CASE STUDY
Rungta Mines Limited – Pellet Division
CASE Group implemented its Pyrolysis Clean Cold Gasification Technology for the Pellet Division of Rungta Mines Limited. The project involved the deployment of 9 sets of 4.2-metre Pyrolysis Clean Gas modules to support the thermal requirements of iron ore pellet manufacturing.
THE CHALLENGE
Reducing Dependence on Furnace Oil
Iron ore pellet manufacturing is an energy-intensive process that requires a reliable and continuous source of thermal energy.
The Straight Grate Technology used in pellet making traditionally required furnace oil, with consumption of approximately:
12 kg of Furnace Oil per Tonne
The challenge was to develop an alternative thermal energy solution capable of delivering:
- Reliable and continuous thermal energy
- High-quality producer gas
- High gas calorific value
- Efficient coal conversion
- Improved thermal efficiency
- Reduced dependence on furnace oil
- Better utilisation of process resources
The objective was not simply to replace a fuel, but to create a more efficient industrial energy system.
THE SOLUTION
CASE Pyrolysis Clean Cold Gasification Technology
CASE Group deployed its Fixed Bed Pyrolysis Clean Cold Gasification Technology.
The project consisted of:
9 × 4.2-Metre Clean Gas Modules
The system was designed to convert coal into producer gas for industrial thermal applications.
Coal Used
Coal Grade: G17
Calorific Value: 2,800–3,100 kcal/kg
The technology generated clean producer gas that could be integrated into the thermal requirements of the pellet-making process.
The project also incorporated a process approach focused on improved resource utilisation.
Circular Resource Utilisation
Phenolic water generated during the process was:
Treated and reused as a gasifying agent.
This enabled the utilisation of process-generated resources within the gasification system.
THE RESULTS
High-Performance Gasification
The CASE Pyrolysis Clean Cold Gasification system demonstrated strong operational performance.
4,200–4,500 Nm³/hr
Gas Generation per 4.2-Metre Module
>1,300 kcal/Nm³
Gas Calorific Value
>80%
Gasification Efficiency
>90%
Thermal Efficiency
100% Furnace Oil Substitution
The most significant outcome of the project was the successful substitution of furnace oil in the Straight Grate Technology used for iron ore pellet making.
Before CASE Gasification
Furnace Oil Consumption:
12 kg per tonne
After CASE Gasification
Furnace Oil Consumption:
ZERO
The installation of 9 Pyrolysis Clean Gas modules enabled 100% substitution of furnace oil in the specified application.
PROJECT AT A GLANCE
Parameter | Project Performance |
Client | Rungta Mines Limited – Pellet Division |
Technology | Fixed Bed Pyrolysis Clean Cold Gasification |
Installation | 9 Sets |
Module Size | 4.2 Metres |
Coal Grade | G17 |
Coal GCV | 2,800–3,100 kcal/kg |
Gas Generation | 4,200–4,500 Nm³/hr |
Gas Calorific Value | >1,300 kcal/Nm³ |
Gasification Efficiency | >80% |
Thermal Efficiency | >90% |
Furnace Oil Substitution | 100% |
Phenolic Water | Treated and reused as a gasifying agent |
THE IMPACT
A New Approach to Industrial Thermal Energy
The project demonstrates how coal can be converted into a valuable industrial energy source through advanced gasification technology.
By generating producer gas with high calorific value and achieving high gasification and thermal efficiencies, CASE Group created an alternative to conventional furnace oil for industrial thermal applications.
The Project Delivered
100% Furnace Oil Substitution
A transition from approximately 12 kg of furnace oil per tonne to zero in the specified Straight Grate Technology application.
High Thermal Performance
More than 90% thermal efficiency demonstrated by the 4.2-meter module.
Efficient Coal Conversion
More than 80% gasification efficiency.
High-Quality Producer Gas
Gas calorific value of more than 1,300 kcal/Nm³.
Resource Utilization
Phenolic water is treated and reused as a gasifying agent.
THE CASE GROUP ADVANTAGE
Engineering Industrial Energy Transformation
At CASE Group, gasification is not viewed simply as a fuel conversion process.
It is an opportunity to redesign how industries generate and utilise thermal energy.
The Rungta Mines Pellet Division project demonstrates the potential of Pyrolysis Clean Cold Gasification Technology to:
- Replace conventional thermal fuels
- Generate high-calorific-value producer gas
- Improve energy utilisation
- Support industrial-scale thermal applications
- Enable better utilisation of process resources
With more than three decades of industrial engineering experience, CASE Group continues to develop energy solutions designed around the evolving requirements of Indian industry.
FROM COAL TO CLEANER INDUSTRIAL ENERGY
9 Clean Gas Modules.
High-Efficiency Gasification.
100% Furnace Oil Substitution.
CASE Group’s Pyrolysis Clean Cold Gasification Technology demonstrates how industrial energy systems can move beyond conventional fuel consumption towards more efficient utilisation of available resources.