.

At the time of economic globalization, it is our consistent target and objective to integrate and export all kinds of technology, management mode, engineering project and manpower as per the actual requirement of our client With our own abundant technical strength, superior integration capability of technology and resources, well experienced of project implementation and management as basis and platform;Let China go out to the world, and make the world know of China;

Professional
Professional technical and management team with abundant experience in the implementation of domestic and international projects;
Responsive
Responsively and meticulously, translating your needs into complete solutions;
Integration
Integrating various technologies and resources in China and fulfilling complementary advantages, by relying on professional teams;
Motivation
Motivated to provide the optimal solution and quality products;
Exceptional
Exceptional, delivery and,implementation of projects to meet, your expectations;

Our Team
Professional technical team
Prime is staffed with professional import & export team skilled with the practice of import and export business, including sea freight packing, logistics organization, L/C review, cargo booking, and customs clearance, L/C negotiation, double authentication of shipment documents, etc.
All above personnel are well experienced in the execution of projects in Southeast Asia and Middle East. 

Complete procurement mechanism
Our professional team of procurement offers strict management of supplier 's qualification inspection and selection, complete system of supplier listing, rating and elimination, to ensure the supplier is qualified and capable of implementing the project and supplied with product of high quality, and maintain a healthy and good condition of credibility, contract settlement and capital flow management.

Quality management system
Our complete quality management system , the process control covering from Scheme formulation , engineering technology, detailed design, to processing and manufacturing of equipment and material , ex-factory test and site erection and commissioning till it put into production, which through multi-level inspection, tour inspection, supervision and node control can ensure quality of the final product.

Well experienced
Executive team is abundant in experience of overseas project implementation with similar project working experiences, esp. experience in Southeast Asia, Middle East projects;
 

ISO System Certification

 

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