Industrial-scale gasifiers are traditionally
designed using performance
data from small-scale systems and expert experiences. In this research,
the computational fluid dynamics (CFD)-coarse-grained discrete element
method (CGDEM) model in open-source software MFiX was employed to
assist the design of a 22 MW updraft moving-bed coal gasifier. A quasi-one-dimensional
CFD-DEM simulation was first performed; its results were then served
as an accurate initial condition for the three-dimensional (3D) CFD-CGDEM
simulation. Then, long-time 3D simulation of 3.89 h of physical time
using 120 CPU cores was achieved for the industrial-scale reactor
at a quasi-steady state. Important results were obtained such as syngas
compositions, gas flows, solid and gas temperatures inside the reactor,
ash distribution, and zone locations. The high-fidelity CFD results
compare well with experience-based design from Hamilton Maurer International,
Inc. Apart from predicting the steady-state operations, several transient
operations including intermittent coal feed, turndown, shutdown, and
accident load loss were investigated. The results showed that syngas
components share the same cycles in intermittent coal feed conditions.
There is a decrease in H2 and CO and an increase in tar
when the gasifier operates at a lower capacity. The shutdown process
took more than 4.4 h and the recovery from a sudden loss of the bed
material took more than 2 h. These studies provide helpful guidance
for industrial-scale reactor design and rehearsal of potential risks
in real-life operations.