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The main component of Coaltec’s gasification technology is a down-draft fixed-bed gasifier
manufactured by MaxWest Energy. The gasification process takes place in the primary unit in an
oxygen-starved environment, thus controlling nitrous oxide (NOx) formation. The low-pressure
system allows for gasification with no or minimal carryover of particulate matter from most fuels.
The main product of gasification is carbon monoxide (CO) with some hydrogen and methane gases.
Each gasifier has a 4 foot by 9 foot interior floor. For projects requiring larger capacity, multiple
units are trained together. The primary units are paired in groups of two with each primary being
connected to a single oxidizer.
The temperature inside the gasifier and the retention time of the fuel in the primary unit are
controlled dependent on the requirements of the project. In instances when a formulated biochar is
produced, a low fuel bed temperature is specified. For projects when there is a need to minimize
the carbon in the ash, a longer retention time and/or higher temperatures is needed to react the
carbon gases.
The syngas composition is fuel dependent with temperatures typically ranging between 1000-
1400 degrees F. Once the syngas leaves the gasifier and flows into the oxidizer, ambient
temperature air is introduced to combust the syngas, with the CO being converted to carbon
dioxide (CO2). The combustion process produces a gas stream of about 1800 to 2000 degrees F.
Because of the low Btu value of the syngas and the expense involved in potential clean up, this
technology does not produce a gas that is economically feasible to take directly from the gasifier
and convert to a liquid fuel – with the commercially available, proven technologies that Coaltec has
seen.
The ability to use the thermal energy product as direct heat, steam, or electricity is a simple
matter of adding equipment. The modular design makes construction quick and relatively easy,
and the addition of components is comparatively simple.
An advantage of this technology as compared to alternatives is the acceptable range of
variations in quality and varieties of fuels. The system will easily operate with fuels containing
4,000 BTU/pound, and has operated with fuels containing more than 60% moisture. The gasifier
includes hydraulic ram fuel feed and ash removal allowing for the use of fuels with up to 6 inch
particle size.
The system is web-based remote controlled allowing off-site operation of the system if
desired. This provides tremendous flexibility and oversight to the owner and the ability for real-
time troubleshooting which can eliminate downtime. The system has PLC controls which can be
interfaced to most existing systems and provides a wide range of flexibility in operating parameters
and the ability to control the system to provide the proper amount of energy for the customer’s
needs – both when and where they need it.
In 2002, Coaltec developed and installed a gasifier as a demonstration and test system at their
facility at Carterville, Illinois. A new two-cell 72-square foot gasifier with design improvements was
installed in November 2006. The purpose of the facility is to test new fuels, or combinations of
fuels, at a commercial scale. The test system has a significant amount of monitoring equipment to
track performance during testing and is ported to allow for third-party emissions testing. Once a
test is concluded, the emissions, heat rate, ash composition, and any operational issues created
by specific fuels are identified. A heat and materials balance is completed which allows for an
economic evaluation of the system and helps to identify the best options for a system. Data from
the testing is used to design a system best adapted to the fuel(s) tested.
The commercial scale test facility and the experience that Coaltec has gained over time working
with a wide variety of fuels and operating parameters sets them apart in the industry. The ability to
control the technology operating parameters allows them to formulate various grades of biochar
which offers significant economic and environmental value to projects.
manufactured by MaxWest Energy. The gasification process takes place in the primary unit in an
oxygen-starved environment, thus controlling nitrous oxide (NOx) formation. The low-pressure
system allows for gasification with no or minimal carryover of particulate matter from most fuels.
The main product of gasification is carbon monoxide (CO) with some hydrogen and methane gases.
Each gasifier has a 4 foot by 9 foot interior floor. For projects requiring larger capacity, multiple
units are trained together. The primary units are paired in groups of two with each primary being
connected to a single oxidizer.
The temperature inside the gasifier and the retention time of the fuel in the primary unit are
controlled dependent on the requirements of the project. In instances when a formulated biochar is
produced, a low fuel bed temperature is specified. For projects when there is a need to minimize
the carbon in the ash, a longer retention time and/or higher temperatures is needed to react the
carbon gases.
The syngas composition is fuel dependent with temperatures typically ranging between 1000-
1400 degrees F. Once the syngas leaves the gasifier and flows into the oxidizer, ambient
temperature air is introduced to combust the syngas, with the CO being converted to carbon
dioxide (CO2). The combustion process produces a gas stream of about 1800 to 2000 degrees F.
Because of the low Btu value of the syngas and the expense involved in potential clean up, this
technology does not produce a gas that is economically feasible to take directly from the gasifier
and convert to a liquid fuel – with the commercially available, proven technologies that Coaltec has
seen.
The ability to use the thermal energy product as direct heat, steam, or electricity is a simple
matter of adding equipment. The modular design makes construction quick and relatively easy,
and the addition of components is comparatively simple.
An advantage of this technology as compared to alternatives is the acceptable range of
variations in quality and varieties of fuels. The system will easily operate with fuels containing
4,000 BTU/pound, and has operated with fuels containing more than 60% moisture. The gasifier
includes hydraulic ram fuel feed and ash removal allowing for the use of fuels with up to 6 inch
particle size.
The system is web-based remote controlled allowing off-site operation of the system if
desired. This provides tremendous flexibility and oversight to the owner and the ability for real-
time troubleshooting which can eliminate downtime. The system has PLC controls which can be
interfaced to most existing systems and provides a wide range of flexibility in operating parameters
and the ability to control the system to provide the proper amount of energy for the customer’s
needs – both when and where they need it.
In 2002, Coaltec developed and installed a gasifier as a demonstration and test system at their
facility at Carterville, Illinois. A new two-cell 72-square foot gasifier with design improvements was
installed in November 2006. The purpose of the facility is to test new fuels, or combinations of
fuels, at a commercial scale. The test system has a significant amount of monitoring equipment to
track performance during testing and is ported to allow for third-party emissions testing. Once a
test is concluded, the emissions, heat rate, ash composition, and any operational issues created
by specific fuels are identified. A heat and materials balance is completed which allows for an
economic evaluation of the system and helps to identify the best options for a system. Data from
the testing is used to design a system best adapted to the fuel(s) tested.
The commercial scale test facility and the experience that Coaltec has gained over time working
with a wide variety of fuels and operating parameters sets them apart in the industry. The ability to
control the technology operating parameters allows them to formulate various grades of biochar
which offers significant economic and environmental value to projects.
Technical
Copyright 2006, 2009, Coaltec Energy USA, Inc., Carterville, Illinois