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ZWL series cone gas stove energy efficiency significantly
The ZWL series of cone gas generators, a nationally patented technology developed by Zou Wenli, the chief engineer at Zibo Yuke Machinery Co., Ltd., represents a significant advancement in gasification technology. This innovative system features excellent gas permeability, an expanded oxygen-rich zone at the bottom of the gasification layer, and a more porous structure. As a result, lump coal is fully gasified, leading to reduced residual carbon and improved operational efficiency of the carbon bed. This technology effectively addresses the issue of high coal consumption in nitrogen fertilizer plants and was recognized by the China Nitrogen Fertilizer Industry Association as a key circular economy support technology between 2007 and 2010. It was also recommended to the National Development and Reform Commission as a national priority for circular economy development.
The core principle behind this technology involves modifying the traditional jacketed boiler design based on the UGI batch gas furnace. By changing the shape from a straight cylinder to a truncated cone—narrower at the top and wider at the bottom—it creates new gasification characteristics. This design enhances heat retention in the bed and improves the steam decomposition rate, which significantly lowers the oxygen and methane content in semi-water gas. During manufacturing, the ventilation area, air distribution spacing, and slag prevention mechanisms can be customized according to the user’s coal type and process requirements. Additionally, the height-to-diameter ratio, carbon bed thickness, and cone angle of the furnace can be adjusted flexibly to optimize performance.
In recent years, with rising coal prices, many companies have turned to lower-quality coal and briquettes to cut costs. However, this has led to unstable gasifier conditions and challenges in maintaining consistent gas production. In response, Zibo Chenke Machinery Co., Ltd. initiated the development of a new gas generator in early 2004. By March of that year, they successfully launched a cone-shaped gas generator with an upper diameter of 2610 mm and a lower diameter of 2800 mm. This model was first applied in Qilu Petrochemical's fertilizer plant, where it significantly improved gasification efficiency. After implementation, gasification intensity increased by approximately 20%, oxygen levels in semi-water gas dropped to just 0.15%, methane content decreased by 10%, and carbon content in the slag was reduced by about 10%.
To date, this technology has been widely adopted across over 100 fertilizer production facilities in more than 20 provinces, including Shandong, Shanxi, Henan, and Hebei. It has been implemented in over 400 units, demonstrating its effectiveness and reliability in improving gasification processes and reducing overall energy consumption. The ZWL series continues to play a vital role in supporting sustainable and efficient industrial operations.