Reduced order models that accurately predict the operation of entrained flow gasifiers as components within integrated gasification combined cycle (IGCC) or polygeneration plants are essential for greater commercialization of gasification-based energy systems. A reduced order model, implemented in Aspen Custom Modeler, for entrained flow gasifiers that incorporates mixing and recirculation, rigorously calculated char properties, drying and devolatilization, chemical kinetics, simplified fluid dynamics, heat transfer, slag behavior and syngas cooling is presented. The model structure and submodels are described. Results are presented for the steady-state simulation of a two-metric-tonne-per-day (2 tpd) laboratory-scale Mitsubishi Heavy Industries (MHI) gasifier, fed by two different types of coal. Improvements over the state-of-the-art for reduced order modeling include the ability to incorporate realistic flow conditions and hence predict the gasifier internal and external temperature profiles, the ability to easily interface the model with plant-wide flowsheet models, and the flexibility to apply the same model to a variety of entrained flow gasifier designs. Model validation shows satisfactory agreement with measured values and computational fluid dynamics (CFD) results for syngas temperature profiles, syngas composition, carbon conversion, char flow rate, syngas heating value and cold gas efficiency. Analysis of the results shows the accuracy of the reduced order model to be similar to that of more detailed models that incorporate CFD. Next steps include the activation of pollutant chemistry and slag submodels, application of the reduced order model to other gasifier designs, parameter studies and uncertainty analysis of unknown and/or assumed physical and modeling parameters, and activation of dynamic simulation capability.
