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

Bahoosh, Mohsen; Kashi, Eslam

doi:10.22104/hfe.2025.7606.1358

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

Document Type : Research Paper

Authors

Mohsen Bahoosh

Eslam Kashi

Department of Chemical Technologies, Iranian Research Organization for Science and Technology (IROST), Tehran, Iran

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 a coal gasification unit aimed at producing synthesis gas. The developed model was initially validated using available reference data, confirming its reliability and accuracy. Using Tabas coal as feedstock, the gasification process was simulated in Aspen Plus software using an entrained-flow gasifier. Sensitivity analysis was conducted on the type of coal, as well as the water-to-coal and oxygen-to-coal ratios, to identify key factors affecting the gasification process. The key results show that approximately 22 tons per hour of Tabas coal are required to produce 77000 Nm³/h of syngas, sufficient to support the production of 110 tons per hour of sponge iron. 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 the type of coal and the ratios of water-to-coal and oxygen-to-coal are critical parameters, 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 productivity in the steel industry.

Keywords

Coal gasification

Syngas

Tabas coal

Steel

Aspen Plus

Subjects

Chemical Engineering

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