Coarse-Grained CFD-DEM Simulation and the Design of an Industrial-Scale Coal Gasifier

• DOI: 10.1021/acs.iecr.1c03386
• Publication Date: 2021-12-20T16:03:02Z
• Authors: Jia Yu; Liqiang Lu; Yupeng Xu; Xi Gao; Mehrdad Shahnam; William Rogers
• Keywords: Wood gas generator

Industrial-scale gasifiers are traditionally designed using performance data from small-scale systems and expert experiences. In this research, the computational fluid dynamics (CFD)-coarse-grained discrete element method (CGDEM) model in open-source software MFiX was employed to assist design of a 22 MW updraft moving-bed coal gasifier. A quasi-one-dimensional CFD-DEM simulation first performed; its results were then served as an accurate initial condition for three-dimensional (3D) CFD-CGDEM simulation. Then, long-time 3D 3.89 h physical time 120 CPU cores achieved industrial-scale reactor at quasi-steady state. Important obtained such syngas compositions, gas flows, solid temperatures inside reactor, ash distribution, zone locations. The high-fidelity CFD compare well with experience-based Hamilton Maurer International, Inc. Apart predicting steady-state operations, several transient operations including intermittent feed, turndown, shutdown, accident load loss investigated. showed that components share same cycles feed conditions. There is decrease H2 CO increase tar when gasifier operates lower capacity. shutdown process took more than 4.4 recovery sudden bed material 2 h. These studies provide helpful guidance rehearsal potential risks real-life operations.