Localization of coal gasifier is a bit difficult
In recent years, China's independent coal gasification technology has made remarkable progress, with technologies like coal-water slurry gasification reaching world-class standards. As this technology advances, the demand for coal gasifiers—central to the gasification process—has surged in the domestic market. According to Ni Weidou, an academician of the Chinese Academy of Engineering and professor at Tsinghua University, China is expected to require 2,250 coal gasifiers by 2020, making it the largest gasifier market globally. Wen Jianwei, a chief engineer at Hunan Xiangdong Chemical Machinery Co., Ltd., noted that the cost of a single shell-shell gasifier can exceed 300 million yuan, while a coal-water slurry gasifier costs at least 10 million yuan. Even with the lower-end estimate, the total cost for 2,250 units would reach 22.5 billion yuan.
With such a massive market, the question arises: Can China’s domestic manufacturing capabilities meet the growing demand? What challenges still exist in the production of these complex systems? To explore these issues, reporters interviewed industry experts and professionals.
Currently, only a limited number of companies in China have the capability to manufacture coal gasifiers. The process is highly technical, requiring precision, advanced materials, and long lead times. Zhao Mengqing, deputy secretary-general of the China National Chemical Equipment Association, emphasized that coal gasifiers are among the most challenging equipment to produce, with strict requirements on structure, material quality, and accuracy.
For example, multi-nozzle gasifiers require precise alignment of nozzles, with deviations allowed only within 0.5 mm. Additionally, internal diameter shrinkage during the quenching process presents another major challenge. Zhao Qingwan, head of the gasifier department at the Chemical Industry Equipment Quality Supervision and Inspection Center, highlighted the complexity of the Shell coal gasifier, which consists of four major components and weighs about 1,000 tons. Its assembly and transportation pose significant logistical difficulties.
Only a dozen companies in China, including Dalian Jinzhou Heavy Machinery and Harbin Boiler Works, currently have the capacity to produce coal gasifiers. However, each company can only manufacture around 10 units per year. If demand surges, these companies may struggle to keep up, as Wen Jianwei pointed out.
Another major challenge lies in the availability of high-quality steel. Most domestic gasifiers rely on imported steels like SA387Gr11CL2 from Japan, Germany, and Sweden, which are significantly more expensive than domestic alternatives. Despite similar performance, users often prefer imported steel due to concerns over domestic quality. This preference increases costs by up to 60% per unit.
Domestic steel supply is also tight, with only one company in Henan producing the required CrMo steel. This shortage leads to long delivery times, further complicating the manufacturing process. While some improvements are expected, the current situation remains a bottleneck.
Tax policies also hinder the localization of coal gasifiers. Imported equipment benefits from tax exemptions, while domestically produced components face full taxation. This policy discourages local production and increases the cost of domestic gasifiers. Many manufacturers hope the government will introduce preferential tax measures for locally produced materials and support the development of homegrown gasifier technology.
In conclusion, while China has made significant strides in coal gasification technology, challenges remain in manufacturing capacity, material supply, and policy support. Addressing these issues is crucial for the sustainable growth of the coal chemical industry and the broader energy sector.
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