Investigation of fluctuation behavior in viscosity of coal slags used in entrained-flow gasifiers

Entrained-flow gasification has attracted extensive attention because of its clean and efficient utilization of coal as well as flexible application in industry for power generation and chemical production. Numerous theoretical and experimental investigations on slag flow in entrained-flow gasifiers have been performed to ensure a smooth operation, but an unscheduled shutdown due to slag tap blockage remains an ongoing challenge. A fluctuation phenomenon of slag viscosity gives a rise in the risk of slag tap blockage. In this work, three Chinese coal slags with low silicon content and high iron content were used to investigate the viscosity fluctuation phenomenon. It was found that the crystalline phases and suspended bubbles can cause the fluctuation phenomenon. The fluctuation degree is related to the volume fraction of crystalline phases and the crystallization rate. In the search for the mechanism of the viscosity fluctuation, an in-situ observation using a high temperature stage microscope system (HTSM) in combination with XRD and SEM analyses was carried out. In addition, the viscosity of investigated slags with the suppression of solid phases as well as the phase distribution at high temperatures was calculated. Based on a comprehensive analysis of the results, a possible mechanism has been proposed that the viscosity fluctuation is attributed to an instant local change in the macrostructure such as the deformation of suspended bubbles, the change of the orientation of acicular crystals and the interaction of the acicular crystals and suspended bubbles.