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Figure 3-14: Thermax coal gasification systemSteamFuelFuel sizing&classifierLockhoppersGasifierCycloneGascoolerSyngasWaterASUSteamN2De-ashingFine ashThere were several design-level challenges for the gasifier system:• High-pressure operation (30 bar);• High-temperature operation (1000°C);• High dust load (>10 gm/Nm 3 );• Safe handing of carbon monoxide and hydrogen at high temperature and pressure;• Syngas composition and its energy content;• Pollutants in syngas;• Refractory erosion;• Equipment dimensions (kinetics and hydrodynamics play important roles); and• Manufacturing critical components and sourcing some auxiliary equipment.Equipment-level challenges included:• High-pressure fuel feeding♦ Lock hopper feeding system♦ High-pressure hydraulic pump♦ Stamet posimetric pumpDry solid pump challenges included:• High-pressure and -temperature ash extraction♦ Screw cooler♦ Lock hopper system• Syngas coolerIntegration of various components (such as ASU, high-pressure feeder, gasifier, gascooler and barrier filter), as well as maintaining strict quality parameters for advanceprocess control and instrumentation posed system integration challenges.Under the Seventh Framework Programme (FP7) of the European Union, Thermax isworking with Centre National de la Recherche Scientifique of France, Energy CentrumNederland of the Netherlands, Indian Institute of Technology Madras, Turkish CoalEnterprises and Hacettepe University of Turkey on Optimization of Gasifier for High-Ash Coal (OPTIMASH) Project for coal gasification development.100