

Meenakshi
Business Executive
CASE Group
The CASE Group has made a significant contribution to industrial sustainability with the installation of nine advanced CASE Clean Gas Coal Gasifiers at Rungta Mines Limited in Kamanda, Odisha. These cutting-edge gasifiers represent a major step forward in coal gasification technology, offering improved energy efficiency and enhanced environmental performance in the iron and steel industry. The new technology has helped Rungta Mines reduce its reliance on traditional fuels, improve operational sustainability, and cut costs
A key achievement of the CASE gasification system is its ability to replace up to 60% of the furnace oil used in the straight grate pellet production process. This substitution not only makes the pellet production more cost-effective but also reduces environmental impact by lowering oil consumption. Additionally, the gasifiers have made it possible to use high-ash coal (coal with more than 40% ash), which was previously unsuitable for industrial heating applications. By utilizing this locally abundant resource, Rungta Mines has increased fuel flexibility, enabling it to use more affordable coal while still meeting high operational standards. Beyond the straight grate system, the CASE gasifiers have also achieved a remarkable milestone by completely replacing furnace oil in a 1.0 MTPA grate kiln. This full oil replacement further reduces operating costs and demonstrates the effectiveness of the gasifiers in driving both economic and environmental benefits. Looking ahead, Rungta Mines plans to reach up to 90% furnace oil substitution.
In the Phase 2 of its straight grate system, showing the scalability of the CASE technology and its potential for continued improvements in sustainability. The CASE gasifiers are highly efficient, with a coalto-gas conversion rate of over 1.8 Nm³ of gas per kilogram of coal, achieving an impressive conversion efficiency of more than 80%. This means that the gasifiers extract more energy from each unit of coal, maximizing output while minimizing waste. Additionally, more than 4% of the feed coal is converted into tar, a byproduct with high energy content, further enhancing the system’s thermal efficiency, which exceeds 90%. These efficiencies contribute to lower operational costs and a significant reduction in the environmental footprint of pellet production.
The gasifiers maintain consistent gas quality, ensuring stable combustion and optimal air-to-fuel ratio control. This consistency is crucial for producing highquality iron ore pellets that meet industry standards. Another key feature of the CASE technology is its Zero Liquid Discharge (ZLD) design, which recycles 100% of phenol water produced during the gasification process. This closed-loop system helps minimize water wastage, protect local water resources, and comply with pollution control regulations.
Moreover, the gasifiers produce exceptionally pure gas, which allows for cleaner combustion and reduces the need for frequent maintenance. The elimination of the need for refractory linings, commonly used in conventional gasifiers, further reduces maintenance costs and downtime. CASE gasifiers also operate without the need for compressed air or nitrogen, cutting both operational and environmental costs, and simplifying system management. Overall , the CASE gasifiers at Rungta Mines represen t a major advance ment in coal gasification technology. Their ability to efficiently replace furnace oil, maintain consistent gas quality, and minimize environmental impact sets a new benchmark for industrial sustainability. Rungta Mines’ adoption of these gasifiers not only boosts operational efficiency but also showcases a model for other industries to follow in balancing productivity with environmental responsibility. As the global demand for cleaner, more sustainable industrial processes grows, the success of the CASE gasifiers underscores the important role of advanced energy technologies in shaping a greener future for the iron and steel industry