High Temperature System for Gasification Process

General Description

A gasification system converts solid or liquid feedstock (coal, biomass, or waste) into combustible syngas through high-temperature thermochemical processes with limited oxygen supply. The feedstock enters a gasifier vessel heated to 1,200 to 1,800-degrees F. In this oxygen-starved environment, materials undergo pyrolysis, breaking down into volatile compounds and char. Limited oxygen prevents complete combustion, instead promoting partial oxidation reactions that convert the feedstock into syngas—primarily carbon monoxide, hydrogen, methane, and carbon dioxide. Water vapor is often added to enhance hydrogen production through steam reforming. The resulting syngas exits the gasifier and undergoes cleaning to remove contaminants and particulates.

The cleaned syngas serves multiple applications: electricity generation through gas turbines, conversion to liquid fuels via Fischer-Tropsch synthesis, use as chemical feedstock, or direct combustion for heat. This technology efficiently processes various feedstocks while offering environmental advantages over traditional combustion, making it valuable for waste-to-energy and renewable energy applications.

KWS Manufacturing proved to be the optimal solution provider, offering extensive engineering experience and a demonstrated history of producing high-performance bulk material handling systems for extreme temperature applications, with complete domestic manufacturing capabilities.

Feedstock is Metered to Gasification Vessel with KWS Shaftless Screw Feeder

Design Parameters

Product Type: Solid Plastics
Design Temperature: 2,000-Degrees F
Material Density: 20 Lbs. per Cubic Foot
Capacity: 30 Cubic Feet per Hour
Duty: Intermittent

KWS Advantages

With over five decades of expertise in high-temperature applications, KWS has developed specialized designs that accommodate extreme heat while accounting for thermal expansion in both screw components and housing assemblies. For this specific application involving a maximum temperature of 2000-degrees F, KWS specified 310 stainless steel construction throughout to withstand the severe operating temperatures. KWS maintains the fabrication capabilities to work with any steel grade required to meet customer specifications and application demands.

The KWS collaborative engineering approach delivered a precisely tailored equipment solution with rapid turnaround, reducing installation complexity and optimizing operational performance. KWS’s capacity for custom design and expedited manufacturing enabled the customer to achieve fast implementation, minimize production disruptions, and quickly bring their upgraded material handling system online.

KWS Special Features

WS engineered a drive pedestal solution that shields the gear reducer and motor from thermal stress and shock loading in high-temperature conveyor applications. This configuration positions the gear reducer and motor several feet from the heat source, enabling the gearmotor to function at ambient temperatures and preventing potential damage from excessive material heat. Beyond thermal protection, the drive pedestal design ensures convenient access to critical components—including the shaft seal, gearmotor, low-speed coupling, and pillow block bearing—streamlining maintenance operations.

For the non-heated infeed zone, KWS implemented a shaftless spiral design to receive solid plastics from a rotary airlock. This innovative configuration enables the spiral to extend directly into the main housing, eliminating the need for end bearings. The shaftless spiral operates on AR400 wear bars that provide housing protection while reducing maintenance requirements. KWS supplied the shaftless spiral with our one-piece flanged drive shaft, precision-machined from solid bar stock and backed by a lifetime guarantee.

Customer Testimonial

“The KWS equipment is extremely well designed and manufactured. We installed everything with no fitment issues!” Chief Operating Officer – Alternative Energy Company