Simulation and optimization of the coal gasification process using an entrained flow gasifier to produce synthesis gas

Coal plays a vital role in the global energy supply, making the development of advanced technologies to enhance production efficiency and process performance increasingly important. Among the available technologies, coal gasification is recognized as one of the most effective approaches for producing energy and petrochemical feedstocks. Therefore, the development of a multi-objective optimization framework for coal gasifier design is essential to simultaneously improve syngas quality and carbon conversion efficiency. In this study, two simulation models were developed to investigate the coal gasification process. Initially, the physicochemical properties of the coal were characterized, after which the process was simulated and optimized through a two-stage methodology. The optimization strategy focused on maximizing hydrogen production, thereby enhancing the quality and industrial value of the produced syngas. Comparison of the optimized results with experimental data demonstrated that the first model achieved a 28% increase in hydrogen production. Moreover, under the optimal operating conditions, the hydrogen-to-carbon monoxide (H₂/CO) ratio increased by 65%, indicating a substantial improvement in syngas quality and the overall performance of the gasification process.