Prediction of coal slag foaming under gasification conditions by thermodynamic equilibrium calculations

In slagging gasifiers, slag foaming can cause serious operational problems, so there is a need for investigation into the conditions causing slag foaming. Viscosity experiments were carried out examining viscosity, extent of swelling and Fe formation. Although extensive swelling was not observed, FeO reduction was observed under an N2/CO gas atmosphere, but not under CO2/CO. In order to predict FeO reduction conditions in the gasifier, a model for an adiabatic equilibrium gasifier was developed. The gas composition, the amount of gas to slag, and Po2 were calculated for a slurry-feed gasifier, and the results of the calculation were used to predict the reduction of FeO in slag by using FactSage. Under typical gasification conditions for Denisovsky coal, the predicted Po2 in the gasifier was not low enough to cause FeO reduction. The FactSage simulation for the viscometer conditions predicted no FeO reduction under a CO/CO2 atmosphere, but did predict Fe formation under CO/N2 conditions. At a 20% CO concentration, FeO reduction starts at temperatures above 1,600°C. Since the slag has a low viscosity at 1,600°C, the oxygen bubble may have escaped as it formed. Therefore, slag foaming, caused by FeO reduction in the slag, can only occur when the right conditions of viscosity and oxygen partial pressure are met.