Effect of Operating Conditions on the Gasification of Pet-Coke Water Slurry in an Entrained-Flow Gasifier Simulation

Petroleum coke, commonly known as pet-coke, represents a promising and cost-effective alternative fuel source, produced as a byproduct of large-scale heavy crude oil refining. This study first simulated the gasification process of pet-coke slurry using a three-dimensional computational fluid dynamics (CFD) approach based on the Eulerian-Lagrangian method. The simulation was carried out in a 2-ton-per-day (2TPD) entrained-flow gasifier, aiming to optimize the production of hydrogen (H₂) and carbon monoxide (CO) as synthetic gases. This study investigated the effects of operational parameters, including the oxygen/slurry ratio and moisture content in the slurry, on various aspects such as fluid dynamics, temperature distribution, particle trajectories, carbon conversion, and gas composition within the pet-coke slurry gasifier. The base conditions of the simulation were meticulously cross-validated with high-precision experimental data. The results indicated that higher oxygen/slurry ratios led to increased concentrations of carbon dioxide (CO₂) and decreased fractions of H₂, primarily due to the prevalence of the reverse water-gas shift reaction. Moreover, raising the moisture content in the pet-coke slurry led to decreased CO levels and enhanced production of H₂ and CO₂, triggered by the activation of the forward water-gas shift reaction. These results underscore the potential of pet-coke slurry as a favorable feedstock for syngas production and the achievement of carbon neutrality through the careful optimization of operational conditions. Our findings provide valuable insights for further experimental exploration and the development of practical applications for pet-coke gasification.