Maximizing Gasification Efficiency and Reliability using Novagen™
Introduction
Microbeam Technologies, Inc. (MTI) developed a software platform called Novagen™ to manage feedstock properties and optimize operations in gasification systems. Next-generation gasifiers are faced with high-variability challenging feedstocks that threaten to decrease efficiency and force outages. Novagen™ enables dynamic blending of challenging waste feedstocks to maximize efficiency while minimizing downtime.
Background
Biomass gasification presents a promising route towards meeting sustainability goals, especially net-negative CO2 production. Opportunity fuels such as waste biomass and coal waste can manufacture low-cost hydrogen, but present numerous ash-related challenges. In fluidized-bed gasification systems, these include material handling issues, wall slagging, fluidized-bed agglomeration, and syngas cooler fouling. Other types of gasifiers experience additional issues such as slag freezing, refractory wear, clinker formation, and syngas cooler fouling.
Case Study: Optimizing Coal Waste - Biomass Gasification for Hydrogen Production
Novagen™ was developed to track and monitor fuels through the fuel handling system, sorting and blending feedstocks to maintain a consistent blend. It provides real-time diagnostics of gasifier systems as a function of fuel properties and operating conditions, alerting operators to changes in feedstock properties and component performance (Figure 1). Additionally, Novagen™’s simulation capability allows operators to project future performance and make informed decisions for fuel delivery and outage scheduling.
Figure 1. Novagen™ gasifier user interface for biomass/waste coal.
Novagen™ was used to simulate gasification system performance running different blend scenarios: 100% coal waste, 100% biomass, and a dynamic Novagen™ Blend that actively blends coal waste and biomass to achieve a target of 5.5 wt. % ash.
As demonstrated in Figure 2, risk of a shutdown (quantified using MTI’s plant performance index) increases over time due to agglomeration and fouling, then drops to zero when a shutdown occurs. The Novagen™ blend experienced far fewer shutdowns as compared to the coal waste and biomass cases.
Figure 2. Plant performance index over time for biomass, coal waste, and blend simulations.
Predicted gasifier availability and runtime are summarized in Table 1. Results showed dramatic improvements in availability by using the Novagen™ tool to blend biomass and coal waste. Novagen™ improved performance by 62% over the 100% biomass case and by 9% over the 100% coal waste case.
Table 1. Predicted availability and runtime for biomass, coal waste, and blend.
Summary
MTI’s Novagen™ platform provides a unique tool for simulating various waste coal and biomass feedstocks to optimize gasifier performance, supporting carbon-neutral and carbon-negative production. Novagen™ increases revenue due to higher plant availability and lowers cost by reducing ash-related outages. Its implementation advances the goal of making green hydrogen more affordable and scalable.