Coal Gasifiers

Coal gasification is a high-temperature thermochemical process that converts bituminous coal, sub-bituminous coal, lignite, anthracite, and petcoke into clean syngas rich in carbon monoxide (CO), hydrogen (H₂), and methane (CH₄) through partial oxidation, steam-coal reactions, and the water gas shift at temperatures between 1000 and 1600°C. Modern plants utilize fixed-bed, fluidized-bed, entrained-flow, or underground gasifiers, achieving carbon conversion rates between 85% and 98%, processing coal sizes from 100 microns to 50 mm, depending on reactor type. The system includes coal preparation such as crushing and drying to less than 10 -15% moisture, pressurized feeding, a refractory-lined gasifier reactor, and oxygen/steam injection to control the conversion process. Produced syngas undergoes conditioning using cyclone separators, waste-heat recovery units, wet scrubbers, and fine gas cleaning systems to remove particulates, tar, and ultra-fine impurities. Acid-gas removal processes further reduce up to 98% of CO₂ and H₂S content. Clean syngas is then used for power generation, integrated gasification combined cycle (IGCC) plants, boilers, furnaces, and chemical synthesis including methanol, ammonia, and hydrogen production. With plant capacities ranging from 1 MW to over 500 MW, coal gasification offers higher efficiency, lower SOx and NOx emissions, the ability to utilize low-grade coals, and integration with carbon capture technologies for cleaner, large-scale industrial energy production.

Burnovate Energy Systems Pvt. Ltd. designs and develops the following thermal systems (used for energy & heat transfer equipment) in Coal Gasification plants