Process Modeling and Optimization of Coal Gasification for Enhanced Hydrogen and Syngas Yield in Sponge Iron Production

Articles in Press

Document Type : Research Paper

Authors

1 Sh. Ehsani Rad St., Enqelab St., Parsa Sq., Ahmadabad Mostoufi Rd., Azadegan Highway

2 Iranian Research Organization for Science & Technology

10.22104/hfe.2025.7606.1358

Abstract

Due to the irregular availability of natural gas, coal has been proposed as an alternative source for the production of synthesis gas in steel plants. This study simulated of a coal gasification unit aimed at producing synthesis gas. The model was initially validated against available reference data, confirming its accuracy. Using Tabas coal as feedstock, and the gasification process was simulated using an entrained-flow gasifier in Aspen Plus software. Sensitivity analysis was conducted on the type of coal, as well as on the water-to-coal and oxygen-to-coal ratios, to identify key factors affecting the process.

Key results show that approximately 29 tons per hour of Tabas coal is required to produce 174.6 m³/h of syngas, sufficient for 110 tons per hour of sponge iron production. Process water consumption is around 0.3 times the coal input, with a cooling and quenching water-to-coal ratio of approximately 1.7, much of which is reused. Significantly, additional water is not required for the water-gas shift reaction due to syngas quenching within the gasifier. The study confirmed that both the type of coal used and the ratios of water and oxygen to coal are critical, with high-quality Tabas coal demanding lower amounts of oxygen and water for syngas production compared to lower-grade coals. This research serves as a valuable guide for improving the efficiency and productivity of coal gasification units in the steel industry. Overall, the findings indicate that using coal for synthesis gas production has great potential in meeting energy demands and enhancing steel industry productivity.

Keywords

Main Subjects

Hydrogen, Fuel Cell & Energy Storage

Articles in Press, Accepted Manuscript
Available Online from 20 December 2025

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