A Data Reconciliation-Based Method for Performance Estimation of Entrained-Flow Pulverized Coal Gasification

Accurate performance estimation of the entrained-flow pulverized coal gasification unit is essential for production scheduling and process optimization, but these are often hindered by inaccurate or insufficient measurements in the industrial system. This paper proposes a data reconciliation-based method to address this challenge. The thermodynamic equilibrium model is employed as constraints of the gasification and quench processes, and the Particle Swarm Optimization (PSO) algorithm is applied for parameter estimation. Measured data under stable and variable operating conditions are reconciled, detecting and eliminating a 12% error in syngas flow rate at the scrubber outlet, thereby improving gasification performance accuracy. Two characteristic models concerning carbon conversion rate and the flow rate of reacted quench water are derived from the reconciled results. By combining these models with thermodynamic equilibrium models, the modified R2 of offline predicted syngas flow rate exceeds 0.92, and those of syngas compositions reach 0.72–0.85. Additionally, an Artificial Neural Network (ANN) model, trained on reconciled and predicted data, is proposed for real-time performance estimation. The ANN model calculates performance metrics within 10 s and achieves R2 values above 0.95 for most parameters. This method can be integrated into control systems and serves as a valuable tool for gasification process monitoring and optimization.