How Raw Coal Become Clean Fuel.
A proprietary, end-to-end process — purpose-designed
and pilot-demonstrated for high-ash Indian coal at the 1
TPD scale.
The Gasifier
At the heart of the coal conversion process is an oxy-blown bubbling fluidised bed gasifier: purpose-built to handle Indian coal with ash content ranging from 26% to 57%, where conventional gasifiers fail.
The R&D Engine Behind Every Decision: Gasifier1D Model of Gasifier
The R&D Engine Behind Every Decision: Gasifier Advanced Computational Modelling of Gasifier
The hydrodynamic behaviour of the fluidised bed gasifier is studied using both Computational Fluid Dynamics (CFD) and Computational Fluid Dynamics – Discrete Element Model (CFD-DEM) simulations. While CFD captures large-scale gas-solid flow patterns and temperature profiles across the bed, CFD-DEM resolves individual coal and ash particle interactions at the particle scale.
The R&D Engine Behind Every Decision: Gasifier Radioactive Particle Tracking Experiments
The R&D Engine Behind Every Decision: Gasifier Radioactive Particle Tracking Experiments
The R&D Engine Behind Every Decision: Gas Cleanup & Conditioning
Raw syngas from the gasifier carries tars, corrosive compounds, and trace metals - each harmful to the methanol catalyst.
Karbonis has developed and validated a tailored multi-stage cleanup sequence.
The R&D Engine Behind Every Decision: Catalyst Development
Every design choice in the Karbonis process is supported by multi-scale modeling, lab-scale experimentation, and pilot plant validation - not assumptions.
Methanol Synthesis & What It Means
Clean syngas at the right H₂/CO ratio enters a fixed-bed reactor operating at 50-80 bar, producing fuel-grade methanol with purity exceeding 99 wt% — ready for blending, chemical feedstock, or onward conversion.
India's coal reserves have some of the highest ash burdens in the world, a challenge that has historically limited the economics of gasification. The Karbonis process turns this constraint into an engineering opportunity: an oxy-blown fluidised bed gasifier, purpose-designed for 26-57% ash coal, produces a stable, nitrogen-free syngas stream at H₂/CO ratios above 2.0. From there, a multi-stage conditioning train strips tars, corrosives, and trace metals before the purified syngas is compressed and converted to fuel-grade methanol at >99 wt% purity in a fixed-bed reactor.
"Every step - gasification, cleanup, synthesis, has been validated at the 1 TPD pilot scale on five grades of real Indian coal, across 18 test campaigns and 150 tonnes of feedstock, 6 types of coal"