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COAL GASIFICATION IN A MOLTEN IRON REACTOR

Ziel

To establish the performance of coal gasification trials based on the principle of the molten iron reactor.
In the 60 T converter the coal rate in the trial was 15 to 20T/H of a 14. 4% ash and 29. 5% volatile coal. The trials have shown that the molten bath temperature was stable during the gasification. The gas composition and the main pollutants concentration are given in table 1.
Table1
Composition and pollutants in the gas produced by the klockner process.
CO 64%
CO2 2-3%
H2 30-31%
CH4 730PPM
N2* 3%
H2S 2-70PPM
COS 5-28PPM
SO2+SO3 0-42PPM
CL 0. 2-7. 1PPM
F 0-3. 6PPM
HCN 0-4. 2PPM
NH3 0. 1-0. 9PPM
NOX 0. 1-0. 5PPM
*Primarily from carrier gas for coal transportation.
Due to the high process temperature of 1 400 up to 1 500 C, as well the function of the nolten iron, higher molecular hydrocarbons ( tars) were not present.
The concentrations of chlorine, fluor cyanide of hydrogen, ammonia and nitrogen oxides are extremly low. Also the sulphur concentrations are low. This is a particularly interesting feature of this process compared to other gasification processes. The dust quantity was in the range of 20 to 60G/NM3 but this quantity will be easily reduced to about 5MG/NM3 by the gas cleaning system applied in steel making. The recirculation of fines is considered. The results show that the carbon losses canb be limited to 1 to 2% and that desulphurisation of the gases occurs partly in the converter stack. In a longer trial (67 T of coal), the converter lining and the tuyeres are in an excellent condition.
The slag produced although containing 3% sulphur - is suitable for the production of concrete, as a material for road construction and as fertilizer. The research work has been continued with subsidies of the Federal German Research Ministry.
The process is based on the simultaneous carbonization and decarbonization of liquid iron. In a vessel containing a high -carbon iron bath (hot metal), pulverized coal and oxygen are injected through tuyeres installed in the bottom. Lime or converted slag, in ground form, can also be injected through the bottom tuyeres. In a simplified way the following process runs autothermically at a temperature in the range 1450c - 1550c :
- the volatile components of the coal escape and are cracked:
- the carbon is dissolved in the iron:
- the coal ash together with added materials, such as steel plant slag or lime, forms a basic final slag;
- the sulphur introduced by the coal is bound in the basic reactor slag
As well as in the reactor dust:
- the coal dissolved in the molten iron reacts with the oxygen and thus generated the product gas.

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Klöckner Stahl GmbH
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