The CASE Group has set a new benchmark in industrial sustainability with the installation of nine cutting-edge CASE Clean Gas Coal Gasifiers at Rungta Mines Limited Kamanda, Odisha. These gasifiers, developed by CASE, represent a revolutionary advancement in coal gasification technology, contributing to more sustainable operations in the iron and steel industry by significantly, improving energy efficiency, and enhancing environmental compliance. This article explores the impressive features and outcomes of this technology at Rungta Mines by CASE Group.

Author
Meenakshi
Business Executive
CASE Group

A Breakthrough in Furnace Oil Substitution for Straight Grate Pellet Production

One of the most notable achievements of the CASE gasification technology is its ability to substitute up to 60% of the furnace oil required in the straight grate pellet-making process (Phase 1). This substantial reduction in furnace oil usage is particularly impactful as it enables a cleaner, more cost-effective method of producing iron ore pellets, optimizing production costs and aligning with global sustainability goals in an economically efficient way.

Pioneering the Use of High-Ash Coal for Pellet Heating

CASE technology at Rungta Mines has made possible the unprecedented use of high-ash coal (containing more than 40% ash) in the heating of iron ore pellets within a straight grate system. Traditionally, such high-ash coal would not be suitable for industrial applications requiring consistent heating. However, by efficiently utilizing this locally abundant resource, CASE gasifiers have increased fuel flexibility, allowing Rungta Mines to rely on more affordable, readily available coal while maintaining high operational standards. This flexibility has significant economic advantages, especially in regions where high-quality, low-ash coal is scarce or costly.

Achieving 100% Furnace Oil Replacement in Grate Kiln Systems

 

In addition to oil substitution in straight grate technology, the CASE gasifiers have successfully achieved 100% replacement of furnace oil in a 1.0 MTPA (million tons per annum) grate kiln. This accomplishment underscores the gasifiers’ effectiveness in completely offsetting the need for furnace oil in specific pellet production systems. By fully eliminating furnace oil, the gasifiers significantly reduce operating costs, aligning with both economic and environmental objectives.

Targeting Up to 90% Oil Substitution in Straight Grate Phase 2

Looking to the future, Rungta Mines aims to achieve an ambitious 90% furnace oil substitution rate in the Phase 2 of the straight grate system (3.0 MTPA) by providing more burners for coal gas. This target reflects the scalability and adaptability of CASE gasification technology, which continues to push the boundaries of fuel substitution in industrial applications. If achieved, this milestone will further solidify the technology’s role in promoting sustainable production methods.

Exceptional Coal-to-Gas Conversion Efficiency

The CASE gasifiers have demonstrated an impressive coal-to-gas conversion rate, producing over 1.8 Nm³ of gas per kilogram of coal, with a conversion efficiency that exceeds 80%. This high level of efficiency means that each unit of coal produces a significant amount of gas, maximizing the energy yield from the raw material. By optimizing coal-to-gas conversion, the gasifiers ensure that energy production is both cost-effective and environmentally friendly, reducing waste and increasing productivity across the pellet production process.

High Tar Conversion Leading to Enhanced Thermal Efficiency

In addition to efficient gas production, the gasifiers convert more than 4% of the feed coal into tar, a byproduct with a high energy content. This high rate of tar conversion contributes to the gasifier’s outstanding thermal efficiency, which exceeds 90%. By efficiently converting coal into both gas and tar, the gasifiers capture as much energy as possible from the raw material, minimizing waste and maximizing fuel value. This high thermal efficiency directly translates to lower operational costs and reduced environmental impact.

Consistent Gas Quality for Optimal Air-to-Fuel Management

A key strength of the CASE gasifiers is their ability to maintain consistent gas quality, with stable calorific values and pressure levels. This reliability is critical in industrial applications, as it ensures precise air-to-fuel ratio control. Consistent gas quality enables operators to optimize combustion, improving the thermal efficiency of the entire system. This stability results in high-quality pellets that meet strict industry standards, making the gasifiers an ideal choice for industries that require precision and reliability in their energy supply.

Zero Liquid Discharge with 100% Phenol Water Reuse

CASE gasification technology also addresses environmental concerns with its Zero Liquid Discharge (ZLD) design. The system recycles 100% of the phenol water, a byproduct of the gasification process, as a gasifying agent. This closed-loop recycling process ensures that no liquid waste is discharged, fully adhering to pollution control norms. By implementing ZLD technology, Rungta Mines reduces its environmental footprint, protecting local water resources and contributing to sustainable industrial practices

High Purity Gas for Cleaner Combustion

The gas produced by the CASE gasifiers is exceptionally pure, allowing for clean and efficient combustion at the burners. This purity ensures minimal buildup of impurities on the burners, which reduces the need for frequent cleaning and maintenance. As a result, operational downtime is minimized, and burner efficiency is maintained, further enhancing productivity and cost-effectiveness. This feature of CASE technology is particularly valuable for industries where continuous operation and minimal maintenance are crucial.

No Refractory Requirement for Safe, Consistent Operations

Unlike conventional gasifiers, the CASE gasifiers operate without a refractory lining. Refractory linings are prone to clogging and require frequent maintenance, which can disrupt operations. By eliminating the need for refractory, the gasifiers avoid these common issues, ensuring safe, consistent operations with minimal downtime. This innovation improves reliability and reduces the long-term maintenance costs associated with conventional gasifiers, making the CASE technology a more practical and cost-effective choice for industrial applications.

Reduced Operating Costs with No Need for Compressed Air or Nitrogen

The CASE gasifiers are designed to operate without the need for compressed air or nitrogen, further reducing operating expenses (OPEX). This self-sufficiency not only cuts costs but also simplifies the overall system, making it more efficient and easier to operate. The reduction in resource requirements lowers both the economic and environmental costs associated with pellet production, supporting sustainable industrial growth.

Conclusion: Leading the Way in Sustainable Coal Gasification Technology

The installation of CASE coal gasifiers at Rungta Mines Limited represents a significant advancement in the field of industrial gasification. These gasifiers provide an energy-efficient and environmentally sustainable solution for pellet production, with a range of benefits that include  high coal-to-gas conversion efficiency, and full compliance with pollution control standards.

By achieving high levels of furnace oil substitution, maximizing thermal efficiency, and maintaining consistent gas quality, the CASE gasifiers demonstrate the transformative potential of clean energy technologies in heavy industry. Furthermore, features such as Zero Liquid Discharge, high tar conversion, and gas purity ensure that the system operates sustainably, responsibly, and efficiently, setting a new benchmark for coal gasification technology in India and beyond.

Rungta Mines’ commitment to innovation and sustainability through the adoption of CASE gasifiers not only enhances operational efficiency but also serves as a model for other industries seeking to balance productivity with environmental stewardship. As the demand for cleaner, more sustainable industrial processes continues to grow, the success of the CASE gasifiers at Rungta Mines highlights the vital role of advanced gasification technology in driving a cleaner, greener future for the global iron and steel industry.